Report No. 89-02 A Report of the Office of Energy Bureau for Science and Technology United States Agency for International Development PREFEASIBILITY STUDY OIL SHALE UTILIZATION FOR POWER PRODUCTION IN THE HASHEMITE KINGDOM OF JORDAN VOLUME II OF VI ORAL PRESENTATION, QUESTIONS AND ANSWERS Contributors: Jordan Electricity Authority Oak Ridge National Laboratories, Energy Division Pyropower Corpora ti on Bechtel National, Inc. Prepared by: Bechtel National, Inc. - Prime Contractor Conventional Ene:rgy Technical Assistance (CETA) Project 1601 North Kent Street, Suite 914 Arlirgion, Virginia 22209 703-528--4488 Contract No. LAC--5724-C-5126-000 Project No. 936-5724 May 1989 /1
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Report No 89-02
A Report of the
Office of EnergyBureau for Science and Technology
United States Agency for International Development
PREFEASIBILITY STUDY
OIL SHALE UTILIZATION FOR POWER PRODUCTION IN THE
HASHEMITE KINGDOM OF JORDAN
VOLUME II OF VI ORAL PRESENTATION
QUESTIONS AND ANSWERS
Contributors
Jordan Electricity AuthorityOak Ridge National Laboratories Energy Division
Pyropower Corpora ti on Bechtel National Inc
Prepared by
Bechtel National Inc - Prime Contractor Conventional Energy Technical Assistance (CETA) Project
1601 North Kent Street Suite 914 Arlirgion Virginia 22209
703-528--4488
Contract No LAC--5724-C-5126-000 Project No 936-5724
May 1989
1
This report was prepared as an account of work sponsored by the United States Government Neither the United Staies nor the US Agency fo International Development nor any of their employees nor any of their contractors subcontractors or their employees makas any warranty exshypress or implied or assumes any legal liability or responsibility for the accuracy completeness or usefulness of any information apparatus produc or process disclosed or represents that its use would not infringe privately owned rights
I
JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
SUMMARY TABLE OF CONTENTS FOR ALL VOLUMES
VOLUME I o Study Report and Executive Summary
VOLUME II o March 1989 Prefeasibility Study Presentation
o March 15 JEA Questions (MS Arafah) on Prefeasibility Study Draft Report
o March 21 Response to JEA Questions
VOLUME III o Appendix 1 - Design Basis Criteria
o Appendix 2 - Sultani Deposit Geological Data
- 1987 NRA Report
- 1988 Draft NRA Report on Supplemental Core Drilling
o Appendix 3 - Ahlstrom Pyroflow Process Background
o Appendix 4 - NRA Sultani Blended Sample Report
VOLUME IV o Appendix 5 - Bechtel Mining Report
VOLUME V o Appendix 6 - Oak Ridge National Laboratory Report Preliminary Assessment of Using Oil Shale for Power Production in the Hashemite Kingdom of Jordan
VOLUME VI o Appendix 7 - Pyropower Corporation Test Burn Report
o Appendix 8 - Pyropower Boiler Design - 50 MW
o Appendix 9 - Bechtel Power Block Design - 50 MW
o Appendix 10 - Pyropower Boiler Design - 20 MW
o Appendix 11 - Bechtel Power Block Design - 20 MW
o Appendix 12 - Chevron Corporation - World Energy Outlook
0511T
JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
VOLUME II TABLE OF CONTENTS
o March 1989 Prefeasibility Study Presentation
o March 15 JEA Questions (MS Arafah) on Prefeasibility Study Draft Report
o March 21 Response to JEA Questions
0511T
MARCH 1989 PREFEASIBILITY STUDY PRESENTATION
PREFEASIBILITY STUDY
OIL SHALE FUELED POWER GENERA TION
Presentation to
HASHEMITE KINGDOM OF JORDAN
March 1989
OUTLINE
M Introduction
Technical feasibility
U EConomic feasibility
Study conclusions
Recommended action plan
S Prefeasibility StudyOil Sftle Fueled Power Generation
Introduction
m Study program
m Integrated project scope
Prefeasibility StudyOil Shale Fueled Power Generation
VOO740LAd R 3
STUDY PROGRAM
Task
N Program management
U Test sample procurement
Test burn report
N Jordan power demand assessment
N 2050 MW boiler designcost
2050 MW project BOP designcost
i 4x100 (factored) boiler designcost
4x100 (factored) BOP designcost
Environmental assessment
N Economic assessment
Risk assessment
Action plan
Final report
BOP = balance of plant
Prefeasibility Study Oil Shale Fueled Power Generation
V007S AEI 4
Assignment
Bechtel
JEANRA
Pyropower
ORNL
Pyropower
Bechtel
Pyropower
Bechtel
ORNLBechtel
BechtelORNL
ORNLBechtel
Bechtel
Bechtel et al
a
INTEGRATED PROJECT SCOPE
For 20504x100 MW installations
Open pit mine
M Oil shale processing
U Power block
- Boiler plant
- Power generation facilities
- Raw water supplytreating
Ash disposal system
U Onsite infrastructure
U Offsite infrastructure
Prefeasibility StudyOil Shale Fueled Power Generation
VOO764GE1 S
i
_Conceptual Facilities
Truck end ShovelOperationrtHO Open Pit Mine Mineral Rock Stockpiles Waste To JEA Substation and
Electric PowerGid
Hurden and
Off Shale Communly Faciliies Central Central a0000con
0cr~nn Plant Malntenance and Warehouse
Pyroflow Cornbusbr
Steam Turbine Generator
(gt Power - -o-
Three Day BW ----- C nest
Waer Supply System Food Hopper Baghouse
Pr cees Domestic Boiler Feedwater
Water Water Water
Ra
Wells to Underground
Watr
Plant
Boltom Ash Overhead Ash Fly Ash A
Condenser Wastewar
P n r r Slowdown AqrnrServiceMI Pugdow Water~
Water system Slowdown
Cooling Dioalsposal
Tower Spent Shale Ash Disposal i Prefeasbly Study
Oil Shale Fueled Power Generalion
179 5896aJordari 183-10-89 r30
TECHNICAL EVALUATION
N Pilot plant test program - 75-ton sample procurement - Test results
- Test conclusions
0 Conceptual design studies - Oil shale reserves and analyses - Mine and shale processing - Power plant and auxiliaries n Development schedule
bull Material developed by Pyropower and Bechtel
o 1Shale Fueled powr Genera VOM4ME~j
Technical Feasibility
N Technical evaluation
N Technology risk assessment
U Environmental assessment
U Power demand versus supply assessment
Prefeasibility StudyOil Shale Fueled Power Generation
i
Pilot Plant Test Sample
Expected Blended Avg Mine- 75-ton Run Shale(a) Sample(b)
Fischer assay oil content wt 75 8486
Organic carbon wt 102 plusmn13(c)
Gross calorific value BtuIb 2000 2250(c)
Sulfur content wt 238 255(c)
(a) Rechtel evaluation of core hole data (b) NRA analysis (c) By correlation with Fischer assay
Prefeasibility StudyOil Shale Fueled Power Generation
VOO4JOEARI I
i
Pilot Plant Test Program
Conducted at Ahlstrom LaboratoryFinland
U Performed 8 test runs
Tested four process conditions
- Primarysecondary air ratio
- Bed AP = 405070 M bar
- Load level = 4060100 pct
Combustion temperature = 830 to 9000C
Prefeasibility StudyOil Shale Fueled Power Generation 119
- FCC plant sizes equivalent to proposed power application
Prefeasibility Study Oil Shale Fueled Power Generation
VOO94GEampJRI26
i
PYROFLOW UNITS IN THE US
COLORADOUTE IOYA STATE UNIV UNIV OFNUCLA CO NORTHERNAMES IA BF GOODRICH110 1o0MW(a) 2x170000 Ibhr HENRYILCEDAR FALLS IA 120000 Ibhr GENERALGULF OILu EiN P MOTORSSbtUpStart-UIL 1987 O A 1I N000 TC
NORT10 PONTIACH B MIRANCHWV00000 lbhr
CORN PRODUCTSSM NORTH-CAROLINA STOCKTOD CA
400000 lbbhl t
RUMF RD ME
CEMENT CO CALIF PORTLAND-COLTON CA
190000 Iblhr Start-Up 1985 TRUMTFTWN NYU
3I75ERTOWN N
etar t-Up loss ACE COGENERATIONCABI
TRONA CA Oper t~on l -Start-UP 1990 ~ rt upz 091Start-up loss Start-up PNeLAI 1991
MTKESFICOENERATIO-N1
BASFIELDp Start-uStar-Up WESTCA9 199otgoUp 1 MAHONEV PA|00000 Ibhr A Oz 2X365000 Ibhr
SETtr-Ups 188B CHAT TANOOGA TN
G ULF OIL EXPLORATION 8ta-rt-u) 1085BAKERSFIELD NORTH BRANCHCA SPRING GROVE PANORTH BRANCH WV 400000 IbhtOperational 19835 5 0 0 I b h 9 0 0 0 Iblh r- tart-Upi 1991 S t r - U p s l e s s
SOUTHEAST PAPER MFG CO UNIVOF NORTH CAROLINArDUBLIN GA UHAPEL HILL NO400000 IbhrStart-Ups logo Start-Ups2X250O000 1loseIbhr B
- Withdrawing ash from combustor - Withdrawing fly ash
a Internal solids circulation of the steam generator
m Erosioncorrosion of steam generatorinternals
Heat recovery from bottom ash
U Operation with low calorific-value fuel
Prefeasblity Study O Shari Fueled Power Generation
VOO7AI 27
Impact of Scale-Up
Project Size
20 MW
50 MW
100 MW
50 MW boiler in 100 MW plant
Potential Risk
Design Scale-upOperation of to 100 MW Initial Plant Plant
Low Significant
Modest Modest
High Low for duplicate units
Modest Low for duplicate units
Prefeasibility Study Oil Shaje Fueled Power Generation
VOO71-4GEAL4n2
i
Conclusions
Defined risk of CFBC boiler is acceptable
U Operating experience with commercial CFBC boilers built and under construction will strengthen confidencelevel and minimize risk for a plant built in 1995
SPrefeasibility Study Oil Shale Fueled Power Generation
V007GHAAE29
ENVIRONMENTAL ASSESSMENT
a Mine and shale processing
- Fugitive dust emissions
- Noise levels
- Leachability of disposal piles
Power plant
- Fugitive dust emissions
- Gaseous emissions
- Noise levels
- Water effluents
U Conclusions
Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel
Prefeasibility Study Oil Shale Fueled Power Generalon
- Coaloil prices will be at least 15 greater after 1995
- Discovery of indigenous conventional fuel resources is inadequate for power plant purposes
Prefeasibility Study
Oil Shale Fueled Power Generation
VOO) IDWFO
Feasibility(Contd)
N Suitable financing will be available
- For $200 million 50 MW prototypeproject
- For $1000 million 400 MW commercial project
Government of Jordan will make basic commitments
- Long-term power purchase agreement
- Long-term access to Sultani shale deposit
Adequate water and manpower resources
- Attractive tax incentives
Prefeasibility Study
Oil Shale Fueled Power Generaion
VO bull1DUJJRO 6
Timeliness
U Timely development of Jordan oil shale needs prompt action to create - Additional definitive information
- Suitable business plan
Prefeasibility Study
Oil Shale Fueled Power Generation
VooI DUJo 7
i
Expansion Conditions
U Continued expansion of powergeneration from oil shale in Jordan depends on water availability
Prospects for power export or importand domestic load growth will affect size of the needed shale-to-power program
Prefeasibility Sudy
Oil Shale Fueled Power Generation
yOWl lVuJO
Environmental Impacts
N Environmental impacts of shale development will be minimal
Prefeasibility Study Oi Shale Fueled Power Generation
i
Development Advantages
Will create significant new jobopportunities in Jordan
Will avoidreduce foreign exchangelosses for expanding alternate fuel imports
Prefeasibility Study
Oil Shale Fueled Power Generation
VOOIIULL tO
Recommended Action Plan
N Basic recommendation
N Conceptual development schedule
U Project development plan
Key plan elements
N Funding requirements
Prefeasibility Study Oil Shale Fueled Power Generation
VOO4II )U OII
i
Basic Recommendation
N Expand efforts to develop an oil shaleshyfueled power generation program at the Sultani deposit
- Conduct required supporting studies
- Define facilities costs and business plans
- Obtain project funding
Prefeasibility Study
Oil Shale Fueled Power Generation
VON I II)ILL 12
C
Conceptual DevelopmentSchedule
1989-1990
- Conduct supporting studies - Define costsbusiness plans for 50
MW prototype and 400 MW commercial projects
- Develop project financing
N 1990-1993 - Build and operate the prototype project
N 1994-1996 - Expand the 50 MW prototype to 100 MW scale
U 1996-2000 - Expand the project to 400 MW scale
N 2000-2005 - Build a second 400 MW commercial project if needed
i 1 Prefeasiblity Study
dOil Shale Fueled Power Generation
VW IMLITO 13
Conceptual Development Plan
Months
1 Project development plan - Define project
costs1busness plans
-24 -12 0 12 24 36 48 60 72 84 96 108 120
2 Secure funding
3 Build and operate 50 MW prototype
Dergn and procurement
Mine development
Plant construction
Startup and testing
Operations
L- -
4 Expand prototype to 100 MW
Design and procurement
bullConstruction
Startup
5 Expand project to 400 MW
2nd 100 MW unit
3rd100 MW unit
i 44
4th 100 MW unit -
O Project dacision point
i Prefeasib~ity Study Oil Shale Fueled Power Generation
17958562aJocdanV 3-14-89 rsO
18
Phase I - ProjectDevelopment Plan
n Program development
Seminar workshop on prefeasibilitystudy Oate project development plan woek scope schedule arid budget
U Carry out project planning program
- Conduct continuing support studies - Test Sultani shale in existing FBC
- Firm up designs and specifications
- Update costs and economic analysis
- Develop business plans and requirements
Explore project funding alternatives
i Prefeasibility Study
Oil Shale Fueled Power Generation
VO MItUOR 14 -0
Key Plan Elements
N Project feasibility analysis
- Firm up designs and equipmentspecifications for all facilities
- Update cost estimates based on preliminary designs and specifications
Explore arrangements for contract mining and mine development
Update forecasts for demand growthand for retirements of older generating capacity
- Create updated economic analysis
Preleasibility StudyO1 Shae Fueled Power Generation
VOO1IOLWRI
Key Plan Elements (Contd)
Business entity requirement
- Explore optionsconditions for a new company to managebuildoperate the project
- Explore optionsconditions for obtaining a concession agreement for Sultani development
Explore optionsconditions for water rights commitment
Prefeasibility Study Oil Shale Fueled Power Generation
VMIOIA)lj 16S
i
Key Plan Elements (Contd)
U Continuing supporting studies
- Combustion tests (additional pilot tests for design and warranty purposes contract for large-scale burn operations in existing plants if appropriate)
- Additional core drilling and core analysis
- Oil shale crushing tests
- Spent ash leaching tests
- Geotechnical data base including soils analysis
- Environmental baseline data
Prefeasibility Study O Shae Fueled Power Generation
VMMMUldMOA
Steps Required to Develop an Oil Shale-to-Power Project
Create a development business plan - Schedule - Decision tree
Develop a work scope and budget for the development plan program including - Firming up designsspecificationscosts
- Developing business entity requirements - Continuing support studies
Carry out development plan program
Assemble all planning results in a report for discussion with financial institutions
Explore project finance opportunities
Finalize business arrangements
Implement prototype project
i Prefeasibility Study
Oil Shale Fueled Power Generation
VM1-11UJROLI
MARCH 15 JEA QUESTIONS (M S ARAFAH) ON PREFEASIBILITY
STUDY DRAFT REPORT
Rt
DIR EScBSULIVAN PHD OFJCEop~BUREAU FOR SCIENCE AND~TECHNOLOGYAGENCY - --FOR INTERNATIONAL DEVELOPMhINTSWASHINGON DC x20523---------4
4 -
-SUBJ E CT - -C O H~ E T 4N l
Dr Mr sullivan ------shy
c-rommnents We ~efr-preaereorPla -tobYou lete dted Jan 91989 regardn~i4po4t P ea e1 f i nd y ubel ow our -e ot r XcOrcerned Jordanian deipartments
- --A ar o~nnYu Y o turjlt~ lt K
4 C~mments
~1 N i gFIN I~fANDECONOMIC1COIMEN S -
It sidicaed that Beohtel and US AIDWash ingtonj~4- re ojy nen ing that E 2hould und ertake the n e tshyihaisAre ~our c leometprogram n order shye-t im~ ate d f n t v design and budget cost
4Al1so Lthe study ncal--ttsutnilndcaei~ A-1 A thas ~ l 1 be eeded idb~~~~~ rn o ei t n i la itheMWa~-~5s~ 4
hrPro hehgemetTh trOfT ses~fnr4 BOT)Vmanu- a n-mnf~cure 4 r~j or contra c4-or ivoIlveiintijn I 4 4investmnt ude smi ~w 2 Zha tev e r --~4~prce e ec r it v p4~ f JA gertiy geeated-at 4 JEA 3 a l b u y ~the same average~~ A
~jithia oncot in4 ordrtan ecpoemic asess thespePower generatjoon J ordan3 oi sha I eroic c inr~etJordan 4
2P ge i1- 1 Aj iit eu that OPin he atocontr~ct 4with owner4 ofext3ing (oconstriiction r(FB rml-t
qu i of S 11 t to test large tonnagen j es StaniUti n d ajIe -for se veralIQf 31 hi
evrEAPreferpilot qr the dP 1prt7n -that the4mPIt
andi to(7 he instalI 1e 2 310 A
_
JODN ELECTRICITYAUTHORIT LL
Dac
operated in Jordan i n or~der~~t ~n nuex~on mnining crushing and haidi igQhre~ and sash Maeia nd aSootoget enough olr ndaita needed for einolre
CEBbole~ -i s~
ccordance with Jordaian oil shale
large to~ bfig
1 3 le 1-2 Page 1-7 Cost Of Pwer~i It i S menti-oned that the conmecial oil hle~ lt~project (4 X1OOmw) 1is ninacompetative roqt~range-~while table 12 indicates thattcost of-pow Ais~mill
q kwiihcii r 1
average wih i ii -much higher ihantheshy-ost of ~Power gnrtofomJEA therimaPower s ta tions Please~ indicate on what basi o ~~ shave-~made your-statement
PK
14 Pae 2 Sction 4-0sIt 1nlkly that theChousing and off- -site infrastructur-ommnity fakilitieR) to be onsidered for both the demo and prototyp prjcs oeoverwe~4 hnk that their~c_6t is raterojects Mo
iwcv~- age -1 1 Mine O(perationIIt is indicate~d that mining cot eevdfoMine contractor~ are ficomiplee h
r and iyudi-t~con qidder contract mnn opio fr4 the min4 cmflt2ng are reIanddrepres~ent the real costs derived from Phspat miin contractors in
lestfor the eo rPooypuat in order tlt7
P I eadenote tha detthe new exchangerate ofthJraian~ Di~nner you may add 20j6 Kto the quoted
1 6 P Ias e consider the followin ecn hage_
171- The new exchange ra teof tUSD=54o0 fils1 72-W2 The new~ aerage tariff for selIn~electricityhas decrreased to 120 8 f ilIsicwh
17- Page 1-7 TbIe 1-2 W bev th tthe cap ita1 cot for the pwhokand forthe min n d ash hMnd1ing equipen
P B~2Anaor a -Tl 8156152 8176 1Q MYf -t -Now 520 t 1U
JDNEECRICIT AU-RA L14lLiL
2 ~are very high We suggest~ thta You rerconsie (- telowerus e~+d accuracy est a rangethan +30
Page4-22 Table 4-5weno0ti ced( that- PyroPowe ha ddeta(IiacCst fori the bo1ilerlocation and terha dutdetlease isxtr fo~ l C~ io~ s~ e~~ 1a~ a if and indicate theonldjusted ~percentagefor construction foin Jordan
19 Page-7 Table 11-2 -Yo aeue ihrinterest rate on Equity thatn on1DehI~laseinclude~ adetaied explanation of thisrr -tni kepin in miUndie JEA is1thaIt a non profit~ shyorgaiztion unik oher private UJSA utility~in ktation
~-~110- Regarding shy
the ra4ital Rt fthe project it is~requesed tobre k it intdo foreignMeanwhile cthe nd lorcal c-osfoeigptario i nt-re3t~shol becnierdo-h
rr n ontiondonnotopdbon the 9 cnieelocal portion~onth
1-1- 237~Pa
oningeny 9tooi s high~~ a lower 4value -should be~
4~ gt ~112- -Tbles t1-1 -8-8~ inclu~de t~he c~alculationscuultie nt enefits for of Th shyunttypes l i4s difeen geeatnmrer likely tocluae
-~ Q~ J7present vk1u for tenet tthe~benefits in feralterntives -t-oa s the
49
ehliyoi shale
Wea gree with you9 tha t th e percentage used ~ an for thenua~l 0 ~amp-M rahr CFBo ndsomewha~t highervrate be n ededma y for a C B l n Me n h l ~ a e r
indir e ta~ts the -estimatedma i variablec st i ddition t he fi-xed-9i 1 mislkih We --
thinktttiis too lowK -5
shy
1-14- e 4-29
opprza tion-o to The o i1s h1 costs-nc I deAbo 1h
Pa10 mman ormTSI62 a
IB I
JORD N EtECTICI1~ 4 E~)~Is-s
Date ib-_
~ ~riii~g~nd~o9~ru~hng h~tnlin cot~u~tv yo
i Dae Jnryit
1ts c 7 4-
i smiig iniand fh co I eY
susendi ca tI t icag th t1 ~an~approximate 15 ~pita L tYII I (-~a~ge or he owe bl ockj f aniitjes isof +the capthe)t~ial7cpi~lrharge Uoratelformny SI~Uj(uiity installa~tions~ whle page 6-1T9 talJshyit is mentioned that~ the Capital rate pe-r JEA isshyi5~PeaseJustify this~matter since~w o
i16- Pae 6-1 6
1 I4~t is mentioned that the costs of 4process Water are ~ 4 ~0 2$1 000 gallons
r~j~lt IHave~You considered additionalvalue ofbying waterfrom~ the Wa ters Aito i ~or ditoa cost~f o revrseoqoesplant if ground water is used
~~ I1 7- Table 6-1 Page 6-6 Please explain how did You come ou ihteoil~ shale miniing and proces~sing uit~Icost
ltII~I~ 8- Please note 1 t hatj the average JEA~productinr ot frmthermal I power stationsr (Istationbus-barCOSt)i sbewen 6 3-17 3 fils 4kwh You may use this~
l4~ 19-i For ~4 X 100~AMW Plat iti etindo pag e14-4 VolI 11 that4 at tota I of W42 14 epoye W II eemplo~yer] And on page 69yo1Iiti mentioned that a~ tot 1 f1 ~p yeI iNbe enp1oyed a
is~ high asrmetitexeds100personorthe ~41X100~MWh~~j nsatnpPrlae
I 1 The 4 following iftemns are a sumed to1 be excluded from theraPi ta 1 cot xoI
120-1 Perits I icen es 7
1_207~3 Imprt ~xe on s7pare par ts -and c(7orfmurab -ma~teria Is
04f4 4
~4 R j4 4
D4
~ ~ ~ AIf eS taxesq in acrac ihteJraand regulations should be considered aw
21- p1ea4s e indic ate Your Ju t f c io r us ga 6
44122- Table 977App 5Page4 9-1 4L IK Car1Yiniae that the hIRR of the 4 Otplantis rather unattractive (66)most
-( Cns1er4 ngthe logical base 4csek c pwhen cii 6OL
average sell~ing prc CkhampDEratio L801~2O~Aoreover4M the ne siellin prcwh o JEA ati theamptime~ Abeing os4ltp n~ot exceed 4 Ckwh~-However Ipage 1shy~ and 14 0 T indicate that ecnms for a commeri
S4A4scale joil 4 shale projc ~
appear Piomisig-nug o4Ywarrant continued dee fgfluht 4 feaibiit 4tudy wihil cost sevea~lili
do ar~sf Plas lear wether the ~x step jqs~$j~~lt 4
gtt 9o be considered arCcording4to jthe 4unattractiveresul to mentioned in IRR7 Table 97 gt4
a C4 44fET2 4 144-4444 P a g 1 T b6 l
htte~We ~ ~ ae~ rqieetfrteX ~ noie ~~ ~ 444 MW un t44 r te4l w w e o p r d i th e w t r n rre u f4m or4444~ the4444 54M4rto y e Pg~A~44EHiveL det ile an l A44
s o awa er c n um t a4r f rofsho in P6Io erT
e ch 2 50 M W aPln wa e d 41004 MW4 1 consumption_____________
ma4~2 k e u p houin~44 p A44 4444444 C O 4ltI4
a nd a sh et in etc 4 2 4 1 -24 P a g e4 2 - 1 A P P 5
4Yo 4_ j1 4 4~h444 N44 44
1gro nd tce t hir fthe w bern coqir mna t efora4e 4X10A M 444444 4 r i n to 4 4 4lo w w ehA 7 n 2 cinCie h rh4 n ttthh1eb -e 4 44t Of3 E4O
ea h n~ ffl 4 4Jl44 4 4444 4giv
6 ig re sofrat4 de in cl ar f w w at5 c hrw pe o
s h b 444 o t h e g nd L 44 h u i n C
r 4ne a4 t44 e L(704 2 4 p ae) 2 - o Au P dn 5ai 7~e r 44 I Y (1t 44a
ve7 rn e qu 1saharvthe y
and n~~~o speci~~~l4 p n l nh i n t x
r ~rA M e d r o t eu n 8 1 wTtl t t h
- c re e N I wo6
~ n n a i n a t d h l7 A PP6 gt
J
S2~3- Page 2-4 ~ ~ It ~is i
that oil eindicated the- sha le r our~ Cesin Jordan are 10 billion tons -The anulp e reere maiy exeed 50 4 billion tons ~
~ 24- 4Page~2 -l1 iujntr We beiv thtCBcmuto~ep i s high and~alSo
~~ ~ -2 ~~ Page 4-1~6 j - shy
Please~~ indicates your procedure to cool the omn ashand atwa icagd-eprtr
A Have you~ considered~ additional he~at exchanger topcool th ash and to imrve h cycleef ficiency
-~2~6 Page 4-16 It s~ indicated that ash from each silo i Amixed19 ~with~fabout 20 waterKb weight to minimize generation of dust~during trnprtto to mine and disposalHave you~ coniidered other 4lternativeto
~ ~eliminate dustiiig -and avoid use ofwat r uring it ransportationi such as~ using closed trucks or closed
of ~fans conUMnPo wihrlaintthe total plant auiir poe osupin 1~21- Table 5_-3 and I ~
Th~~ is- somneere c6ntradiction regardingplnneotpu~t in both am tables 21-~ Tabl~e 1-33
We noticed tha~t yourall9 cacacapac t fatro75 tion ae asdnWe thilt ~that 7capacityshyfacto is tobo high for- an oil shale fired plant duketo lack of existing simila~r ~plants handl~~~firing oil adshale ~K
216~ The study iniae thtawet~coigtower wi11~used Actually a b
dry cooling should be consideda5ini ~HTP S inZ atomnmz so water rnumption4the cycle~ efficiency willbe reducedHenre YO33~reconsider calculating the cyclefficiy
U~~~~~ codnt umconsidered ofhorizontal -aretypethe~ the vertical cian type can alsobeh considered
shy ~ ~ ~ I~~
2~2 Kconcrete shy
shjell stepl fltstack is onidereconcrete shell brick flue Rt c ~s beCaconsidered3V
2-19~- Deminiraized water~ tank3 capacity~ is -76 ui(meterThe recommnended tank cameter- ui tyi 00cbc
220Designconditions Pa~ge (4-74)te5 hat bow 3down percentage splusmn ~fomrpra til re i hou I be 3~)~
PoD Z 2 m a ad~ - e 5 1 2 iJS~ ~ p A f amp ~ ~ y1
4
JO R ECTICITY AUTHORTIT 4L
~ 4
Date~
t etats ttthe quantityof s i S ~1 000Tons ra Sthis tuntity 11- be transporited for severIy --to tu ofI pit a~te torg P KM ra~erm Spower plIatS about 12 midilidoni CUIA(- met ryea
h e ndd mp e he (d u p in i n L
area wil evric power plant6t Please zn1 a te~tiv s tudY for dumping th r~ a enoug
-from the power plantr~~h~
S 2- Please provide deald-ifrat ao etbaaiedrawing hwn TH11 R thaU and~pV ra~te takcing illto o 6it v- consumptionn _uig themrining equipment
alternate~ study 0o Jine operation for 1 shiftday Vand twoshifts day -lt
224- Conceptua~l pflR 1 for mi ing anusdtransportation of oil- shale a 0 dmj of hs f u r therV examinedh iV~sdpatI ho u1d be
orderj to poe~ehicalq and~eoomca1 fesblt of t his operation
SYour are requested te) study and consider all- above - iPoin s at your earliest in rder -to be peete y oiAnimain on March 29-301989 peetdb~o 4 n
S9incerly-You S
WDIRECTORGENERAL -
I~ CCMR WLINTON ~vs
5N
Pa D~t~IoAmmn -Jordtn -Tel 815615 20 Bl76 15 -19j A VINO- AFf TY
MARCH 21 RESPONSE TO JEA QUESTIONS
Bechtel Power Corporation Engineers - Constructors
Fifty Beale Street San Francisco California Mail Address P 0 Box 3965 San Franclco CA 94119
March 21 1989
Mr M S Arafah Director General Jordan Electricity Authority PO Box 2310 Amman Jordan
Subject Jordan Oil Shale Prefeasibility Study
Dear Mr Arafah
Your letter of 15 March 1989 with comments on the Oil Shale to Power Prefeasibility Study draft report has been referred to me for reply
The attached responses to each item in the reference letter follows the order submitted
Also attached are three revised pages for the draft report - Volume I
Page 6-1 Page 6-21 Page 6-23
Please copy these revised pages into the report previously sent to you
We plan to review this material with JEA during the March 2930 and April 1 meetings in Amman
rsuVertrul yours
W Linton Project Manager
WHLdc
Attachments Questionnaire Response Three revised pages
cc C J Aulisio R R Buta G D Gould T J Wilbanks
32389
Page 1
RESPONSE TO MARCH 15 1989 QUESTIONAIRE
OIL SHALE TO POWER PREFEASIBILITY STUDY
This study examines economic prospects in terms of a 1995-2000 timeframe
FIRANCIAL AND ECONOMIC COMMENTS
11 It is likely that a BOT deal can be structured at present JEA
generation costs for either 20 MW or 50 MW size units if GOJ is
willing to subsidize the incremental power generation cost
Furthermore these incremental costs can be recovered during the 25
year operation of a Commercial Scale Project
12 A 3rd Party Test was proposed as an alternate means to raising
$100+ for an independent JEA sponsored 20 MW Demonstration
program
13 71 millsKWH for Shale Power
VS
JEA 1987 costs
Purchased Power 17 filsKWH = 51 mills
Produced Power 1360 filsKWH = 41 mills
19952000 Costs - Expected to be 30 to 40 higher and in line
with the cost estimate presented in this study
It also is important to recognize that the busbar cost of power
generated by any new power source can not be compared directly
with the cost of existing older installed capacity because of the
lower capital cost component of the latter (See enclosed Figure
1-1 which demonstrates how total capital carrying costs decline as
the investment is paid off) Any new capacity whether coal oil
or oil shale will be an unreasonable disadvantage compared with
costs for existing older capacity
l
024
o2
0De return
E 016Total carrying charge
012 qu return
S -008
ety taxes and n rcw vshy000 X 0 5 10 15 20 25
Figure 1-1 Year-by-year Carrying Charge Components for 15-yearTax Recovery Period
1-7
30
32389
Page 2
14 Infrastructure Cost
Total People
OperatorFamilies Installed Cost
20 MW $10000000 185700 $54000Operator
50 MW 15000000 3241200 46000Operator
400 MW 45000000 10364000 43000Operator
Factored allowance for grass roots desert installation
including housing and community facilities was developed as
follows for the 50 MW case study
Infrastructure
50 MW
Family Housing 200 30K = $ 6 Million
Bachelor Housing 100 20K = 2 M
HospitalClinic (8 Beds) 11 M
SchoolMosque I1 M
Stores Services amp Recreation = 2 M
Facilities
Roads Electricity Water Sewage = 3 M
$15 Million
Infrastructure costs for the 20 MW and 400 MW cases was ratioed
from this breakdown
At this conceptual level costs are order-of-magnitude In a Phase
II program these infrastructure costs can be developed in detail
32389
Page 3
15 Contract Mining Alternatives
Page 4-11 Mine Operation
Based on Bechtels evaluation of the mine contractors price as found in Section 15 of the Mining Report it was concluded that
the mine contractors price does not include costs for such things
as developing the mine with a box-cut ramp haul roads
developing an area for the waste material maintaining the
haulroads constructing the mine services facilities diversion
ditches sedimentation ponds water well crushing the oil shale
pre-mixing the oil shale at the mine and other items associated
with operating a mine to support a power plant If it is proven
that the mine contractors price includes cost for the above
mentioned scope of work in additi-n to drill blast load and
haul then the contractors price can be used but in the meantime
the all inclusive cost developed by Bechtel should be used
Contract Mining appears to be attractive for the smaller size
plants but not for the larger commercial scale operation Some
third party must provide the necessary capital for trucks
loading mining machines etc under a contract arrangement
16 Reassessment due to Dinar value change needs further study and can
not be evaluated given present budget limitations If average
labor rate of $300hr still valid then little change involve with
study
If deemed necessary reexamination of project economics can be
done in Phase IIwhen funded
17 Costs in this study are based on recent similar Bechtel experience
on Mount Poso project and on Montana I project The Mount Poso
project is a 50 MW unit firing coal in a Pyropower boiler The
Montana I project is a 35 MW unit firing coal in a Keeler Dorr
Oliver FBC boiler utilizing dry cooling
32389
Page 4
18 The Pyropower quote of $186000000 to futnish and erect the steam
generator stack and baghouse has been adjusted to include
engineering construction indirect cost etc to be consistant
with the rest of the costs shown in Table 65 p 6-10 No
further adjustment for location was made
19 Equity funding has the lowest priority of payoff in case of a
liquidation and carries greater risk Hence a higher rate of
return is needed to attract these funds Debt funding is a first
mortgage and has first priority for payoff in case of liquidation
and carries less risk Hence it requires lower rate of return
than equity funding
The risk taking equity owner will ask for greater interest rate
to make funds available The only way to minimize this expense is
to find a loaning agency willing to provide 90 or perhaps 95 of
the investment cost It is likely that banks will require some
minimum equity participation
This Prefeasibility Study was not based on a non-profit utility
operation
Even though JEA is a non-profit organization its service
contributors are profit making groups It is visualized that the
Jordan Oil Shale Co (JOSCO) will be a stand alone business
enterprise servicing JEA under long term contract To secure
funding for the proposed project JOSCO will need attractive
enough contract terms to attract both equity and debt capital
110 Additional work is needed to develop the requested information
This work can be preformed as part of the Phase II program
111 Bechtel includes contingency in all of its estimates to cover
error emissions and unforeseen items within the defined scope of
the project The level of contingency is dependent upon the
amount of scope definition For a prefeasible study such as this
15 contingency is lower than normal
32389
Page 5
112 Tables 89 through 816 include a present value calculation to
establish the relative benefit for a shale project vs coal and
oil
113 The variable maintenance cost of 1 millsKWH has been adjusted for CFB plants with an additional $200000 per year or 06 millsKWH
This yields the following
Variable Maintenance - 10 millsKWH
CFB Adjustment - 06
Fixed Maintenance Cost - 40
Total Cost 56 MillsKWH
114 Page 4-29
The royalty costs are included in the weighted average oil shale
costs for the 50 megawatt plant
Page 4-8
Shale fuel costs include return on equity and royalty These are
two separate cost items Royalty is the last item mentioned in
the sentence and it therefore reads as royalty and not return on
royalty
Page 4-31 gives rates used by Bechtel based on our calculations
using the referenced procedures
DebtEquity Capital Charge Rate
5050 153
8020 139
Table 69 displays the calculation of the 153 capital charge
rate (Line 7 of Table 69 is not used in the calculation and
should be deleted)
32389
Page 6
116 No water purchase charge from the Water Authority was added to the
operating expense based on the statement that no resource costs
will be charged
$020 per 1000 gallons is rule of thumb for USA installations in
absence of client data
Boiler make up water (p4-17) is treated in a demineralizer
train If deemed necessary comparison with reverse osmosis
process can be performed in Phase II
Water requirements were estimated to be
Cubic Metres Per Year
20 MW 50 MW 400 MW
Mine amp Shale Processing 455000 761000 773000
Power Block 3000 6000 42000
Infrastructure 80000 140000 448000
Total 538000 907000 1263000
117 Annual average operating costs shown on Table 6-1 are in error
Financing Option 5050 8020
Cost Shown 56606 48945
Corrected Cost 60396 53236
Average mining and shale processing costs are developed year by
year in the Mining Report Appendix 5 Table 12-10
32389
Page 7
118 We would be interested in receiving the breakdown of these current
power cost figures (ie capital charges fuel cost number of
operators etc) Further economic analysis employing these
figures can be developed in Phase II
119 Manpower requirements for the three case studies were estimated as
fol lows
Mining amp Shale Processing
Power Block
Operations
Maintenance
Management
20 MW 50 MW 400 MW
75 163 396
54 78 175
46 73 455
10 10 10
185 324 1036
Page 14-4 of the Mine Report is for mine and shale processing
only It should be noted that most of these manpower requirements
involved new jobs for Jordanian people
120 At the April 1988 Amman Meeting it was agreed that the following
costs would be omitted
o Permits and Licenses
o Local Taxes
o Import Taxes
If necessary such costs can be developed and added into a revised
economic analysis as part of the Phase II program
121 6 average inflation rate is the figure recommended by Bechtel
based on USA conditions for use in long term economic analyses of
new power ventures
32389
Page 8
122 This matter is referred to ORNL who prepared a rate of return
analysis
Bechtels conclusion is based on computed busbar costscumulative
benefits compared to alternate fuels in the timeframe 1995 to 2000
Relative Busbar Power Cost Net 25 Year
Mills per KWH Benefits - Million US$
Sultani Oil Shale 71-83 Base Cost
Imported Coal
$50tonne 68-88 778
$70tonne 78-107 2531
Imported Oil
$17Bbl 56-76 (18) $24Bbl 61-96 1810
The above results are based on a capacity factor of 75 which is
considered to be a reasonable target for a new plant over its 25 year
life The average selling price of 6 cents per KWH cited in the
questionnaire is based on existing plant costs which may not include
all cost elements of new capacity evaluated in this study
32389
Page 9
TECHNICAL COMMENTS
21 See answer to Item 116
Total power plant raw wate consumption rates and annual
consumptions including the water requirements for wetting ash at the truck loading p int within the power plant are given in Tables 43 and 44 for 50 MW unit and Tables 53 and 54 for 20 MW unit
The raw water requirements for 4x0 MW plant were factored
excepting the mine where a revised mine pldn is employed to reduce water request The quantities shown on these tables exclude raw
water requirements for housing complex mine and ash wetting if
required at the ash disposal site
Total power plant requirements shown in the above referred tables
are
50 MW 20 MW
Rate gpm 207 102 (See Drawing M004)
Annual Use
Gallons 1400000 675000
Cooling tower blowndown supplemented with raw water is used for
wetting ash at the truck loading point within the power plant Raw water quantities attributable for ash wetting at the power
truck loading point are
50 MW 20 MW
Rate gpm 75 325
Annual Use
Gallons 500000 215000
These quantities are included in the quantities shown in
the above referred tables
32389
Page 10
22 We recognize the POTENTIAL for leaching toxic compounds from the
spent ash However this matter is not yet defined well enough to
recommend specific action steps The Prefeasibility Study page
7-12 recommends creation of a ground water dispersion model to
determine whether more specific contaminated water mitigation
plans are needed It is anticipated that the leachate rate will
be low and that aquifer dispersion will keep problem compounds
bel3w health standards thresholds
23 Noted
We have not received up to date resource study material which
defines 50 billion tons resource base Please furnish
The resource base at Sultani alone is adequate to support two 400
MW power projects capacity subject water availability The
2-million cubic metre per year water allowance for oilshale will
limit development to about 600 MW
24 Selection of a combustion temperature is a balance between carbon
combustion efficiency and heat loss due carbonate decomposition
For purposes of the Prefeasibility Study we have opted for high
combustion efficiency At lower efficiency larger shale
mineprocessing plants will be needed
25 Bottom ash is cooled by water exchange before discharge
Cooling water is supplied to the ash screw coolers as specified by
Pyropower See Drawing MOO5 2140 gpm flow for 50 MW and 860 gpm
flow for 20 MW Heat removed by the cooling water from the ash
screw coolers is dissipated to atmosphere via a wet cooling
tower Pyropower should indicate the temperature of the ash
discharged to be 5OOF
32389
Page 11
Initially we had considered using a heat exchanger to cool the ash
and improve the cycle efficiency Considering low cost of fuel
the additional capital costs and the system complexities it was
decided not to employ such heat recovery systems for this project
26 The suggested alternates were looked at briefly and the potential
for wind blown air pollution from the ash disposal areas are too
great to warrant dry disposal unless GO(] and World Bank are
willing to accept such a potential problem Wetting the ash is
tne only practical solution Hopefully some cementation will
occur helping to reduce future leaching potential
27 JEA requirements are noted This is a conceptual study not a
final design Optimal design analysis can be performed during
Phase II
2829
JEA requirements are noted and can be incorporated into the Phase
II design
210 The transformer size is adequate for base load operation A
higher capacity can be considered at the final design stage if the
Client prefers
211 From our experience it does not appear to be economical to
provide additional dry cooling towers to take care of maximum
ambient temperatures which may prevail only for a short period of
time in a year To study this an annual dry bulb temperature
duration curve is required Also adding additional dry cooling
towers will change the plant performance It should also be noted
that the dry cooling towers are very expensive and the size should
be selected carefly considering performance and cost and not on the basis of maximum ambient temperatures This can be studied
during Phase II
32389
Page 12
212 The plant gross output varies with condenser pressure
Condenser
Pressure Design 55 in HgA Annual Ave 35 in HgA
Unit Size MW 20 50 4xlO0 20 50 4xlO0
Gross Output MW 234 593 496 2415 607 TBD
Net Output MW 1975 501 400 205 515 TBD
To be developed in Phase II
Output for 4x100 MW is estimated by others
213 The fan power consumption of the CFB boiler is about 30 to 35 of
the total auxiliary power The fan power consumption of the dry
cooling tower is about 20 to 25 of the total auxiliary power
214 Table 1-1 does not include plant net output Therefore do not
understand the comment
215 Commercial operating experience with coal fueled CFBC units in LISA
and Europe has been uniformly good showing high on stream
availability in early years (See Table 2-6 which reports on
Pyropower experience)
We expect operations with high ash content fuel like oilshale will
have unique scale up problems such as
o Solid handling in and out
o Internal solids circulation
o Erosioncorrosion steam generator intervals
o Heat recovery from bottom ash
Consequently we are recommending these items be worked out in a
single 50 MW prototype
32389
Page 13
216 Maximum dry cooling is used in this study A small wet cooling
tower is used on circulating service water system
217 Horizontal condensate pump is adequate with dry cooling tower and it is cheaper Vertical condensate pumps with cans can be
considered in the final design if required
218 A concrete shell brick lined flue stack will be larger in diameter and costs more than a steel lined stack Brick lined stack can be
considered in the final design
219 Demineralized water tank capacity for 50 MW is 76 cu meters or 20000 gallons not 1000 cu meters For 20 MW plant it is 38 cu
meters or 10000 gallons
220 It is US practice to use an average continuous blowdown rate of
1 and maximum biowdown rate of 3 for this type of plants
221 This can be studied during Phase II
222 Same as 221
223 Same as 221
224 The recommended action plan calls for continuing support studies covering the referenced items Additional effort is needed to
further define these matters and confirm the conceptual plan
The next step is to develop an outline for a project plan including
o Work Scope
o Schedule
o Budget
accommodate the increase in the number of employees and
equipment Truck bays to accommodate the 136 tonne trucks
will be added The truck bays used for the 77 tonne
trucks will be used for the maintenance of other
equipment The warehouse change house training room
offices and cafeteria will be expanded accordingly
6025 Mining and Processing Economics
Details of the oil shale mining and processing plant
economics for the 400 MW plant are included in the Mining
Report (Appendix 5) These details are of the same
magnitude as prepared for the 20 MW and 50 MW plants
The summary of the cash flow analysis for the mine and
shale processing plant is presented in Table 6-1
Table 6-1
SUMMARY OF 400 MW PLANT OIL SHALE MINING AND PROCESSING COSTS
5050 Debt-Equity 8020 Debt-Equity
US $1000 US $1000
Capital Cost
Mine Development 30915 30915
Mine Equipment 66012 66012
Process Plant Facilities 50889 50889
Spare Parts 5000 5000
Working Capital 10000 10000
Capi tal ized Interest
During Construction 24423 39075
TOTAL 187239 201891
Operating Costs and Other Costs
Annual Cost 60386 53236
Product Mined and Processed
Annual Tonnes x 1000 7783 7783
Unit Cost
US $Tonne (weighted average)
US $l06Btu (weighted average) 776
156
684
138
Year 12 costs taken as 25 year average
6-6
-Au
Table 610 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
This report was prepared as an account of work sponsored by the United States Government Neither the United Staies nor the US Agency fo International Development nor any of their employees nor any of their contractors subcontractors or their employees makas any warranty exshypress or implied or assumes any legal liability or responsibility for the accuracy completeness or usefulness of any information apparatus produc or process disclosed or represents that its use would not infringe privately owned rights
I
JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
SUMMARY TABLE OF CONTENTS FOR ALL VOLUMES
VOLUME I o Study Report and Executive Summary
VOLUME II o March 1989 Prefeasibility Study Presentation
o March 15 JEA Questions (MS Arafah) on Prefeasibility Study Draft Report
o March 21 Response to JEA Questions
VOLUME III o Appendix 1 - Design Basis Criteria
o Appendix 2 - Sultani Deposit Geological Data
- 1987 NRA Report
- 1988 Draft NRA Report on Supplemental Core Drilling
o Appendix 3 - Ahlstrom Pyroflow Process Background
o Appendix 4 - NRA Sultani Blended Sample Report
VOLUME IV o Appendix 5 - Bechtel Mining Report
VOLUME V o Appendix 6 - Oak Ridge National Laboratory Report Preliminary Assessment of Using Oil Shale for Power Production in the Hashemite Kingdom of Jordan
VOLUME VI o Appendix 7 - Pyropower Corporation Test Burn Report
o Appendix 8 - Pyropower Boiler Design - 50 MW
o Appendix 9 - Bechtel Power Block Design - 50 MW
o Appendix 10 - Pyropower Boiler Design - 20 MW
o Appendix 11 - Bechtel Power Block Design - 20 MW
o Appendix 12 - Chevron Corporation - World Energy Outlook
0511T
JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
VOLUME II TABLE OF CONTENTS
o March 1989 Prefeasibility Study Presentation
o March 15 JEA Questions (MS Arafah) on Prefeasibility Study Draft Report
o March 21 Response to JEA Questions
0511T
MARCH 1989 PREFEASIBILITY STUDY PRESENTATION
PREFEASIBILITY STUDY
OIL SHALE FUELED POWER GENERA TION
Presentation to
HASHEMITE KINGDOM OF JORDAN
March 1989
OUTLINE
M Introduction
Technical feasibility
U EConomic feasibility
Study conclusions
Recommended action plan
S Prefeasibility StudyOil Sftle Fueled Power Generation
Introduction
m Study program
m Integrated project scope
Prefeasibility StudyOil Shale Fueled Power Generation
VOO740LAd R 3
STUDY PROGRAM
Task
N Program management
U Test sample procurement
Test burn report
N Jordan power demand assessment
N 2050 MW boiler designcost
2050 MW project BOP designcost
i 4x100 (factored) boiler designcost
4x100 (factored) BOP designcost
Environmental assessment
N Economic assessment
Risk assessment
Action plan
Final report
BOP = balance of plant
Prefeasibility Study Oil Shale Fueled Power Generation
V007S AEI 4
Assignment
Bechtel
JEANRA
Pyropower
ORNL
Pyropower
Bechtel
Pyropower
Bechtel
ORNLBechtel
BechtelORNL
ORNLBechtel
Bechtel
Bechtel et al
a
INTEGRATED PROJECT SCOPE
For 20504x100 MW installations
Open pit mine
M Oil shale processing
U Power block
- Boiler plant
- Power generation facilities
- Raw water supplytreating
Ash disposal system
U Onsite infrastructure
U Offsite infrastructure
Prefeasibility StudyOil Shale Fueled Power Generation
VOO764GE1 S
i
_Conceptual Facilities
Truck end ShovelOperationrtHO Open Pit Mine Mineral Rock Stockpiles Waste To JEA Substation and
Electric PowerGid
Hurden and
Off Shale Communly Faciliies Central Central a0000con
0cr~nn Plant Malntenance and Warehouse
Pyroflow Cornbusbr
Steam Turbine Generator
(gt Power - -o-
Three Day BW ----- C nest
Waer Supply System Food Hopper Baghouse
Pr cees Domestic Boiler Feedwater
Water Water Water
Ra
Wells to Underground
Watr
Plant
Boltom Ash Overhead Ash Fly Ash A
Condenser Wastewar
P n r r Slowdown AqrnrServiceMI Pugdow Water~
Water system Slowdown
Cooling Dioalsposal
Tower Spent Shale Ash Disposal i Prefeasbly Study
Oil Shale Fueled Power Generalion
179 5896aJordari 183-10-89 r30
TECHNICAL EVALUATION
N Pilot plant test program - 75-ton sample procurement - Test results
- Test conclusions
0 Conceptual design studies - Oil shale reserves and analyses - Mine and shale processing - Power plant and auxiliaries n Development schedule
bull Material developed by Pyropower and Bechtel
o 1Shale Fueled powr Genera VOM4ME~j
Technical Feasibility
N Technical evaluation
N Technology risk assessment
U Environmental assessment
U Power demand versus supply assessment
Prefeasibility StudyOil Shale Fueled Power Generation
i
Pilot Plant Test Sample
Expected Blended Avg Mine- 75-ton Run Shale(a) Sample(b)
Fischer assay oil content wt 75 8486
Organic carbon wt 102 plusmn13(c)
Gross calorific value BtuIb 2000 2250(c)
Sulfur content wt 238 255(c)
(a) Rechtel evaluation of core hole data (b) NRA analysis (c) By correlation with Fischer assay
Prefeasibility StudyOil Shale Fueled Power Generation
VOO4JOEARI I
i
Pilot Plant Test Program
Conducted at Ahlstrom LaboratoryFinland
U Performed 8 test runs
Tested four process conditions
- Primarysecondary air ratio
- Bed AP = 405070 M bar
- Load level = 4060100 pct
Combustion temperature = 830 to 9000C
Prefeasibility StudyOil Shale Fueled Power Generation 119
- FCC plant sizes equivalent to proposed power application
Prefeasibility Study Oil Shale Fueled Power Generation
VOO94GEampJRI26
i
PYROFLOW UNITS IN THE US
COLORADOUTE IOYA STATE UNIV UNIV OFNUCLA CO NORTHERNAMES IA BF GOODRICH110 1o0MW(a) 2x170000 Ibhr HENRYILCEDAR FALLS IA 120000 Ibhr GENERALGULF OILu EiN P MOTORSSbtUpStart-UIL 1987 O A 1I N000 TC
NORT10 PONTIACH B MIRANCHWV00000 lbhr
CORN PRODUCTSSM NORTH-CAROLINA STOCKTOD CA
400000 lbbhl t
RUMF RD ME
CEMENT CO CALIF PORTLAND-COLTON CA
190000 Iblhr Start-Up 1985 TRUMTFTWN NYU
3I75ERTOWN N
etar t-Up loss ACE COGENERATIONCABI
TRONA CA Oper t~on l -Start-UP 1990 ~ rt upz 091Start-up loss Start-up PNeLAI 1991
MTKESFICOENERATIO-N1
BASFIELDp Start-uStar-Up WESTCA9 199otgoUp 1 MAHONEV PA|00000 Ibhr A Oz 2X365000 Ibhr
SETtr-Ups 188B CHAT TANOOGA TN
G ULF OIL EXPLORATION 8ta-rt-u) 1085BAKERSFIELD NORTH BRANCHCA SPRING GROVE PANORTH BRANCH WV 400000 IbhtOperational 19835 5 0 0 I b h 9 0 0 0 Iblh r- tart-Upi 1991 S t r - U p s l e s s
SOUTHEAST PAPER MFG CO UNIVOF NORTH CAROLINArDUBLIN GA UHAPEL HILL NO400000 IbhrStart-Ups logo Start-Ups2X250O000 1loseIbhr B
- Withdrawing ash from combustor - Withdrawing fly ash
a Internal solids circulation of the steam generator
m Erosioncorrosion of steam generatorinternals
Heat recovery from bottom ash
U Operation with low calorific-value fuel
Prefeasblity Study O Shari Fueled Power Generation
VOO7AI 27
Impact of Scale-Up
Project Size
20 MW
50 MW
100 MW
50 MW boiler in 100 MW plant
Potential Risk
Design Scale-upOperation of to 100 MW Initial Plant Plant
Low Significant
Modest Modest
High Low for duplicate units
Modest Low for duplicate units
Prefeasibility Study Oil Shaje Fueled Power Generation
VOO71-4GEAL4n2
i
Conclusions
Defined risk of CFBC boiler is acceptable
U Operating experience with commercial CFBC boilers built and under construction will strengthen confidencelevel and minimize risk for a plant built in 1995
SPrefeasibility Study Oil Shale Fueled Power Generation
V007GHAAE29
ENVIRONMENTAL ASSESSMENT
a Mine and shale processing
- Fugitive dust emissions
- Noise levels
- Leachability of disposal piles
Power plant
- Fugitive dust emissions
- Gaseous emissions
- Noise levels
- Water effluents
U Conclusions
Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel
Prefeasibility Study Oil Shale Fueled Power Generalon
- Coaloil prices will be at least 15 greater after 1995
- Discovery of indigenous conventional fuel resources is inadequate for power plant purposes
Prefeasibility Study
Oil Shale Fueled Power Generation
VOO) IDWFO
Feasibility(Contd)
N Suitable financing will be available
- For $200 million 50 MW prototypeproject
- For $1000 million 400 MW commercial project
Government of Jordan will make basic commitments
- Long-term power purchase agreement
- Long-term access to Sultani shale deposit
Adequate water and manpower resources
- Attractive tax incentives
Prefeasibility Study
Oil Shale Fueled Power Generaion
VO bull1DUJJRO 6
Timeliness
U Timely development of Jordan oil shale needs prompt action to create - Additional definitive information
- Suitable business plan
Prefeasibility Study
Oil Shale Fueled Power Generation
VooI DUJo 7
i
Expansion Conditions
U Continued expansion of powergeneration from oil shale in Jordan depends on water availability
Prospects for power export or importand domestic load growth will affect size of the needed shale-to-power program
Prefeasibility Sudy
Oil Shale Fueled Power Generation
yOWl lVuJO
Environmental Impacts
N Environmental impacts of shale development will be minimal
Prefeasibility Study Oi Shale Fueled Power Generation
i
Development Advantages
Will create significant new jobopportunities in Jordan
Will avoidreduce foreign exchangelosses for expanding alternate fuel imports
Prefeasibility Study
Oil Shale Fueled Power Generation
VOOIIULL tO
Recommended Action Plan
N Basic recommendation
N Conceptual development schedule
U Project development plan
Key plan elements
N Funding requirements
Prefeasibility Study Oil Shale Fueled Power Generation
VOO4II )U OII
i
Basic Recommendation
N Expand efforts to develop an oil shaleshyfueled power generation program at the Sultani deposit
- Conduct required supporting studies
- Define facilities costs and business plans
- Obtain project funding
Prefeasibility Study
Oil Shale Fueled Power Generation
VON I II)ILL 12
C
Conceptual DevelopmentSchedule
1989-1990
- Conduct supporting studies - Define costsbusiness plans for 50
MW prototype and 400 MW commercial projects
- Develop project financing
N 1990-1993 - Build and operate the prototype project
N 1994-1996 - Expand the 50 MW prototype to 100 MW scale
U 1996-2000 - Expand the project to 400 MW scale
N 2000-2005 - Build a second 400 MW commercial project if needed
i 1 Prefeasiblity Study
dOil Shale Fueled Power Generation
VW IMLITO 13
Conceptual Development Plan
Months
1 Project development plan - Define project
costs1busness plans
-24 -12 0 12 24 36 48 60 72 84 96 108 120
2 Secure funding
3 Build and operate 50 MW prototype
Dergn and procurement
Mine development
Plant construction
Startup and testing
Operations
L- -
4 Expand prototype to 100 MW
Design and procurement
bullConstruction
Startup
5 Expand project to 400 MW
2nd 100 MW unit
3rd100 MW unit
i 44
4th 100 MW unit -
O Project dacision point
i Prefeasib~ity Study Oil Shale Fueled Power Generation
17958562aJocdanV 3-14-89 rsO
18
Phase I - ProjectDevelopment Plan
n Program development
Seminar workshop on prefeasibilitystudy Oate project development plan woek scope schedule arid budget
U Carry out project planning program
- Conduct continuing support studies - Test Sultani shale in existing FBC
- Firm up designs and specifications
- Update costs and economic analysis
- Develop business plans and requirements
Explore project funding alternatives
i Prefeasibility Study
Oil Shale Fueled Power Generation
VO MItUOR 14 -0
Key Plan Elements
N Project feasibility analysis
- Firm up designs and equipmentspecifications for all facilities
- Update cost estimates based on preliminary designs and specifications
Explore arrangements for contract mining and mine development
Update forecasts for demand growthand for retirements of older generating capacity
- Create updated economic analysis
Preleasibility StudyO1 Shae Fueled Power Generation
VOO1IOLWRI
Key Plan Elements (Contd)
Business entity requirement
- Explore optionsconditions for a new company to managebuildoperate the project
- Explore optionsconditions for obtaining a concession agreement for Sultani development
Explore optionsconditions for water rights commitment
Prefeasibility Study Oil Shale Fueled Power Generation
VMIOIA)lj 16S
i
Key Plan Elements (Contd)
U Continuing supporting studies
- Combustion tests (additional pilot tests for design and warranty purposes contract for large-scale burn operations in existing plants if appropriate)
- Additional core drilling and core analysis
- Oil shale crushing tests
- Spent ash leaching tests
- Geotechnical data base including soils analysis
- Environmental baseline data
Prefeasibility Study O Shae Fueled Power Generation
VMMMUldMOA
Steps Required to Develop an Oil Shale-to-Power Project
Create a development business plan - Schedule - Decision tree
Develop a work scope and budget for the development plan program including - Firming up designsspecificationscosts
- Developing business entity requirements - Continuing support studies
Carry out development plan program
Assemble all planning results in a report for discussion with financial institutions
Explore project finance opportunities
Finalize business arrangements
Implement prototype project
i Prefeasibility Study
Oil Shale Fueled Power Generation
VM1-11UJROLI
MARCH 15 JEA QUESTIONS (M S ARAFAH) ON PREFEASIBILITY
STUDY DRAFT REPORT
Rt
DIR EScBSULIVAN PHD OFJCEop~BUREAU FOR SCIENCE AND~TECHNOLOGYAGENCY - --FOR INTERNATIONAL DEVELOPMhINTSWASHINGON DC x20523---------4
4 -
-SUBJ E CT - -C O H~ E T 4N l
Dr Mr sullivan ------shy
c-rommnents We ~efr-preaereorPla -tobYou lete dted Jan 91989 regardn~i4po4t P ea e1 f i nd y ubel ow our -e ot r XcOrcerned Jordanian deipartments
- --A ar o~nnYu Y o turjlt~ lt K
4 C~mments
~1 N i gFIN I~fANDECONOMIC1COIMEN S -
It sidicaed that Beohtel and US AIDWash ingtonj~4- re ojy nen ing that E 2hould und ertake the n e tshyihaisAre ~our c leometprogram n order shye-t im~ ate d f n t v design and budget cost
4Al1so Lthe study ncal--ttsutnilndcaei~ A-1 A thas ~ l 1 be eeded idb~~~~~ rn o ei t n i la itheMWa~-~5s~ 4
hrPro hehgemetTh trOfT ses~fnr4 BOT)Vmanu- a n-mnf~cure 4 r~j or contra c4-or ivoIlveiintijn I 4 4investmnt ude smi ~w 2 Zha tev e r --~4~prce e ec r it v p4~ f JA gertiy geeated-at 4 JEA 3 a l b u y ~the same average~~ A
~jithia oncot in4 ordrtan ecpoemic asess thespePower generatjoon J ordan3 oi sha I eroic c inr~etJordan 4
2P ge i1- 1 Aj iit eu that OPin he atocontr~ct 4with owner4 ofext3ing (oconstriiction r(FB rml-t
qu i of S 11 t to test large tonnagen j es StaniUti n d ajIe -for se veralIQf 31 hi
evrEAPreferpilot qr the dP 1prt7n -that the4mPIt
andi to(7 he instalI 1e 2 310 A
_
JODN ELECTRICITYAUTHORIT LL
Dac
operated in Jordan i n or~der~~t ~n nuex~on mnining crushing and haidi igQhre~ and sash Maeia nd aSootoget enough olr ndaita needed for einolre
CEBbole~ -i s~
ccordance with Jordaian oil shale
large to~ bfig
1 3 le 1-2 Page 1-7 Cost Of Pwer~i It i S menti-oned that the conmecial oil hle~ lt~project (4 X1OOmw) 1is ninacompetative roqt~range-~while table 12 indicates thattcost of-pow Ais~mill
q kwiihcii r 1
average wih i ii -much higher ihantheshy-ost of ~Power gnrtofomJEA therimaPower s ta tions Please~ indicate on what basi o ~~ shave-~made your-statement
PK
14 Pae 2 Sction 4-0sIt 1nlkly that theChousing and off- -site infrastructur-ommnity fakilitieR) to be onsidered for both the demo and prototyp prjcs oeoverwe~4 hnk that their~c_6t is raterojects Mo
iwcv~- age -1 1 Mine O(perationIIt is indicate~d that mining cot eevdfoMine contractor~ are ficomiplee h
r and iyudi-t~con qidder contract mnn opio fr4 the min4 cmflt2ng are reIanddrepres~ent the real costs derived from Phspat miin contractors in
lestfor the eo rPooypuat in order tlt7
P I eadenote tha detthe new exchangerate ofthJraian~ Di~nner you may add 20j6 Kto the quoted
1 6 P Ias e consider the followin ecn hage_
171- The new exchange ra teof tUSD=54o0 fils1 72-W2 The new~ aerage tariff for selIn~electricityhas decrreased to 120 8 f ilIsicwh
17- Page 1-7 TbIe 1-2 W bev th tthe cap ita1 cot for the pwhokand forthe min n d ash hMnd1ing equipen
P B~2Anaor a -Tl 8156152 8176 1Q MYf -t -Now 520 t 1U
JDNEECRICIT AU-RA L14lLiL
2 ~are very high We suggest~ thta You rerconsie (- telowerus e~+d accuracy est a rangethan +30
Page4-22 Table 4-5weno0ti ced( that- PyroPowe ha ddeta(IiacCst fori the bo1ilerlocation and terha dutdetlease isxtr fo~ l C~ io~ s~ e~~ 1a~ a if and indicate theonldjusted ~percentagefor construction foin Jordan
19 Page-7 Table 11-2 -Yo aeue ihrinterest rate on Equity thatn on1DehI~laseinclude~ adetaied explanation of thisrr -tni kepin in miUndie JEA is1thaIt a non profit~ shyorgaiztion unik oher private UJSA utility~in ktation
~-~110- Regarding shy
the ra4ital Rt fthe project it is~requesed tobre k it intdo foreignMeanwhile cthe nd lorcal c-osfoeigptario i nt-re3t~shol becnierdo-h
rr n ontiondonnotopdbon the 9 cnieelocal portion~onth
1-1- 237~Pa
oningeny 9tooi s high~~ a lower 4value -should be~
4~ gt ~112- -Tbles t1-1 -8-8~ inclu~de t~he c~alculationscuultie nt enefits for of Th shyunttypes l i4s difeen geeatnmrer likely tocluae
-~ Q~ J7present vk1u for tenet tthe~benefits in feralterntives -t-oa s the
49
ehliyoi shale
Wea gree with you9 tha t th e percentage used ~ an for thenua~l 0 ~amp-M rahr CFBo ndsomewha~t highervrate be n ededma y for a C B l n Me n h l ~ a e r
indir e ta~ts the -estimatedma i variablec st i ddition t he fi-xed-9i 1 mislkih We --
thinktttiis too lowK -5
shy
1-14- e 4-29
opprza tion-o to The o i1s h1 costs-nc I deAbo 1h
Pa10 mman ormTSI62 a
IB I
JORD N EtECTICI1~ 4 E~)~Is-s
Date ib-_
~ ~riii~g~nd~o9~ru~hng h~tnlin cot~u~tv yo
i Dae Jnryit
1ts c 7 4-
i smiig iniand fh co I eY
susendi ca tI t icag th t1 ~an~approximate 15 ~pita L tYII I (-~a~ge or he owe bl ockj f aniitjes isof +the capthe)t~ial7cpi~lrharge Uoratelformny SI~Uj(uiity installa~tions~ whle page 6-1T9 talJshyit is mentioned that~ the Capital rate pe-r JEA isshyi5~PeaseJustify this~matter since~w o
i16- Pae 6-1 6
1 I4~t is mentioned that the costs of 4process Water are ~ 4 ~0 2$1 000 gallons
r~j~lt IHave~You considered additionalvalue ofbying waterfrom~ the Wa ters Aito i ~or ditoa cost~f o revrseoqoesplant if ground water is used
~~ I1 7- Table 6-1 Page 6-6 Please explain how did You come ou ihteoil~ shale miniing and proces~sing uit~Icost
ltII~I~ 8- Please note 1 t hatj the average JEA~productinr ot frmthermal I power stationsr (Istationbus-barCOSt)i sbewen 6 3-17 3 fils 4kwh You may use this~
l4~ 19-i For ~4 X 100~AMW Plat iti etindo pag e14-4 VolI 11 that4 at tota I of W42 14 epoye W II eemplo~yer] And on page 69yo1Iiti mentioned that a~ tot 1 f1 ~p yeI iNbe enp1oyed a
is~ high asrmetitexeds100personorthe ~41X100~MWh~~j nsatnpPrlae
I 1 The 4 following iftemns are a sumed to1 be excluded from theraPi ta 1 cot xoI
120-1 Perits I icen es 7
1_207~3 Imprt ~xe on s7pare par ts -and c(7orfmurab -ma~teria Is
04f4 4
~4 R j4 4
D4
~ ~ ~ AIf eS taxesq in acrac ihteJraand regulations should be considered aw
21- p1ea4s e indic ate Your Ju t f c io r us ga 6
44122- Table 977App 5Page4 9-1 4L IK Car1Yiniae that the hIRR of the 4 Otplantis rather unattractive (66)most
-( Cns1er4 ngthe logical base 4csek c pwhen cii 6OL
average sell~ing prc CkhampDEratio L801~2O~Aoreover4M the ne siellin prcwh o JEA ati theamptime~ Abeing os4ltp n~ot exceed 4 Ckwh~-However Ipage 1shy~ and 14 0 T indicate that ecnms for a commeri
S4A4scale joil 4 shale projc ~
appear Piomisig-nug o4Ywarrant continued dee fgfluht 4 feaibiit 4tudy wihil cost sevea~lili
do ar~sf Plas lear wether the ~x step jqs~$j~~lt 4
gtt 9o be considered arCcording4to jthe 4unattractiveresul to mentioned in IRR7 Table 97 gt4
a C4 44fET2 4 144-4444 P a g 1 T b6 l
htte~We ~ ~ ae~ rqieetfrteX ~ noie ~~ ~ 444 MW un t44 r te4l w w e o p r d i th e w t r n rre u f4m or4444~ the4444 54M4rto y e Pg~A~44EHiveL det ile an l A44
s o awa er c n um t a4r f rofsho in P6Io erT
e ch 2 50 M W aPln wa e d 41004 MW4 1 consumption_____________
ma4~2 k e u p houin~44 p A44 4444444 C O 4ltI4
a nd a sh et in etc 4 2 4 1 -24 P a g e4 2 - 1 A P P 5
4Yo 4_ j1 4 4~h444 N44 44
1gro nd tce t hir fthe w bern coqir mna t efora4e 4X10A M 444444 4 r i n to 4 4 4lo w w ehA 7 n 2 cinCie h rh4 n ttthh1eb -e 4 44t Of3 E4O
ea h n~ ffl 4 4Jl44 4 4444 4giv
6 ig re sofrat4 de in cl ar f w w at5 c hrw pe o
s h b 444 o t h e g nd L 44 h u i n C
r 4ne a4 t44 e L(704 2 4 p ae) 2 - o Au P dn 5ai 7~e r 44 I Y (1t 44a
ve7 rn e qu 1saharvthe y
and n~~~o speci~~~l4 p n l nh i n t x
r ~rA M e d r o t eu n 8 1 wTtl t t h
- c re e N I wo6
~ n n a i n a t d h l7 A PP6 gt
J
S2~3- Page 2-4 ~ ~ It ~is i
that oil eindicated the- sha le r our~ Cesin Jordan are 10 billion tons -The anulp e reere maiy exeed 50 4 billion tons ~
~ 24- 4Page~2 -l1 iujntr We beiv thtCBcmuto~ep i s high and~alSo
~~ ~ -2 ~~ Page 4-1~6 j - shy
Please~~ indicates your procedure to cool the omn ashand atwa icagd-eprtr
A Have you~ considered~ additional he~at exchanger topcool th ash and to imrve h cycleef ficiency
-~2~6 Page 4-16 It s~ indicated that ash from each silo i Amixed19 ~with~fabout 20 waterKb weight to minimize generation of dust~during trnprtto to mine and disposalHave you~ coniidered other 4lternativeto
~ ~eliminate dustiiig -and avoid use ofwat r uring it ransportationi such as~ using closed trucks or closed
of ~fans conUMnPo wihrlaintthe total plant auiir poe osupin 1~21- Table 5_-3 and I ~
Th~~ is- somneere c6ntradiction regardingplnneotpu~t in both am tables 21-~ Tabl~e 1-33
We noticed tha~t yourall9 cacacapac t fatro75 tion ae asdnWe thilt ~that 7capacityshyfacto is tobo high for- an oil shale fired plant duketo lack of existing simila~r ~plants handl~~~firing oil adshale ~K
216~ The study iniae thtawet~coigtower wi11~used Actually a b
dry cooling should be consideda5ini ~HTP S inZ atomnmz so water rnumption4the cycle~ efficiency willbe reducedHenre YO33~reconsider calculating the cyclefficiy
U~~~~~ codnt umconsidered ofhorizontal -aretypethe~ the vertical cian type can alsobeh considered
shy ~ ~ ~ I~~
2~2 Kconcrete shy
shjell stepl fltstack is onidereconcrete shell brick flue Rt c ~s beCaconsidered3V
2-19~- Deminiraized water~ tank3 capacity~ is -76 ui(meterThe recommnended tank cameter- ui tyi 00cbc
220Designconditions Pa~ge (4-74)te5 hat bow 3down percentage splusmn ~fomrpra til re i hou I be 3~)~
PoD Z 2 m a ad~ - e 5 1 2 iJS~ ~ p A f amp ~ ~ y1
4
JO R ECTICITY AUTHORTIT 4L
~ 4
Date~
t etats ttthe quantityof s i S ~1 000Tons ra Sthis tuntity 11- be transporited for severIy --to tu ofI pit a~te torg P KM ra~erm Spower plIatS about 12 midilidoni CUIA(- met ryea
h e ndd mp e he (d u p in i n L
area wil evric power plant6t Please zn1 a te~tiv s tudY for dumping th r~ a enoug
-from the power plantr~~h~
S 2- Please provide deald-ifrat ao etbaaiedrawing hwn TH11 R thaU and~pV ra~te takcing illto o 6it v- consumptionn _uig themrining equipment
alternate~ study 0o Jine operation for 1 shiftday Vand twoshifts day -lt
224- Conceptua~l pflR 1 for mi ing anusdtransportation of oil- shale a 0 dmj of hs f u r therV examinedh iV~sdpatI ho u1d be
orderj to poe~ehicalq and~eoomca1 fesblt of t his operation
SYour are requested te) study and consider all- above - iPoin s at your earliest in rder -to be peete y oiAnimain on March 29-301989 peetdb~o 4 n
S9incerly-You S
WDIRECTORGENERAL -
I~ CCMR WLINTON ~vs
5N
Pa D~t~IoAmmn -Jordtn -Tel 815615 20 Bl76 15 -19j A VINO- AFf TY
MARCH 21 RESPONSE TO JEA QUESTIONS
Bechtel Power Corporation Engineers - Constructors
Fifty Beale Street San Francisco California Mail Address P 0 Box 3965 San Franclco CA 94119
March 21 1989
Mr M S Arafah Director General Jordan Electricity Authority PO Box 2310 Amman Jordan
Subject Jordan Oil Shale Prefeasibility Study
Dear Mr Arafah
Your letter of 15 March 1989 with comments on the Oil Shale to Power Prefeasibility Study draft report has been referred to me for reply
The attached responses to each item in the reference letter follows the order submitted
Also attached are three revised pages for the draft report - Volume I
Page 6-1 Page 6-21 Page 6-23
Please copy these revised pages into the report previously sent to you
We plan to review this material with JEA during the March 2930 and April 1 meetings in Amman
rsuVertrul yours
W Linton Project Manager
WHLdc
Attachments Questionnaire Response Three revised pages
cc C J Aulisio R R Buta G D Gould T J Wilbanks
32389
Page 1
RESPONSE TO MARCH 15 1989 QUESTIONAIRE
OIL SHALE TO POWER PREFEASIBILITY STUDY
This study examines economic prospects in terms of a 1995-2000 timeframe
FIRANCIAL AND ECONOMIC COMMENTS
11 It is likely that a BOT deal can be structured at present JEA
generation costs for either 20 MW or 50 MW size units if GOJ is
willing to subsidize the incremental power generation cost
Furthermore these incremental costs can be recovered during the 25
year operation of a Commercial Scale Project
12 A 3rd Party Test was proposed as an alternate means to raising
$100+ for an independent JEA sponsored 20 MW Demonstration
program
13 71 millsKWH for Shale Power
VS
JEA 1987 costs
Purchased Power 17 filsKWH = 51 mills
Produced Power 1360 filsKWH = 41 mills
19952000 Costs - Expected to be 30 to 40 higher and in line
with the cost estimate presented in this study
It also is important to recognize that the busbar cost of power
generated by any new power source can not be compared directly
with the cost of existing older installed capacity because of the
lower capital cost component of the latter (See enclosed Figure
1-1 which demonstrates how total capital carrying costs decline as
the investment is paid off) Any new capacity whether coal oil
or oil shale will be an unreasonable disadvantage compared with
costs for existing older capacity
l
024
o2
0De return
E 016Total carrying charge
012 qu return
S -008
ety taxes and n rcw vshy000 X 0 5 10 15 20 25
Figure 1-1 Year-by-year Carrying Charge Components for 15-yearTax Recovery Period
1-7
30
32389
Page 2
14 Infrastructure Cost
Total People
OperatorFamilies Installed Cost
20 MW $10000000 185700 $54000Operator
50 MW 15000000 3241200 46000Operator
400 MW 45000000 10364000 43000Operator
Factored allowance for grass roots desert installation
including housing and community facilities was developed as
follows for the 50 MW case study
Infrastructure
50 MW
Family Housing 200 30K = $ 6 Million
Bachelor Housing 100 20K = 2 M
HospitalClinic (8 Beds) 11 M
SchoolMosque I1 M
Stores Services amp Recreation = 2 M
Facilities
Roads Electricity Water Sewage = 3 M
$15 Million
Infrastructure costs for the 20 MW and 400 MW cases was ratioed
from this breakdown
At this conceptual level costs are order-of-magnitude In a Phase
II program these infrastructure costs can be developed in detail
32389
Page 3
15 Contract Mining Alternatives
Page 4-11 Mine Operation
Based on Bechtels evaluation of the mine contractors price as found in Section 15 of the Mining Report it was concluded that
the mine contractors price does not include costs for such things
as developing the mine with a box-cut ramp haul roads
developing an area for the waste material maintaining the
haulroads constructing the mine services facilities diversion
ditches sedimentation ponds water well crushing the oil shale
pre-mixing the oil shale at the mine and other items associated
with operating a mine to support a power plant If it is proven
that the mine contractors price includes cost for the above
mentioned scope of work in additi-n to drill blast load and
haul then the contractors price can be used but in the meantime
the all inclusive cost developed by Bechtel should be used
Contract Mining appears to be attractive for the smaller size
plants but not for the larger commercial scale operation Some
third party must provide the necessary capital for trucks
loading mining machines etc under a contract arrangement
16 Reassessment due to Dinar value change needs further study and can
not be evaluated given present budget limitations If average
labor rate of $300hr still valid then little change involve with
study
If deemed necessary reexamination of project economics can be
done in Phase IIwhen funded
17 Costs in this study are based on recent similar Bechtel experience
on Mount Poso project and on Montana I project The Mount Poso
project is a 50 MW unit firing coal in a Pyropower boiler The
Montana I project is a 35 MW unit firing coal in a Keeler Dorr
Oliver FBC boiler utilizing dry cooling
32389
Page 4
18 The Pyropower quote of $186000000 to futnish and erect the steam
generator stack and baghouse has been adjusted to include
engineering construction indirect cost etc to be consistant
with the rest of the costs shown in Table 65 p 6-10 No
further adjustment for location was made
19 Equity funding has the lowest priority of payoff in case of a
liquidation and carries greater risk Hence a higher rate of
return is needed to attract these funds Debt funding is a first
mortgage and has first priority for payoff in case of liquidation
and carries less risk Hence it requires lower rate of return
than equity funding
The risk taking equity owner will ask for greater interest rate
to make funds available The only way to minimize this expense is
to find a loaning agency willing to provide 90 or perhaps 95 of
the investment cost It is likely that banks will require some
minimum equity participation
This Prefeasibility Study was not based on a non-profit utility
operation
Even though JEA is a non-profit organization its service
contributors are profit making groups It is visualized that the
Jordan Oil Shale Co (JOSCO) will be a stand alone business
enterprise servicing JEA under long term contract To secure
funding for the proposed project JOSCO will need attractive
enough contract terms to attract both equity and debt capital
110 Additional work is needed to develop the requested information
This work can be preformed as part of the Phase II program
111 Bechtel includes contingency in all of its estimates to cover
error emissions and unforeseen items within the defined scope of
the project The level of contingency is dependent upon the
amount of scope definition For a prefeasible study such as this
15 contingency is lower than normal
32389
Page 5
112 Tables 89 through 816 include a present value calculation to
establish the relative benefit for a shale project vs coal and
oil
113 The variable maintenance cost of 1 millsKWH has been adjusted for CFB plants with an additional $200000 per year or 06 millsKWH
This yields the following
Variable Maintenance - 10 millsKWH
CFB Adjustment - 06
Fixed Maintenance Cost - 40
Total Cost 56 MillsKWH
114 Page 4-29
The royalty costs are included in the weighted average oil shale
costs for the 50 megawatt plant
Page 4-8
Shale fuel costs include return on equity and royalty These are
two separate cost items Royalty is the last item mentioned in
the sentence and it therefore reads as royalty and not return on
royalty
Page 4-31 gives rates used by Bechtel based on our calculations
using the referenced procedures
DebtEquity Capital Charge Rate
5050 153
8020 139
Table 69 displays the calculation of the 153 capital charge
rate (Line 7 of Table 69 is not used in the calculation and
should be deleted)
32389
Page 6
116 No water purchase charge from the Water Authority was added to the
operating expense based on the statement that no resource costs
will be charged
$020 per 1000 gallons is rule of thumb for USA installations in
absence of client data
Boiler make up water (p4-17) is treated in a demineralizer
train If deemed necessary comparison with reverse osmosis
process can be performed in Phase II
Water requirements were estimated to be
Cubic Metres Per Year
20 MW 50 MW 400 MW
Mine amp Shale Processing 455000 761000 773000
Power Block 3000 6000 42000
Infrastructure 80000 140000 448000
Total 538000 907000 1263000
117 Annual average operating costs shown on Table 6-1 are in error
Financing Option 5050 8020
Cost Shown 56606 48945
Corrected Cost 60396 53236
Average mining and shale processing costs are developed year by
year in the Mining Report Appendix 5 Table 12-10
32389
Page 7
118 We would be interested in receiving the breakdown of these current
power cost figures (ie capital charges fuel cost number of
operators etc) Further economic analysis employing these
figures can be developed in Phase II
119 Manpower requirements for the three case studies were estimated as
fol lows
Mining amp Shale Processing
Power Block
Operations
Maintenance
Management
20 MW 50 MW 400 MW
75 163 396
54 78 175
46 73 455
10 10 10
185 324 1036
Page 14-4 of the Mine Report is for mine and shale processing
only It should be noted that most of these manpower requirements
involved new jobs for Jordanian people
120 At the April 1988 Amman Meeting it was agreed that the following
costs would be omitted
o Permits and Licenses
o Local Taxes
o Import Taxes
If necessary such costs can be developed and added into a revised
economic analysis as part of the Phase II program
121 6 average inflation rate is the figure recommended by Bechtel
based on USA conditions for use in long term economic analyses of
new power ventures
32389
Page 8
122 This matter is referred to ORNL who prepared a rate of return
analysis
Bechtels conclusion is based on computed busbar costscumulative
benefits compared to alternate fuels in the timeframe 1995 to 2000
Relative Busbar Power Cost Net 25 Year
Mills per KWH Benefits - Million US$
Sultani Oil Shale 71-83 Base Cost
Imported Coal
$50tonne 68-88 778
$70tonne 78-107 2531
Imported Oil
$17Bbl 56-76 (18) $24Bbl 61-96 1810
The above results are based on a capacity factor of 75 which is
considered to be a reasonable target for a new plant over its 25 year
life The average selling price of 6 cents per KWH cited in the
questionnaire is based on existing plant costs which may not include
all cost elements of new capacity evaluated in this study
32389
Page 9
TECHNICAL COMMENTS
21 See answer to Item 116
Total power plant raw wate consumption rates and annual
consumptions including the water requirements for wetting ash at the truck loading p int within the power plant are given in Tables 43 and 44 for 50 MW unit and Tables 53 and 54 for 20 MW unit
The raw water requirements for 4x0 MW plant were factored
excepting the mine where a revised mine pldn is employed to reduce water request The quantities shown on these tables exclude raw
water requirements for housing complex mine and ash wetting if
required at the ash disposal site
Total power plant requirements shown in the above referred tables
are
50 MW 20 MW
Rate gpm 207 102 (See Drawing M004)
Annual Use
Gallons 1400000 675000
Cooling tower blowndown supplemented with raw water is used for
wetting ash at the truck loading point within the power plant Raw water quantities attributable for ash wetting at the power
truck loading point are
50 MW 20 MW
Rate gpm 75 325
Annual Use
Gallons 500000 215000
These quantities are included in the quantities shown in
the above referred tables
32389
Page 10
22 We recognize the POTENTIAL for leaching toxic compounds from the
spent ash However this matter is not yet defined well enough to
recommend specific action steps The Prefeasibility Study page
7-12 recommends creation of a ground water dispersion model to
determine whether more specific contaminated water mitigation
plans are needed It is anticipated that the leachate rate will
be low and that aquifer dispersion will keep problem compounds
bel3w health standards thresholds
23 Noted
We have not received up to date resource study material which
defines 50 billion tons resource base Please furnish
The resource base at Sultani alone is adequate to support two 400
MW power projects capacity subject water availability The
2-million cubic metre per year water allowance for oilshale will
limit development to about 600 MW
24 Selection of a combustion temperature is a balance between carbon
combustion efficiency and heat loss due carbonate decomposition
For purposes of the Prefeasibility Study we have opted for high
combustion efficiency At lower efficiency larger shale
mineprocessing plants will be needed
25 Bottom ash is cooled by water exchange before discharge
Cooling water is supplied to the ash screw coolers as specified by
Pyropower See Drawing MOO5 2140 gpm flow for 50 MW and 860 gpm
flow for 20 MW Heat removed by the cooling water from the ash
screw coolers is dissipated to atmosphere via a wet cooling
tower Pyropower should indicate the temperature of the ash
discharged to be 5OOF
32389
Page 11
Initially we had considered using a heat exchanger to cool the ash
and improve the cycle efficiency Considering low cost of fuel
the additional capital costs and the system complexities it was
decided not to employ such heat recovery systems for this project
26 The suggested alternates were looked at briefly and the potential
for wind blown air pollution from the ash disposal areas are too
great to warrant dry disposal unless GO(] and World Bank are
willing to accept such a potential problem Wetting the ash is
tne only practical solution Hopefully some cementation will
occur helping to reduce future leaching potential
27 JEA requirements are noted This is a conceptual study not a
final design Optimal design analysis can be performed during
Phase II
2829
JEA requirements are noted and can be incorporated into the Phase
II design
210 The transformer size is adequate for base load operation A
higher capacity can be considered at the final design stage if the
Client prefers
211 From our experience it does not appear to be economical to
provide additional dry cooling towers to take care of maximum
ambient temperatures which may prevail only for a short period of
time in a year To study this an annual dry bulb temperature
duration curve is required Also adding additional dry cooling
towers will change the plant performance It should also be noted
that the dry cooling towers are very expensive and the size should
be selected carefly considering performance and cost and not on the basis of maximum ambient temperatures This can be studied
during Phase II
32389
Page 12
212 The plant gross output varies with condenser pressure
Condenser
Pressure Design 55 in HgA Annual Ave 35 in HgA
Unit Size MW 20 50 4xlO0 20 50 4xlO0
Gross Output MW 234 593 496 2415 607 TBD
Net Output MW 1975 501 400 205 515 TBD
To be developed in Phase II
Output for 4x100 MW is estimated by others
213 The fan power consumption of the CFB boiler is about 30 to 35 of
the total auxiliary power The fan power consumption of the dry
cooling tower is about 20 to 25 of the total auxiliary power
214 Table 1-1 does not include plant net output Therefore do not
understand the comment
215 Commercial operating experience with coal fueled CFBC units in LISA
and Europe has been uniformly good showing high on stream
availability in early years (See Table 2-6 which reports on
Pyropower experience)
We expect operations with high ash content fuel like oilshale will
have unique scale up problems such as
o Solid handling in and out
o Internal solids circulation
o Erosioncorrosion steam generator intervals
o Heat recovery from bottom ash
Consequently we are recommending these items be worked out in a
single 50 MW prototype
32389
Page 13
216 Maximum dry cooling is used in this study A small wet cooling
tower is used on circulating service water system
217 Horizontal condensate pump is adequate with dry cooling tower and it is cheaper Vertical condensate pumps with cans can be
considered in the final design if required
218 A concrete shell brick lined flue stack will be larger in diameter and costs more than a steel lined stack Brick lined stack can be
considered in the final design
219 Demineralized water tank capacity for 50 MW is 76 cu meters or 20000 gallons not 1000 cu meters For 20 MW plant it is 38 cu
meters or 10000 gallons
220 It is US practice to use an average continuous blowdown rate of
1 and maximum biowdown rate of 3 for this type of plants
221 This can be studied during Phase II
222 Same as 221
223 Same as 221
224 The recommended action plan calls for continuing support studies covering the referenced items Additional effort is needed to
further define these matters and confirm the conceptual plan
The next step is to develop an outline for a project plan including
o Work Scope
o Schedule
o Budget
accommodate the increase in the number of employees and
equipment Truck bays to accommodate the 136 tonne trucks
will be added The truck bays used for the 77 tonne
trucks will be used for the maintenance of other
equipment The warehouse change house training room
offices and cafeteria will be expanded accordingly
6025 Mining and Processing Economics
Details of the oil shale mining and processing plant
economics for the 400 MW plant are included in the Mining
Report (Appendix 5) These details are of the same
magnitude as prepared for the 20 MW and 50 MW plants
The summary of the cash flow analysis for the mine and
shale processing plant is presented in Table 6-1
Table 6-1
SUMMARY OF 400 MW PLANT OIL SHALE MINING AND PROCESSING COSTS
5050 Debt-Equity 8020 Debt-Equity
US $1000 US $1000
Capital Cost
Mine Development 30915 30915
Mine Equipment 66012 66012
Process Plant Facilities 50889 50889
Spare Parts 5000 5000
Working Capital 10000 10000
Capi tal ized Interest
During Construction 24423 39075
TOTAL 187239 201891
Operating Costs and Other Costs
Annual Cost 60386 53236
Product Mined and Processed
Annual Tonnes x 1000 7783 7783
Unit Cost
US $Tonne (weighted average)
US $l06Btu (weighted average) 776
156
684
138
Year 12 costs taken as 25 year average
6-6
-Au
Table 610 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
VOLUME II o March 1989 Prefeasibility Study Presentation
o March 15 JEA Questions (MS Arafah) on Prefeasibility Study Draft Report
o March 21 Response to JEA Questions
VOLUME III o Appendix 1 - Design Basis Criteria
o Appendix 2 - Sultani Deposit Geological Data
- 1987 NRA Report
- 1988 Draft NRA Report on Supplemental Core Drilling
o Appendix 3 - Ahlstrom Pyroflow Process Background
o Appendix 4 - NRA Sultani Blended Sample Report
VOLUME IV o Appendix 5 - Bechtel Mining Report
VOLUME V o Appendix 6 - Oak Ridge National Laboratory Report Preliminary Assessment of Using Oil Shale for Power Production in the Hashemite Kingdom of Jordan
VOLUME VI o Appendix 7 - Pyropower Corporation Test Burn Report
o Appendix 8 - Pyropower Boiler Design - 50 MW
o Appendix 9 - Bechtel Power Block Design - 50 MW
o Appendix 10 - Pyropower Boiler Design - 20 MW
o Appendix 11 - Bechtel Power Block Design - 20 MW
o Appendix 12 - Chevron Corporation - World Energy Outlook
0511T
JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
VOLUME II TABLE OF CONTENTS
o March 1989 Prefeasibility Study Presentation
o March 15 JEA Questions (MS Arafah) on Prefeasibility Study Draft Report
o March 21 Response to JEA Questions
0511T
MARCH 1989 PREFEASIBILITY STUDY PRESENTATION
PREFEASIBILITY STUDY
OIL SHALE FUELED POWER GENERA TION
Presentation to
HASHEMITE KINGDOM OF JORDAN
March 1989
OUTLINE
M Introduction
Technical feasibility
U EConomic feasibility
Study conclusions
Recommended action plan
S Prefeasibility StudyOil Sftle Fueled Power Generation
Introduction
m Study program
m Integrated project scope
Prefeasibility StudyOil Shale Fueled Power Generation
VOO740LAd R 3
STUDY PROGRAM
Task
N Program management
U Test sample procurement
Test burn report
N Jordan power demand assessment
N 2050 MW boiler designcost
2050 MW project BOP designcost
i 4x100 (factored) boiler designcost
4x100 (factored) BOP designcost
Environmental assessment
N Economic assessment
Risk assessment
Action plan
Final report
BOP = balance of plant
Prefeasibility Study Oil Shale Fueled Power Generation
V007S AEI 4
Assignment
Bechtel
JEANRA
Pyropower
ORNL
Pyropower
Bechtel
Pyropower
Bechtel
ORNLBechtel
BechtelORNL
ORNLBechtel
Bechtel
Bechtel et al
a
INTEGRATED PROJECT SCOPE
For 20504x100 MW installations
Open pit mine
M Oil shale processing
U Power block
- Boiler plant
- Power generation facilities
- Raw water supplytreating
Ash disposal system
U Onsite infrastructure
U Offsite infrastructure
Prefeasibility StudyOil Shale Fueled Power Generation
VOO764GE1 S
i
_Conceptual Facilities
Truck end ShovelOperationrtHO Open Pit Mine Mineral Rock Stockpiles Waste To JEA Substation and
Electric PowerGid
Hurden and
Off Shale Communly Faciliies Central Central a0000con
0cr~nn Plant Malntenance and Warehouse
Pyroflow Cornbusbr
Steam Turbine Generator
(gt Power - -o-
Three Day BW ----- C nest
Waer Supply System Food Hopper Baghouse
Pr cees Domestic Boiler Feedwater
Water Water Water
Ra
Wells to Underground
Watr
Plant
Boltom Ash Overhead Ash Fly Ash A
Condenser Wastewar
P n r r Slowdown AqrnrServiceMI Pugdow Water~
Water system Slowdown
Cooling Dioalsposal
Tower Spent Shale Ash Disposal i Prefeasbly Study
Oil Shale Fueled Power Generalion
179 5896aJordari 183-10-89 r30
TECHNICAL EVALUATION
N Pilot plant test program - 75-ton sample procurement - Test results
- Test conclusions
0 Conceptual design studies - Oil shale reserves and analyses - Mine and shale processing - Power plant and auxiliaries n Development schedule
bull Material developed by Pyropower and Bechtel
o 1Shale Fueled powr Genera VOM4ME~j
Technical Feasibility
N Technical evaluation
N Technology risk assessment
U Environmental assessment
U Power demand versus supply assessment
Prefeasibility StudyOil Shale Fueled Power Generation
i
Pilot Plant Test Sample
Expected Blended Avg Mine- 75-ton Run Shale(a) Sample(b)
Fischer assay oil content wt 75 8486
Organic carbon wt 102 plusmn13(c)
Gross calorific value BtuIb 2000 2250(c)
Sulfur content wt 238 255(c)
(a) Rechtel evaluation of core hole data (b) NRA analysis (c) By correlation with Fischer assay
Prefeasibility StudyOil Shale Fueled Power Generation
VOO4JOEARI I
i
Pilot Plant Test Program
Conducted at Ahlstrom LaboratoryFinland
U Performed 8 test runs
Tested four process conditions
- Primarysecondary air ratio
- Bed AP = 405070 M bar
- Load level = 4060100 pct
Combustion temperature = 830 to 9000C
Prefeasibility StudyOil Shale Fueled Power Generation 119
- FCC plant sizes equivalent to proposed power application
Prefeasibility Study Oil Shale Fueled Power Generation
VOO94GEampJRI26
i
PYROFLOW UNITS IN THE US
COLORADOUTE IOYA STATE UNIV UNIV OFNUCLA CO NORTHERNAMES IA BF GOODRICH110 1o0MW(a) 2x170000 Ibhr HENRYILCEDAR FALLS IA 120000 Ibhr GENERALGULF OILu EiN P MOTORSSbtUpStart-UIL 1987 O A 1I N000 TC
NORT10 PONTIACH B MIRANCHWV00000 lbhr
CORN PRODUCTSSM NORTH-CAROLINA STOCKTOD CA
400000 lbbhl t
RUMF RD ME
CEMENT CO CALIF PORTLAND-COLTON CA
190000 Iblhr Start-Up 1985 TRUMTFTWN NYU
3I75ERTOWN N
etar t-Up loss ACE COGENERATIONCABI
TRONA CA Oper t~on l -Start-UP 1990 ~ rt upz 091Start-up loss Start-up PNeLAI 1991
MTKESFICOENERATIO-N1
BASFIELDp Start-uStar-Up WESTCA9 199otgoUp 1 MAHONEV PA|00000 Ibhr A Oz 2X365000 Ibhr
SETtr-Ups 188B CHAT TANOOGA TN
G ULF OIL EXPLORATION 8ta-rt-u) 1085BAKERSFIELD NORTH BRANCHCA SPRING GROVE PANORTH BRANCH WV 400000 IbhtOperational 19835 5 0 0 I b h 9 0 0 0 Iblh r- tart-Upi 1991 S t r - U p s l e s s
SOUTHEAST PAPER MFG CO UNIVOF NORTH CAROLINArDUBLIN GA UHAPEL HILL NO400000 IbhrStart-Ups logo Start-Ups2X250O000 1loseIbhr B
- Withdrawing ash from combustor - Withdrawing fly ash
a Internal solids circulation of the steam generator
m Erosioncorrosion of steam generatorinternals
Heat recovery from bottom ash
U Operation with low calorific-value fuel
Prefeasblity Study O Shari Fueled Power Generation
VOO7AI 27
Impact of Scale-Up
Project Size
20 MW
50 MW
100 MW
50 MW boiler in 100 MW plant
Potential Risk
Design Scale-upOperation of to 100 MW Initial Plant Plant
Low Significant
Modest Modest
High Low for duplicate units
Modest Low for duplicate units
Prefeasibility Study Oil Shaje Fueled Power Generation
VOO71-4GEAL4n2
i
Conclusions
Defined risk of CFBC boiler is acceptable
U Operating experience with commercial CFBC boilers built and under construction will strengthen confidencelevel and minimize risk for a plant built in 1995
SPrefeasibility Study Oil Shale Fueled Power Generation
V007GHAAE29
ENVIRONMENTAL ASSESSMENT
a Mine and shale processing
- Fugitive dust emissions
- Noise levels
- Leachability of disposal piles
Power plant
- Fugitive dust emissions
- Gaseous emissions
- Noise levels
- Water effluents
U Conclusions
Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel
Prefeasibility Study Oil Shale Fueled Power Generalon
- Coaloil prices will be at least 15 greater after 1995
- Discovery of indigenous conventional fuel resources is inadequate for power plant purposes
Prefeasibility Study
Oil Shale Fueled Power Generation
VOO) IDWFO
Feasibility(Contd)
N Suitable financing will be available
- For $200 million 50 MW prototypeproject
- For $1000 million 400 MW commercial project
Government of Jordan will make basic commitments
- Long-term power purchase agreement
- Long-term access to Sultani shale deposit
Adequate water and manpower resources
- Attractive tax incentives
Prefeasibility Study
Oil Shale Fueled Power Generaion
VO bull1DUJJRO 6
Timeliness
U Timely development of Jordan oil shale needs prompt action to create - Additional definitive information
- Suitable business plan
Prefeasibility Study
Oil Shale Fueled Power Generation
VooI DUJo 7
i
Expansion Conditions
U Continued expansion of powergeneration from oil shale in Jordan depends on water availability
Prospects for power export or importand domestic load growth will affect size of the needed shale-to-power program
Prefeasibility Sudy
Oil Shale Fueled Power Generation
yOWl lVuJO
Environmental Impacts
N Environmental impacts of shale development will be minimal
Prefeasibility Study Oi Shale Fueled Power Generation
i
Development Advantages
Will create significant new jobopportunities in Jordan
Will avoidreduce foreign exchangelosses for expanding alternate fuel imports
Prefeasibility Study
Oil Shale Fueled Power Generation
VOOIIULL tO
Recommended Action Plan
N Basic recommendation
N Conceptual development schedule
U Project development plan
Key plan elements
N Funding requirements
Prefeasibility Study Oil Shale Fueled Power Generation
VOO4II )U OII
i
Basic Recommendation
N Expand efforts to develop an oil shaleshyfueled power generation program at the Sultani deposit
- Conduct required supporting studies
- Define facilities costs and business plans
- Obtain project funding
Prefeasibility Study
Oil Shale Fueled Power Generation
VON I II)ILL 12
C
Conceptual DevelopmentSchedule
1989-1990
- Conduct supporting studies - Define costsbusiness plans for 50
MW prototype and 400 MW commercial projects
- Develop project financing
N 1990-1993 - Build and operate the prototype project
N 1994-1996 - Expand the 50 MW prototype to 100 MW scale
U 1996-2000 - Expand the project to 400 MW scale
N 2000-2005 - Build a second 400 MW commercial project if needed
i 1 Prefeasiblity Study
dOil Shale Fueled Power Generation
VW IMLITO 13
Conceptual Development Plan
Months
1 Project development plan - Define project
costs1busness plans
-24 -12 0 12 24 36 48 60 72 84 96 108 120
2 Secure funding
3 Build and operate 50 MW prototype
Dergn and procurement
Mine development
Plant construction
Startup and testing
Operations
L- -
4 Expand prototype to 100 MW
Design and procurement
bullConstruction
Startup
5 Expand project to 400 MW
2nd 100 MW unit
3rd100 MW unit
i 44
4th 100 MW unit -
O Project dacision point
i Prefeasib~ity Study Oil Shale Fueled Power Generation
17958562aJocdanV 3-14-89 rsO
18
Phase I - ProjectDevelopment Plan
n Program development
Seminar workshop on prefeasibilitystudy Oate project development plan woek scope schedule arid budget
U Carry out project planning program
- Conduct continuing support studies - Test Sultani shale in existing FBC
- Firm up designs and specifications
- Update costs and economic analysis
- Develop business plans and requirements
Explore project funding alternatives
i Prefeasibility Study
Oil Shale Fueled Power Generation
VO MItUOR 14 -0
Key Plan Elements
N Project feasibility analysis
- Firm up designs and equipmentspecifications for all facilities
- Update cost estimates based on preliminary designs and specifications
Explore arrangements for contract mining and mine development
Update forecasts for demand growthand for retirements of older generating capacity
- Create updated economic analysis
Preleasibility StudyO1 Shae Fueled Power Generation
VOO1IOLWRI
Key Plan Elements (Contd)
Business entity requirement
- Explore optionsconditions for a new company to managebuildoperate the project
- Explore optionsconditions for obtaining a concession agreement for Sultani development
Explore optionsconditions for water rights commitment
Prefeasibility Study Oil Shale Fueled Power Generation
VMIOIA)lj 16S
i
Key Plan Elements (Contd)
U Continuing supporting studies
- Combustion tests (additional pilot tests for design and warranty purposes contract for large-scale burn operations in existing plants if appropriate)
- Additional core drilling and core analysis
- Oil shale crushing tests
- Spent ash leaching tests
- Geotechnical data base including soils analysis
- Environmental baseline data
Prefeasibility Study O Shae Fueled Power Generation
VMMMUldMOA
Steps Required to Develop an Oil Shale-to-Power Project
Create a development business plan - Schedule - Decision tree
Develop a work scope and budget for the development plan program including - Firming up designsspecificationscosts
- Developing business entity requirements - Continuing support studies
Carry out development plan program
Assemble all planning results in a report for discussion with financial institutions
Explore project finance opportunities
Finalize business arrangements
Implement prototype project
i Prefeasibility Study
Oil Shale Fueled Power Generation
VM1-11UJROLI
MARCH 15 JEA QUESTIONS (M S ARAFAH) ON PREFEASIBILITY
STUDY DRAFT REPORT
Rt
DIR EScBSULIVAN PHD OFJCEop~BUREAU FOR SCIENCE AND~TECHNOLOGYAGENCY - --FOR INTERNATIONAL DEVELOPMhINTSWASHINGON DC x20523---------4
4 -
-SUBJ E CT - -C O H~ E T 4N l
Dr Mr sullivan ------shy
c-rommnents We ~efr-preaereorPla -tobYou lete dted Jan 91989 regardn~i4po4t P ea e1 f i nd y ubel ow our -e ot r XcOrcerned Jordanian deipartments
- --A ar o~nnYu Y o turjlt~ lt K
4 C~mments
~1 N i gFIN I~fANDECONOMIC1COIMEN S -
It sidicaed that Beohtel and US AIDWash ingtonj~4- re ojy nen ing that E 2hould und ertake the n e tshyihaisAre ~our c leometprogram n order shye-t im~ ate d f n t v design and budget cost
4Al1so Lthe study ncal--ttsutnilndcaei~ A-1 A thas ~ l 1 be eeded idb~~~~~ rn o ei t n i la itheMWa~-~5s~ 4
hrPro hehgemetTh trOfT ses~fnr4 BOT)Vmanu- a n-mnf~cure 4 r~j or contra c4-or ivoIlveiintijn I 4 4investmnt ude smi ~w 2 Zha tev e r --~4~prce e ec r it v p4~ f JA gertiy geeated-at 4 JEA 3 a l b u y ~the same average~~ A
~jithia oncot in4 ordrtan ecpoemic asess thespePower generatjoon J ordan3 oi sha I eroic c inr~etJordan 4
2P ge i1- 1 Aj iit eu that OPin he atocontr~ct 4with owner4 ofext3ing (oconstriiction r(FB rml-t
qu i of S 11 t to test large tonnagen j es StaniUti n d ajIe -for se veralIQf 31 hi
evrEAPreferpilot qr the dP 1prt7n -that the4mPIt
andi to(7 he instalI 1e 2 310 A
_
JODN ELECTRICITYAUTHORIT LL
Dac
operated in Jordan i n or~der~~t ~n nuex~on mnining crushing and haidi igQhre~ and sash Maeia nd aSootoget enough olr ndaita needed for einolre
CEBbole~ -i s~
ccordance with Jordaian oil shale
large to~ bfig
1 3 le 1-2 Page 1-7 Cost Of Pwer~i It i S menti-oned that the conmecial oil hle~ lt~project (4 X1OOmw) 1is ninacompetative roqt~range-~while table 12 indicates thattcost of-pow Ais~mill
q kwiihcii r 1
average wih i ii -much higher ihantheshy-ost of ~Power gnrtofomJEA therimaPower s ta tions Please~ indicate on what basi o ~~ shave-~made your-statement
PK
14 Pae 2 Sction 4-0sIt 1nlkly that theChousing and off- -site infrastructur-ommnity fakilitieR) to be onsidered for both the demo and prototyp prjcs oeoverwe~4 hnk that their~c_6t is raterojects Mo
iwcv~- age -1 1 Mine O(perationIIt is indicate~d that mining cot eevdfoMine contractor~ are ficomiplee h
r and iyudi-t~con qidder contract mnn opio fr4 the min4 cmflt2ng are reIanddrepres~ent the real costs derived from Phspat miin contractors in
lestfor the eo rPooypuat in order tlt7
P I eadenote tha detthe new exchangerate ofthJraian~ Di~nner you may add 20j6 Kto the quoted
1 6 P Ias e consider the followin ecn hage_
171- The new exchange ra teof tUSD=54o0 fils1 72-W2 The new~ aerage tariff for selIn~electricityhas decrreased to 120 8 f ilIsicwh
17- Page 1-7 TbIe 1-2 W bev th tthe cap ita1 cot for the pwhokand forthe min n d ash hMnd1ing equipen
P B~2Anaor a -Tl 8156152 8176 1Q MYf -t -Now 520 t 1U
JDNEECRICIT AU-RA L14lLiL
2 ~are very high We suggest~ thta You rerconsie (- telowerus e~+d accuracy est a rangethan +30
Page4-22 Table 4-5weno0ti ced( that- PyroPowe ha ddeta(IiacCst fori the bo1ilerlocation and terha dutdetlease isxtr fo~ l C~ io~ s~ e~~ 1a~ a if and indicate theonldjusted ~percentagefor construction foin Jordan
19 Page-7 Table 11-2 -Yo aeue ihrinterest rate on Equity thatn on1DehI~laseinclude~ adetaied explanation of thisrr -tni kepin in miUndie JEA is1thaIt a non profit~ shyorgaiztion unik oher private UJSA utility~in ktation
~-~110- Regarding shy
the ra4ital Rt fthe project it is~requesed tobre k it intdo foreignMeanwhile cthe nd lorcal c-osfoeigptario i nt-re3t~shol becnierdo-h
rr n ontiondonnotopdbon the 9 cnieelocal portion~onth
1-1- 237~Pa
oningeny 9tooi s high~~ a lower 4value -should be~
4~ gt ~112- -Tbles t1-1 -8-8~ inclu~de t~he c~alculationscuultie nt enefits for of Th shyunttypes l i4s difeen geeatnmrer likely tocluae
-~ Q~ J7present vk1u for tenet tthe~benefits in feralterntives -t-oa s the
49
ehliyoi shale
Wea gree with you9 tha t th e percentage used ~ an for thenua~l 0 ~amp-M rahr CFBo ndsomewha~t highervrate be n ededma y for a C B l n Me n h l ~ a e r
indir e ta~ts the -estimatedma i variablec st i ddition t he fi-xed-9i 1 mislkih We --
thinktttiis too lowK -5
shy
1-14- e 4-29
opprza tion-o to The o i1s h1 costs-nc I deAbo 1h
Pa10 mman ormTSI62 a
IB I
JORD N EtECTICI1~ 4 E~)~Is-s
Date ib-_
~ ~riii~g~nd~o9~ru~hng h~tnlin cot~u~tv yo
i Dae Jnryit
1ts c 7 4-
i smiig iniand fh co I eY
susendi ca tI t icag th t1 ~an~approximate 15 ~pita L tYII I (-~a~ge or he owe bl ockj f aniitjes isof +the capthe)t~ial7cpi~lrharge Uoratelformny SI~Uj(uiity installa~tions~ whle page 6-1T9 talJshyit is mentioned that~ the Capital rate pe-r JEA isshyi5~PeaseJustify this~matter since~w o
i16- Pae 6-1 6
1 I4~t is mentioned that the costs of 4process Water are ~ 4 ~0 2$1 000 gallons
r~j~lt IHave~You considered additionalvalue ofbying waterfrom~ the Wa ters Aito i ~or ditoa cost~f o revrseoqoesplant if ground water is used
~~ I1 7- Table 6-1 Page 6-6 Please explain how did You come ou ihteoil~ shale miniing and proces~sing uit~Icost
ltII~I~ 8- Please note 1 t hatj the average JEA~productinr ot frmthermal I power stationsr (Istationbus-barCOSt)i sbewen 6 3-17 3 fils 4kwh You may use this~
l4~ 19-i For ~4 X 100~AMW Plat iti etindo pag e14-4 VolI 11 that4 at tota I of W42 14 epoye W II eemplo~yer] And on page 69yo1Iiti mentioned that a~ tot 1 f1 ~p yeI iNbe enp1oyed a
is~ high asrmetitexeds100personorthe ~41X100~MWh~~j nsatnpPrlae
I 1 The 4 following iftemns are a sumed to1 be excluded from theraPi ta 1 cot xoI
120-1 Perits I icen es 7
1_207~3 Imprt ~xe on s7pare par ts -and c(7orfmurab -ma~teria Is
04f4 4
~4 R j4 4
D4
~ ~ ~ AIf eS taxesq in acrac ihteJraand regulations should be considered aw
21- p1ea4s e indic ate Your Ju t f c io r us ga 6
44122- Table 977App 5Page4 9-1 4L IK Car1Yiniae that the hIRR of the 4 Otplantis rather unattractive (66)most
-( Cns1er4 ngthe logical base 4csek c pwhen cii 6OL
average sell~ing prc CkhampDEratio L801~2O~Aoreover4M the ne siellin prcwh o JEA ati theamptime~ Abeing os4ltp n~ot exceed 4 Ckwh~-However Ipage 1shy~ and 14 0 T indicate that ecnms for a commeri
S4A4scale joil 4 shale projc ~
appear Piomisig-nug o4Ywarrant continued dee fgfluht 4 feaibiit 4tudy wihil cost sevea~lili
do ar~sf Plas lear wether the ~x step jqs~$j~~lt 4
gtt 9o be considered arCcording4to jthe 4unattractiveresul to mentioned in IRR7 Table 97 gt4
a C4 44fET2 4 144-4444 P a g 1 T b6 l
htte~We ~ ~ ae~ rqieetfrteX ~ noie ~~ ~ 444 MW un t44 r te4l w w e o p r d i th e w t r n rre u f4m or4444~ the4444 54M4rto y e Pg~A~44EHiveL det ile an l A44
s o awa er c n um t a4r f rofsho in P6Io erT
e ch 2 50 M W aPln wa e d 41004 MW4 1 consumption_____________
ma4~2 k e u p houin~44 p A44 4444444 C O 4ltI4
a nd a sh et in etc 4 2 4 1 -24 P a g e4 2 - 1 A P P 5
4Yo 4_ j1 4 4~h444 N44 44
1gro nd tce t hir fthe w bern coqir mna t efora4e 4X10A M 444444 4 r i n to 4 4 4lo w w ehA 7 n 2 cinCie h rh4 n ttthh1eb -e 4 44t Of3 E4O
ea h n~ ffl 4 4Jl44 4 4444 4giv
6 ig re sofrat4 de in cl ar f w w at5 c hrw pe o
s h b 444 o t h e g nd L 44 h u i n C
r 4ne a4 t44 e L(704 2 4 p ae) 2 - o Au P dn 5ai 7~e r 44 I Y (1t 44a
ve7 rn e qu 1saharvthe y
and n~~~o speci~~~l4 p n l nh i n t x
r ~rA M e d r o t eu n 8 1 wTtl t t h
- c re e N I wo6
~ n n a i n a t d h l7 A PP6 gt
J
S2~3- Page 2-4 ~ ~ It ~is i
that oil eindicated the- sha le r our~ Cesin Jordan are 10 billion tons -The anulp e reere maiy exeed 50 4 billion tons ~
~ 24- 4Page~2 -l1 iujntr We beiv thtCBcmuto~ep i s high and~alSo
~~ ~ -2 ~~ Page 4-1~6 j - shy
Please~~ indicates your procedure to cool the omn ashand atwa icagd-eprtr
A Have you~ considered~ additional he~at exchanger topcool th ash and to imrve h cycleef ficiency
-~2~6 Page 4-16 It s~ indicated that ash from each silo i Amixed19 ~with~fabout 20 waterKb weight to minimize generation of dust~during trnprtto to mine and disposalHave you~ coniidered other 4lternativeto
~ ~eliminate dustiiig -and avoid use ofwat r uring it ransportationi such as~ using closed trucks or closed
of ~fans conUMnPo wihrlaintthe total plant auiir poe osupin 1~21- Table 5_-3 and I ~
Th~~ is- somneere c6ntradiction regardingplnneotpu~t in both am tables 21-~ Tabl~e 1-33
We noticed tha~t yourall9 cacacapac t fatro75 tion ae asdnWe thilt ~that 7capacityshyfacto is tobo high for- an oil shale fired plant duketo lack of existing simila~r ~plants handl~~~firing oil adshale ~K
216~ The study iniae thtawet~coigtower wi11~used Actually a b
dry cooling should be consideda5ini ~HTP S inZ atomnmz so water rnumption4the cycle~ efficiency willbe reducedHenre YO33~reconsider calculating the cyclefficiy
U~~~~~ codnt umconsidered ofhorizontal -aretypethe~ the vertical cian type can alsobeh considered
shy ~ ~ ~ I~~
2~2 Kconcrete shy
shjell stepl fltstack is onidereconcrete shell brick flue Rt c ~s beCaconsidered3V
2-19~- Deminiraized water~ tank3 capacity~ is -76 ui(meterThe recommnended tank cameter- ui tyi 00cbc
220Designconditions Pa~ge (4-74)te5 hat bow 3down percentage splusmn ~fomrpra til re i hou I be 3~)~
PoD Z 2 m a ad~ - e 5 1 2 iJS~ ~ p A f amp ~ ~ y1
4
JO R ECTICITY AUTHORTIT 4L
~ 4
Date~
t etats ttthe quantityof s i S ~1 000Tons ra Sthis tuntity 11- be transporited for severIy --to tu ofI pit a~te torg P KM ra~erm Spower plIatS about 12 midilidoni CUIA(- met ryea
h e ndd mp e he (d u p in i n L
area wil evric power plant6t Please zn1 a te~tiv s tudY for dumping th r~ a enoug
-from the power plantr~~h~
S 2- Please provide deald-ifrat ao etbaaiedrawing hwn TH11 R thaU and~pV ra~te takcing illto o 6it v- consumptionn _uig themrining equipment
alternate~ study 0o Jine operation for 1 shiftday Vand twoshifts day -lt
224- Conceptua~l pflR 1 for mi ing anusdtransportation of oil- shale a 0 dmj of hs f u r therV examinedh iV~sdpatI ho u1d be
orderj to poe~ehicalq and~eoomca1 fesblt of t his operation
SYour are requested te) study and consider all- above - iPoin s at your earliest in rder -to be peete y oiAnimain on March 29-301989 peetdb~o 4 n
S9incerly-You S
WDIRECTORGENERAL -
I~ CCMR WLINTON ~vs
5N
Pa D~t~IoAmmn -Jordtn -Tel 815615 20 Bl76 15 -19j A VINO- AFf TY
MARCH 21 RESPONSE TO JEA QUESTIONS
Bechtel Power Corporation Engineers - Constructors
Fifty Beale Street San Francisco California Mail Address P 0 Box 3965 San Franclco CA 94119
March 21 1989
Mr M S Arafah Director General Jordan Electricity Authority PO Box 2310 Amman Jordan
Subject Jordan Oil Shale Prefeasibility Study
Dear Mr Arafah
Your letter of 15 March 1989 with comments on the Oil Shale to Power Prefeasibility Study draft report has been referred to me for reply
The attached responses to each item in the reference letter follows the order submitted
Also attached are three revised pages for the draft report - Volume I
Page 6-1 Page 6-21 Page 6-23
Please copy these revised pages into the report previously sent to you
We plan to review this material with JEA during the March 2930 and April 1 meetings in Amman
rsuVertrul yours
W Linton Project Manager
WHLdc
Attachments Questionnaire Response Three revised pages
cc C J Aulisio R R Buta G D Gould T J Wilbanks
32389
Page 1
RESPONSE TO MARCH 15 1989 QUESTIONAIRE
OIL SHALE TO POWER PREFEASIBILITY STUDY
This study examines economic prospects in terms of a 1995-2000 timeframe
FIRANCIAL AND ECONOMIC COMMENTS
11 It is likely that a BOT deal can be structured at present JEA
generation costs for either 20 MW or 50 MW size units if GOJ is
willing to subsidize the incremental power generation cost
Furthermore these incremental costs can be recovered during the 25
year operation of a Commercial Scale Project
12 A 3rd Party Test was proposed as an alternate means to raising
$100+ for an independent JEA sponsored 20 MW Demonstration
program
13 71 millsKWH for Shale Power
VS
JEA 1987 costs
Purchased Power 17 filsKWH = 51 mills
Produced Power 1360 filsKWH = 41 mills
19952000 Costs - Expected to be 30 to 40 higher and in line
with the cost estimate presented in this study
It also is important to recognize that the busbar cost of power
generated by any new power source can not be compared directly
with the cost of existing older installed capacity because of the
lower capital cost component of the latter (See enclosed Figure
1-1 which demonstrates how total capital carrying costs decline as
the investment is paid off) Any new capacity whether coal oil
or oil shale will be an unreasonable disadvantage compared with
costs for existing older capacity
l
024
o2
0De return
E 016Total carrying charge
012 qu return
S -008
ety taxes and n rcw vshy000 X 0 5 10 15 20 25
Figure 1-1 Year-by-year Carrying Charge Components for 15-yearTax Recovery Period
1-7
30
32389
Page 2
14 Infrastructure Cost
Total People
OperatorFamilies Installed Cost
20 MW $10000000 185700 $54000Operator
50 MW 15000000 3241200 46000Operator
400 MW 45000000 10364000 43000Operator
Factored allowance for grass roots desert installation
including housing and community facilities was developed as
follows for the 50 MW case study
Infrastructure
50 MW
Family Housing 200 30K = $ 6 Million
Bachelor Housing 100 20K = 2 M
HospitalClinic (8 Beds) 11 M
SchoolMosque I1 M
Stores Services amp Recreation = 2 M
Facilities
Roads Electricity Water Sewage = 3 M
$15 Million
Infrastructure costs for the 20 MW and 400 MW cases was ratioed
from this breakdown
At this conceptual level costs are order-of-magnitude In a Phase
II program these infrastructure costs can be developed in detail
32389
Page 3
15 Contract Mining Alternatives
Page 4-11 Mine Operation
Based on Bechtels evaluation of the mine contractors price as found in Section 15 of the Mining Report it was concluded that
the mine contractors price does not include costs for such things
as developing the mine with a box-cut ramp haul roads
developing an area for the waste material maintaining the
haulroads constructing the mine services facilities diversion
ditches sedimentation ponds water well crushing the oil shale
pre-mixing the oil shale at the mine and other items associated
with operating a mine to support a power plant If it is proven
that the mine contractors price includes cost for the above
mentioned scope of work in additi-n to drill blast load and
haul then the contractors price can be used but in the meantime
the all inclusive cost developed by Bechtel should be used
Contract Mining appears to be attractive for the smaller size
plants but not for the larger commercial scale operation Some
third party must provide the necessary capital for trucks
loading mining machines etc under a contract arrangement
16 Reassessment due to Dinar value change needs further study and can
not be evaluated given present budget limitations If average
labor rate of $300hr still valid then little change involve with
study
If deemed necessary reexamination of project economics can be
done in Phase IIwhen funded
17 Costs in this study are based on recent similar Bechtel experience
on Mount Poso project and on Montana I project The Mount Poso
project is a 50 MW unit firing coal in a Pyropower boiler The
Montana I project is a 35 MW unit firing coal in a Keeler Dorr
Oliver FBC boiler utilizing dry cooling
32389
Page 4
18 The Pyropower quote of $186000000 to futnish and erect the steam
generator stack and baghouse has been adjusted to include
engineering construction indirect cost etc to be consistant
with the rest of the costs shown in Table 65 p 6-10 No
further adjustment for location was made
19 Equity funding has the lowest priority of payoff in case of a
liquidation and carries greater risk Hence a higher rate of
return is needed to attract these funds Debt funding is a first
mortgage and has first priority for payoff in case of liquidation
and carries less risk Hence it requires lower rate of return
than equity funding
The risk taking equity owner will ask for greater interest rate
to make funds available The only way to minimize this expense is
to find a loaning agency willing to provide 90 or perhaps 95 of
the investment cost It is likely that banks will require some
minimum equity participation
This Prefeasibility Study was not based on a non-profit utility
operation
Even though JEA is a non-profit organization its service
contributors are profit making groups It is visualized that the
Jordan Oil Shale Co (JOSCO) will be a stand alone business
enterprise servicing JEA under long term contract To secure
funding for the proposed project JOSCO will need attractive
enough contract terms to attract both equity and debt capital
110 Additional work is needed to develop the requested information
This work can be preformed as part of the Phase II program
111 Bechtel includes contingency in all of its estimates to cover
error emissions and unforeseen items within the defined scope of
the project The level of contingency is dependent upon the
amount of scope definition For a prefeasible study such as this
15 contingency is lower than normal
32389
Page 5
112 Tables 89 through 816 include a present value calculation to
establish the relative benefit for a shale project vs coal and
oil
113 The variable maintenance cost of 1 millsKWH has been adjusted for CFB plants with an additional $200000 per year or 06 millsKWH
This yields the following
Variable Maintenance - 10 millsKWH
CFB Adjustment - 06
Fixed Maintenance Cost - 40
Total Cost 56 MillsKWH
114 Page 4-29
The royalty costs are included in the weighted average oil shale
costs for the 50 megawatt plant
Page 4-8
Shale fuel costs include return on equity and royalty These are
two separate cost items Royalty is the last item mentioned in
the sentence and it therefore reads as royalty and not return on
royalty
Page 4-31 gives rates used by Bechtel based on our calculations
using the referenced procedures
DebtEquity Capital Charge Rate
5050 153
8020 139
Table 69 displays the calculation of the 153 capital charge
rate (Line 7 of Table 69 is not used in the calculation and
should be deleted)
32389
Page 6
116 No water purchase charge from the Water Authority was added to the
operating expense based on the statement that no resource costs
will be charged
$020 per 1000 gallons is rule of thumb for USA installations in
absence of client data
Boiler make up water (p4-17) is treated in a demineralizer
train If deemed necessary comparison with reverse osmosis
process can be performed in Phase II
Water requirements were estimated to be
Cubic Metres Per Year
20 MW 50 MW 400 MW
Mine amp Shale Processing 455000 761000 773000
Power Block 3000 6000 42000
Infrastructure 80000 140000 448000
Total 538000 907000 1263000
117 Annual average operating costs shown on Table 6-1 are in error
Financing Option 5050 8020
Cost Shown 56606 48945
Corrected Cost 60396 53236
Average mining and shale processing costs are developed year by
year in the Mining Report Appendix 5 Table 12-10
32389
Page 7
118 We would be interested in receiving the breakdown of these current
power cost figures (ie capital charges fuel cost number of
operators etc) Further economic analysis employing these
figures can be developed in Phase II
119 Manpower requirements for the three case studies were estimated as
fol lows
Mining amp Shale Processing
Power Block
Operations
Maintenance
Management
20 MW 50 MW 400 MW
75 163 396
54 78 175
46 73 455
10 10 10
185 324 1036
Page 14-4 of the Mine Report is for mine and shale processing
only It should be noted that most of these manpower requirements
involved new jobs for Jordanian people
120 At the April 1988 Amman Meeting it was agreed that the following
costs would be omitted
o Permits and Licenses
o Local Taxes
o Import Taxes
If necessary such costs can be developed and added into a revised
economic analysis as part of the Phase II program
121 6 average inflation rate is the figure recommended by Bechtel
based on USA conditions for use in long term economic analyses of
new power ventures
32389
Page 8
122 This matter is referred to ORNL who prepared a rate of return
analysis
Bechtels conclusion is based on computed busbar costscumulative
benefits compared to alternate fuels in the timeframe 1995 to 2000
Relative Busbar Power Cost Net 25 Year
Mills per KWH Benefits - Million US$
Sultani Oil Shale 71-83 Base Cost
Imported Coal
$50tonne 68-88 778
$70tonne 78-107 2531
Imported Oil
$17Bbl 56-76 (18) $24Bbl 61-96 1810
The above results are based on a capacity factor of 75 which is
considered to be a reasonable target for a new plant over its 25 year
life The average selling price of 6 cents per KWH cited in the
questionnaire is based on existing plant costs which may not include
all cost elements of new capacity evaluated in this study
32389
Page 9
TECHNICAL COMMENTS
21 See answer to Item 116
Total power plant raw wate consumption rates and annual
consumptions including the water requirements for wetting ash at the truck loading p int within the power plant are given in Tables 43 and 44 for 50 MW unit and Tables 53 and 54 for 20 MW unit
The raw water requirements for 4x0 MW plant were factored
excepting the mine where a revised mine pldn is employed to reduce water request The quantities shown on these tables exclude raw
water requirements for housing complex mine and ash wetting if
required at the ash disposal site
Total power plant requirements shown in the above referred tables
are
50 MW 20 MW
Rate gpm 207 102 (See Drawing M004)
Annual Use
Gallons 1400000 675000
Cooling tower blowndown supplemented with raw water is used for
wetting ash at the truck loading point within the power plant Raw water quantities attributable for ash wetting at the power
truck loading point are
50 MW 20 MW
Rate gpm 75 325
Annual Use
Gallons 500000 215000
These quantities are included in the quantities shown in
the above referred tables
32389
Page 10
22 We recognize the POTENTIAL for leaching toxic compounds from the
spent ash However this matter is not yet defined well enough to
recommend specific action steps The Prefeasibility Study page
7-12 recommends creation of a ground water dispersion model to
determine whether more specific contaminated water mitigation
plans are needed It is anticipated that the leachate rate will
be low and that aquifer dispersion will keep problem compounds
bel3w health standards thresholds
23 Noted
We have not received up to date resource study material which
defines 50 billion tons resource base Please furnish
The resource base at Sultani alone is adequate to support two 400
MW power projects capacity subject water availability The
2-million cubic metre per year water allowance for oilshale will
limit development to about 600 MW
24 Selection of a combustion temperature is a balance between carbon
combustion efficiency and heat loss due carbonate decomposition
For purposes of the Prefeasibility Study we have opted for high
combustion efficiency At lower efficiency larger shale
mineprocessing plants will be needed
25 Bottom ash is cooled by water exchange before discharge
Cooling water is supplied to the ash screw coolers as specified by
Pyropower See Drawing MOO5 2140 gpm flow for 50 MW and 860 gpm
flow for 20 MW Heat removed by the cooling water from the ash
screw coolers is dissipated to atmosphere via a wet cooling
tower Pyropower should indicate the temperature of the ash
discharged to be 5OOF
32389
Page 11
Initially we had considered using a heat exchanger to cool the ash
and improve the cycle efficiency Considering low cost of fuel
the additional capital costs and the system complexities it was
decided not to employ such heat recovery systems for this project
26 The suggested alternates were looked at briefly and the potential
for wind blown air pollution from the ash disposal areas are too
great to warrant dry disposal unless GO(] and World Bank are
willing to accept such a potential problem Wetting the ash is
tne only practical solution Hopefully some cementation will
occur helping to reduce future leaching potential
27 JEA requirements are noted This is a conceptual study not a
final design Optimal design analysis can be performed during
Phase II
2829
JEA requirements are noted and can be incorporated into the Phase
II design
210 The transformer size is adequate for base load operation A
higher capacity can be considered at the final design stage if the
Client prefers
211 From our experience it does not appear to be economical to
provide additional dry cooling towers to take care of maximum
ambient temperatures which may prevail only for a short period of
time in a year To study this an annual dry bulb temperature
duration curve is required Also adding additional dry cooling
towers will change the plant performance It should also be noted
that the dry cooling towers are very expensive and the size should
be selected carefly considering performance and cost and not on the basis of maximum ambient temperatures This can be studied
during Phase II
32389
Page 12
212 The plant gross output varies with condenser pressure
Condenser
Pressure Design 55 in HgA Annual Ave 35 in HgA
Unit Size MW 20 50 4xlO0 20 50 4xlO0
Gross Output MW 234 593 496 2415 607 TBD
Net Output MW 1975 501 400 205 515 TBD
To be developed in Phase II
Output for 4x100 MW is estimated by others
213 The fan power consumption of the CFB boiler is about 30 to 35 of
the total auxiliary power The fan power consumption of the dry
cooling tower is about 20 to 25 of the total auxiliary power
214 Table 1-1 does not include plant net output Therefore do not
understand the comment
215 Commercial operating experience with coal fueled CFBC units in LISA
and Europe has been uniformly good showing high on stream
availability in early years (See Table 2-6 which reports on
Pyropower experience)
We expect operations with high ash content fuel like oilshale will
have unique scale up problems such as
o Solid handling in and out
o Internal solids circulation
o Erosioncorrosion steam generator intervals
o Heat recovery from bottom ash
Consequently we are recommending these items be worked out in a
single 50 MW prototype
32389
Page 13
216 Maximum dry cooling is used in this study A small wet cooling
tower is used on circulating service water system
217 Horizontal condensate pump is adequate with dry cooling tower and it is cheaper Vertical condensate pumps with cans can be
considered in the final design if required
218 A concrete shell brick lined flue stack will be larger in diameter and costs more than a steel lined stack Brick lined stack can be
considered in the final design
219 Demineralized water tank capacity for 50 MW is 76 cu meters or 20000 gallons not 1000 cu meters For 20 MW plant it is 38 cu
meters or 10000 gallons
220 It is US practice to use an average continuous blowdown rate of
1 and maximum biowdown rate of 3 for this type of plants
221 This can be studied during Phase II
222 Same as 221
223 Same as 221
224 The recommended action plan calls for continuing support studies covering the referenced items Additional effort is needed to
further define these matters and confirm the conceptual plan
The next step is to develop an outline for a project plan including
o Work Scope
o Schedule
o Budget
accommodate the increase in the number of employees and
equipment Truck bays to accommodate the 136 tonne trucks
will be added The truck bays used for the 77 tonne
trucks will be used for the maintenance of other
equipment The warehouse change house training room
offices and cafeteria will be expanded accordingly
6025 Mining and Processing Economics
Details of the oil shale mining and processing plant
economics for the 400 MW plant are included in the Mining
Report (Appendix 5) These details are of the same
magnitude as prepared for the 20 MW and 50 MW plants
The summary of the cash flow analysis for the mine and
shale processing plant is presented in Table 6-1
Table 6-1
SUMMARY OF 400 MW PLANT OIL SHALE MINING AND PROCESSING COSTS
5050 Debt-Equity 8020 Debt-Equity
US $1000 US $1000
Capital Cost
Mine Development 30915 30915
Mine Equipment 66012 66012
Process Plant Facilities 50889 50889
Spare Parts 5000 5000
Working Capital 10000 10000
Capi tal ized Interest
During Construction 24423 39075
TOTAL 187239 201891
Operating Costs and Other Costs
Annual Cost 60386 53236
Product Mined and Processed
Annual Tonnes x 1000 7783 7783
Unit Cost
US $Tonne (weighted average)
US $l06Btu (weighted average) 776
156
684
138
Year 12 costs taken as 25 year average
6-6
-Au
Table 610 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
- FCC plant sizes equivalent to proposed power application
Prefeasibility Study Oil Shale Fueled Power Generation
VOO94GEampJRI26
i
PYROFLOW UNITS IN THE US
COLORADOUTE IOYA STATE UNIV UNIV OFNUCLA CO NORTHERNAMES IA BF GOODRICH110 1o0MW(a) 2x170000 Ibhr HENRYILCEDAR FALLS IA 120000 Ibhr GENERALGULF OILu EiN P MOTORSSbtUpStart-UIL 1987 O A 1I N000 TC
NORT10 PONTIACH B MIRANCHWV00000 lbhr
CORN PRODUCTSSM NORTH-CAROLINA STOCKTOD CA
400000 lbbhl t
RUMF RD ME
CEMENT CO CALIF PORTLAND-COLTON CA
190000 Iblhr Start-Up 1985 TRUMTFTWN NYU
3I75ERTOWN N
etar t-Up loss ACE COGENERATIONCABI
TRONA CA Oper t~on l -Start-UP 1990 ~ rt upz 091Start-up loss Start-up PNeLAI 1991
MTKESFICOENERATIO-N1
BASFIELDp Start-uStar-Up WESTCA9 199otgoUp 1 MAHONEV PA|00000 Ibhr A Oz 2X365000 Ibhr
SETtr-Ups 188B CHAT TANOOGA TN
G ULF OIL EXPLORATION 8ta-rt-u) 1085BAKERSFIELD NORTH BRANCHCA SPRING GROVE PANORTH BRANCH WV 400000 IbhtOperational 19835 5 0 0 I b h 9 0 0 0 Iblh r- tart-Upi 1991 S t r - U p s l e s s
SOUTHEAST PAPER MFG CO UNIVOF NORTH CAROLINArDUBLIN GA UHAPEL HILL NO400000 IbhrStart-Ups logo Start-Ups2X250O000 1loseIbhr B
- Withdrawing ash from combustor - Withdrawing fly ash
a Internal solids circulation of the steam generator
m Erosioncorrosion of steam generatorinternals
Heat recovery from bottom ash
U Operation with low calorific-value fuel
Prefeasblity Study O Shari Fueled Power Generation
VOO7AI 27
Impact of Scale-Up
Project Size
20 MW
50 MW
100 MW
50 MW boiler in 100 MW plant
Potential Risk
Design Scale-upOperation of to 100 MW Initial Plant Plant
Low Significant
Modest Modest
High Low for duplicate units
Modest Low for duplicate units
Prefeasibility Study Oil Shaje Fueled Power Generation
VOO71-4GEAL4n2
i
Conclusions
Defined risk of CFBC boiler is acceptable
U Operating experience with commercial CFBC boilers built and under construction will strengthen confidencelevel and minimize risk for a plant built in 1995
SPrefeasibility Study Oil Shale Fueled Power Generation
V007GHAAE29
ENVIRONMENTAL ASSESSMENT
a Mine and shale processing
- Fugitive dust emissions
- Noise levels
- Leachability of disposal piles
Power plant
- Fugitive dust emissions
- Gaseous emissions
- Noise levels
- Water effluents
U Conclusions
Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel
Prefeasibility Study Oil Shale Fueled Power Generalon
- Coaloil prices will be at least 15 greater after 1995
- Discovery of indigenous conventional fuel resources is inadequate for power plant purposes
Prefeasibility Study
Oil Shale Fueled Power Generation
VOO) IDWFO
Feasibility(Contd)
N Suitable financing will be available
- For $200 million 50 MW prototypeproject
- For $1000 million 400 MW commercial project
Government of Jordan will make basic commitments
- Long-term power purchase agreement
- Long-term access to Sultani shale deposit
Adequate water and manpower resources
- Attractive tax incentives
Prefeasibility Study
Oil Shale Fueled Power Generaion
VO bull1DUJJRO 6
Timeliness
U Timely development of Jordan oil shale needs prompt action to create - Additional definitive information
- Suitable business plan
Prefeasibility Study
Oil Shale Fueled Power Generation
VooI DUJo 7
i
Expansion Conditions
U Continued expansion of powergeneration from oil shale in Jordan depends on water availability
Prospects for power export or importand domestic load growth will affect size of the needed shale-to-power program
Prefeasibility Sudy
Oil Shale Fueled Power Generation
yOWl lVuJO
Environmental Impacts
N Environmental impacts of shale development will be minimal
Prefeasibility Study Oi Shale Fueled Power Generation
i
Development Advantages
Will create significant new jobopportunities in Jordan
Will avoidreduce foreign exchangelosses for expanding alternate fuel imports
Prefeasibility Study
Oil Shale Fueled Power Generation
VOOIIULL tO
Recommended Action Plan
N Basic recommendation
N Conceptual development schedule
U Project development plan
Key plan elements
N Funding requirements
Prefeasibility Study Oil Shale Fueled Power Generation
VOO4II )U OII
i
Basic Recommendation
N Expand efforts to develop an oil shaleshyfueled power generation program at the Sultani deposit
- Conduct required supporting studies
- Define facilities costs and business plans
- Obtain project funding
Prefeasibility Study
Oil Shale Fueled Power Generation
VON I II)ILL 12
C
Conceptual DevelopmentSchedule
1989-1990
- Conduct supporting studies - Define costsbusiness plans for 50
MW prototype and 400 MW commercial projects
- Develop project financing
N 1990-1993 - Build and operate the prototype project
N 1994-1996 - Expand the 50 MW prototype to 100 MW scale
U 1996-2000 - Expand the project to 400 MW scale
N 2000-2005 - Build a second 400 MW commercial project if needed
i 1 Prefeasiblity Study
dOil Shale Fueled Power Generation
VW IMLITO 13
Conceptual Development Plan
Months
1 Project development plan - Define project
costs1busness plans
-24 -12 0 12 24 36 48 60 72 84 96 108 120
2 Secure funding
3 Build and operate 50 MW prototype
Dergn and procurement
Mine development
Plant construction
Startup and testing
Operations
L- -
4 Expand prototype to 100 MW
Design and procurement
bullConstruction
Startup
5 Expand project to 400 MW
2nd 100 MW unit
3rd100 MW unit
i 44
4th 100 MW unit -
O Project dacision point
i Prefeasib~ity Study Oil Shale Fueled Power Generation
17958562aJocdanV 3-14-89 rsO
18
Phase I - ProjectDevelopment Plan
n Program development
Seminar workshop on prefeasibilitystudy Oate project development plan woek scope schedule arid budget
U Carry out project planning program
- Conduct continuing support studies - Test Sultani shale in existing FBC
- Firm up designs and specifications
- Update costs and economic analysis
- Develop business plans and requirements
Explore project funding alternatives
i Prefeasibility Study
Oil Shale Fueled Power Generation
VO MItUOR 14 -0
Key Plan Elements
N Project feasibility analysis
- Firm up designs and equipmentspecifications for all facilities
- Update cost estimates based on preliminary designs and specifications
Explore arrangements for contract mining and mine development
Update forecasts for demand growthand for retirements of older generating capacity
- Create updated economic analysis
Preleasibility StudyO1 Shae Fueled Power Generation
VOO1IOLWRI
Key Plan Elements (Contd)
Business entity requirement
- Explore optionsconditions for a new company to managebuildoperate the project
- Explore optionsconditions for obtaining a concession agreement for Sultani development
Explore optionsconditions for water rights commitment
Prefeasibility Study Oil Shale Fueled Power Generation
VMIOIA)lj 16S
i
Key Plan Elements (Contd)
U Continuing supporting studies
- Combustion tests (additional pilot tests for design and warranty purposes contract for large-scale burn operations in existing plants if appropriate)
- Additional core drilling and core analysis
- Oil shale crushing tests
- Spent ash leaching tests
- Geotechnical data base including soils analysis
- Environmental baseline data
Prefeasibility Study O Shae Fueled Power Generation
VMMMUldMOA
Steps Required to Develop an Oil Shale-to-Power Project
Create a development business plan - Schedule - Decision tree
Develop a work scope and budget for the development plan program including - Firming up designsspecificationscosts
- Developing business entity requirements - Continuing support studies
Carry out development plan program
Assemble all planning results in a report for discussion with financial institutions
Explore project finance opportunities
Finalize business arrangements
Implement prototype project
i Prefeasibility Study
Oil Shale Fueled Power Generation
VM1-11UJROLI
MARCH 15 JEA QUESTIONS (M S ARAFAH) ON PREFEASIBILITY
STUDY DRAFT REPORT
Rt
DIR EScBSULIVAN PHD OFJCEop~BUREAU FOR SCIENCE AND~TECHNOLOGYAGENCY - --FOR INTERNATIONAL DEVELOPMhINTSWASHINGON DC x20523---------4
4 -
-SUBJ E CT - -C O H~ E T 4N l
Dr Mr sullivan ------shy
c-rommnents We ~efr-preaereorPla -tobYou lete dted Jan 91989 regardn~i4po4t P ea e1 f i nd y ubel ow our -e ot r XcOrcerned Jordanian deipartments
- --A ar o~nnYu Y o turjlt~ lt K
4 C~mments
~1 N i gFIN I~fANDECONOMIC1COIMEN S -
It sidicaed that Beohtel and US AIDWash ingtonj~4- re ojy nen ing that E 2hould und ertake the n e tshyihaisAre ~our c leometprogram n order shye-t im~ ate d f n t v design and budget cost
4Al1so Lthe study ncal--ttsutnilndcaei~ A-1 A thas ~ l 1 be eeded idb~~~~~ rn o ei t n i la itheMWa~-~5s~ 4
hrPro hehgemetTh trOfT ses~fnr4 BOT)Vmanu- a n-mnf~cure 4 r~j or contra c4-or ivoIlveiintijn I 4 4investmnt ude smi ~w 2 Zha tev e r --~4~prce e ec r it v p4~ f JA gertiy geeated-at 4 JEA 3 a l b u y ~the same average~~ A
~jithia oncot in4 ordrtan ecpoemic asess thespePower generatjoon J ordan3 oi sha I eroic c inr~etJordan 4
2P ge i1- 1 Aj iit eu that OPin he atocontr~ct 4with owner4 ofext3ing (oconstriiction r(FB rml-t
qu i of S 11 t to test large tonnagen j es StaniUti n d ajIe -for se veralIQf 31 hi
evrEAPreferpilot qr the dP 1prt7n -that the4mPIt
andi to(7 he instalI 1e 2 310 A
_
JODN ELECTRICITYAUTHORIT LL
Dac
operated in Jordan i n or~der~~t ~n nuex~on mnining crushing and haidi igQhre~ and sash Maeia nd aSootoget enough olr ndaita needed for einolre
CEBbole~ -i s~
ccordance with Jordaian oil shale
large to~ bfig
1 3 le 1-2 Page 1-7 Cost Of Pwer~i It i S menti-oned that the conmecial oil hle~ lt~project (4 X1OOmw) 1is ninacompetative roqt~range-~while table 12 indicates thattcost of-pow Ais~mill
q kwiihcii r 1
average wih i ii -much higher ihantheshy-ost of ~Power gnrtofomJEA therimaPower s ta tions Please~ indicate on what basi o ~~ shave-~made your-statement
PK
14 Pae 2 Sction 4-0sIt 1nlkly that theChousing and off- -site infrastructur-ommnity fakilitieR) to be onsidered for both the demo and prototyp prjcs oeoverwe~4 hnk that their~c_6t is raterojects Mo
iwcv~- age -1 1 Mine O(perationIIt is indicate~d that mining cot eevdfoMine contractor~ are ficomiplee h
r and iyudi-t~con qidder contract mnn opio fr4 the min4 cmflt2ng are reIanddrepres~ent the real costs derived from Phspat miin contractors in
lestfor the eo rPooypuat in order tlt7
P I eadenote tha detthe new exchangerate ofthJraian~ Di~nner you may add 20j6 Kto the quoted
1 6 P Ias e consider the followin ecn hage_
171- The new exchange ra teof tUSD=54o0 fils1 72-W2 The new~ aerage tariff for selIn~electricityhas decrreased to 120 8 f ilIsicwh
17- Page 1-7 TbIe 1-2 W bev th tthe cap ita1 cot for the pwhokand forthe min n d ash hMnd1ing equipen
P B~2Anaor a -Tl 8156152 8176 1Q MYf -t -Now 520 t 1U
JDNEECRICIT AU-RA L14lLiL
2 ~are very high We suggest~ thta You rerconsie (- telowerus e~+d accuracy est a rangethan +30
Page4-22 Table 4-5weno0ti ced( that- PyroPowe ha ddeta(IiacCst fori the bo1ilerlocation and terha dutdetlease isxtr fo~ l C~ io~ s~ e~~ 1a~ a if and indicate theonldjusted ~percentagefor construction foin Jordan
19 Page-7 Table 11-2 -Yo aeue ihrinterest rate on Equity thatn on1DehI~laseinclude~ adetaied explanation of thisrr -tni kepin in miUndie JEA is1thaIt a non profit~ shyorgaiztion unik oher private UJSA utility~in ktation
~-~110- Regarding shy
the ra4ital Rt fthe project it is~requesed tobre k it intdo foreignMeanwhile cthe nd lorcal c-osfoeigptario i nt-re3t~shol becnierdo-h
rr n ontiondonnotopdbon the 9 cnieelocal portion~onth
1-1- 237~Pa
oningeny 9tooi s high~~ a lower 4value -should be~
4~ gt ~112- -Tbles t1-1 -8-8~ inclu~de t~he c~alculationscuultie nt enefits for of Th shyunttypes l i4s difeen geeatnmrer likely tocluae
-~ Q~ J7present vk1u for tenet tthe~benefits in feralterntives -t-oa s the
49
ehliyoi shale
Wea gree with you9 tha t th e percentage used ~ an for thenua~l 0 ~amp-M rahr CFBo ndsomewha~t highervrate be n ededma y for a C B l n Me n h l ~ a e r
indir e ta~ts the -estimatedma i variablec st i ddition t he fi-xed-9i 1 mislkih We --
thinktttiis too lowK -5
shy
1-14- e 4-29
opprza tion-o to The o i1s h1 costs-nc I deAbo 1h
Pa10 mman ormTSI62 a
IB I
JORD N EtECTICI1~ 4 E~)~Is-s
Date ib-_
~ ~riii~g~nd~o9~ru~hng h~tnlin cot~u~tv yo
i Dae Jnryit
1ts c 7 4-
i smiig iniand fh co I eY
susendi ca tI t icag th t1 ~an~approximate 15 ~pita L tYII I (-~a~ge or he owe bl ockj f aniitjes isof +the capthe)t~ial7cpi~lrharge Uoratelformny SI~Uj(uiity installa~tions~ whle page 6-1T9 talJshyit is mentioned that~ the Capital rate pe-r JEA isshyi5~PeaseJustify this~matter since~w o
i16- Pae 6-1 6
1 I4~t is mentioned that the costs of 4process Water are ~ 4 ~0 2$1 000 gallons
r~j~lt IHave~You considered additionalvalue ofbying waterfrom~ the Wa ters Aito i ~or ditoa cost~f o revrseoqoesplant if ground water is used
~~ I1 7- Table 6-1 Page 6-6 Please explain how did You come ou ihteoil~ shale miniing and proces~sing uit~Icost
ltII~I~ 8- Please note 1 t hatj the average JEA~productinr ot frmthermal I power stationsr (Istationbus-barCOSt)i sbewen 6 3-17 3 fils 4kwh You may use this~
l4~ 19-i For ~4 X 100~AMW Plat iti etindo pag e14-4 VolI 11 that4 at tota I of W42 14 epoye W II eemplo~yer] And on page 69yo1Iiti mentioned that a~ tot 1 f1 ~p yeI iNbe enp1oyed a
is~ high asrmetitexeds100personorthe ~41X100~MWh~~j nsatnpPrlae
I 1 The 4 following iftemns are a sumed to1 be excluded from theraPi ta 1 cot xoI
120-1 Perits I icen es 7
1_207~3 Imprt ~xe on s7pare par ts -and c(7orfmurab -ma~teria Is
04f4 4
~4 R j4 4
D4
~ ~ ~ AIf eS taxesq in acrac ihteJraand regulations should be considered aw
21- p1ea4s e indic ate Your Ju t f c io r us ga 6
44122- Table 977App 5Page4 9-1 4L IK Car1Yiniae that the hIRR of the 4 Otplantis rather unattractive (66)most
-( Cns1er4 ngthe logical base 4csek c pwhen cii 6OL
average sell~ing prc CkhampDEratio L801~2O~Aoreover4M the ne siellin prcwh o JEA ati theamptime~ Abeing os4ltp n~ot exceed 4 Ckwh~-However Ipage 1shy~ and 14 0 T indicate that ecnms for a commeri
S4A4scale joil 4 shale projc ~
appear Piomisig-nug o4Ywarrant continued dee fgfluht 4 feaibiit 4tudy wihil cost sevea~lili
do ar~sf Plas lear wether the ~x step jqs~$j~~lt 4
gtt 9o be considered arCcording4to jthe 4unattractiveresul to mentioned in IRR7 Table 97 gt4
a C4 44fET2 4 144-4444 P a g 1 T b6 l
htte~We ~ ~ ae~ rqieetfrteX ~ noie ~~ ~ 444 MW un t44 r te4l w w e o p r d i th e w t r n rre u f4m or4444~ the4444 54M4rto y e Pg~A~44EHiveL det ile an l A44
s o awa er c n um t a4r f rofsho in P6Io erT
e ch 2 50 M W aPln wa e d 41004 MW4 1 consumption_____________
ma4~2 k e u p houin~44 p A44 4444444 C O 4ltI4
a nd a sh et in etc 4 2 4 1 -24 P a g e4 2 - 1 A P P 5
4Yo 4_ j1 4 4~h444 N44 44
1gro nd tce t hir fthe w bern coqir mna t efora4e 4X10A M 444444 4 r i n to 4 4 4lo w w ehA 7 n 2 cinCie h rh4 n ttthh1eb -e 4 44t Of3 E4O
ea h n~ ffl 4 4Jl44 4 4444 4giv
6 ig re sofrat4 de in cl ar f w w at5 c hrw pe o
s h b 444 o t h e g nd L 44 h u i n C
r 4ne a4 t44 e L(704 2 4 p ae) 2 - o Au P dn 5ai 7~e r 44 I Y (1t 44a
ve7 rn e qu 1saharvthe y
and n~~~o speci~~~l4 p n l nh i n t x
r ~rA M e d r o t eu n 8 1 wTtl t t h
- c re e N I wo6
~ n n a i n a t d h l7 A PP6 gt
J
S2~3- Page 2-4 ~ ~ It ~is i
that oil eindicated the- sha le r our~ Cesin Jordan are 10 billion tons -The anulp e reere maiy exeed 50 4 billion tons ~
~ 24- 4Page~2 -l1 iujntr We beiv thtCBcmuto~ep i s high and~alSo
~~ ~ -2 ~~ Page 4-1~6 j - shy
Please~~ indicates your procedure to cool the omn ashand atwa icagd-eprtr
A Have you~ considered~ additional he~at exchanger topcool th ash and to imrve h cycleef ficiency
-~2~6 Page 4-16 It s~ indicated that ash from each silo i Amixed19 ~with~fabout 20 waterKb weight to minimize generation of dust~during trnprtto to mine and disposalHave you~ coniidered other 4lternativeto
~ ~eliminate dustiiig -and avoid use ofwat r uring it ransportationi such as~ using closed trucks or closed
of ~fans conUMnPo wihrlaintthe total plant auiir poe osupin 1~21- Table 5_-3 and I ~
Th~~ is- somneere c6ntradiction regardingplnneotpu~t in both am tables 21-~ Tabl~e 1-33
We noticed tha~t yourall9 cacacapac t fatro75 tion ae asdnWe thilt ~that 7capacityshyfacto is tobo high for- an oil shale fired plant duketo lack of existing simila~r ~plants handl~~~firing oil adshale ~K
216~ The study iniae thtawet~coigtower wi11~used Actually a b
dry cooling should be consideda5ini ~HTP S inZ atomnmz so water rnumption4the cycle~ efficiency willbe reducedHenre YO33~reconsider calculating the cyclefficiy
U~~~~~ codnt umconsidered ofhorizontal -aretypethe~ the vertical cian type can alsobeh considered
shy ~ ~ ~ I~~
2~2 Kconcrete shy
shjell stepl fltstack is onidereconcrete shell brick flue Rt c ~s beCaconsidered3V
2-19~- Deminiraized water~ tank3 capacity~ is -76 ui(meterThe recommnended tank cameter- ui tyi 00cbc
220Designconditions Pa~ge (4-74)te5 hat bow 3down percentage splusmn ~fomrpra til re i hou I be 3~)~
PoD Z 2 m a ad~ - e 5 1 2 iJS~ ~ p A f amp ~ ~ y1
4
JO R ECTICITY AUTHORTIT 4L
~ 4
Date~
t etats ttthe quantityof s i S ~1 000Tons ra Sthis tuntity 11- be transporited for severIy --to tu ofI pit a~te torg P KM ra~erm Spower plIatS about 12 midilidoni CUIA(- met ryea
h e ndd mp e he (d u p in i n L
area wil evric power plant6t Please zn1 a te~tiv s tudY for dumping th r~ a enoug
-from the power plantr~~h~
S 2- Please provide deald-ifrat ao etbaaiedrawing hwn TH11 R thaU and~pV ra~te takcing illto o 6it v- consumptionn _uig themrining equipment
alternate~ study 0o Jine operation for 1 shiftday Vand twoshifts day -lt
224- Conceptua~l pflR 1 for mi ing anusdtransportation of oil- shale a 0 dmj of hs f u r therV examinedh iV~sdpatI ho u1d be
orderj to poe~ehicalq and~eoomca1 fesblt of t his operation
SYour are requested te) study and consider all- above - iPoin s at your earliest in rder -to be peete y oiAnimain on March 29-301989 peetdb~o 4 n
S9incerly-You S
WDIRECTORGENERAL -
I~ CCMR WLINTON ~vs
5N
Pa D~t~IoAmmn -Jordtn -Tel 815615 20 Bl76 15 -19j A VINO- AFf TY
MARCH 21 RESPONSE TO JEA QUESTIONS
Bechtel Power Corporation Engineers - Constructors
Fifty Beale Street San Francisco California Mail Address P 0 Box 3965 San Franclco CA 94119
March 21 1989
Mr M S Arafah Director General Jordan Electricity Authority PO Box 2310 Amman Jordan
Subject Jordan Oil Shale Prefeasibility Study
Dear Mr Arafah
Your letter of 15 March 1989 with comments on the Oil Shale to Power Prefeasibility Study draft report has been referred to me for reply
The attached responses to each item in the reference letter follows the order submitted
Also attached are three revised pages for the draft report - Volume I
Page 6-1 Page 6-21 Page 6-23
Please copy these revised pages into the report previously sent to you
We plan to review this material with JEA during the March 2930 and April 1 meetings in Amman
rsuVertrul yours
W Linton Project Manager
WHLdc
Attachments Questionnaire Response Three revised pages
cc C J Aulisio R R Buta G D Gould T J Wilbanks
32389
Page 1
RESPONSE TO MARCH 15 1989 QUESTIONAIRE
OIL SHALE TO POWER PREFEASIBILITY STUDY
This study examines economic prospects in terms of a 1995-2000 timeframe
FIRANCIAL AND ECONOMIC COMMENTS
11 It is likely that a BOT deal can be structured at present JEA
generation costs for either 20 MW or 50 MW size units if GOJ is
willing to subsidize the incremental power generation cost
Furthermore these incremental costs can be recovered during the 25
year operation of a Commercial Scale Project
12 A 3rd Party Test was proposed as an alternate means to raising
$100+ for an independent JEA sponsored 20 MW Demonstration
program
13 71 millsKWH for Shale Power
VS
JEA 1987 costs
Purchased Power 17 filsKWH = 51 mills
Produced Power 1360 filsKWH = 41 mills
19952000 Costs - Expected to be 30 to 40 higher and in line
with the cost estimate presented in this study
It also is important to recognize that the busbar cost of power
generated by any new power source can not be compared directly
with the cost of existing older installed capacity because of the
lower capital cost component of the latter (See enclosed Figure
1-1 which demonstrates how total capital carrying costs decline as
the investment is paid off) Any new capacity whether coal oil
or oil shale will be an unreasonable disadvantage compared with
costs for existing older capacity
l
024
o2
0De return
E 016Total carrying charge
012 qu return
S -008
ety taxes and n rcw vshy000 X 0 5 10 15 20 25
Figure 1-1 Year-by-year Carrying Charge Components for 15-yearTax Recovery Period
1-7
30
32389
Page 2
14 Infrastructure Cost
Total People
OperatorFamilies Installed Cost
20 MW $10000000 185700 $54000Operator
50 MW 15000000 3241200 46000Operator
400 MW 45000000 10364000 43000Operator
Factored allowance for grass roots desert installation
including housing and community facilities was developed as
follows for the 50 MW case study
Infrastructure
50 MW
Family Housing 200 30K = $ 6 Million
Bachelor Housing 100 20K = 2 M
HospitalClinic (8 Beds) 11 M
SchoolMosque I1 M
Stores Services amp Recreation = 2 M
Facilities
Roads Electricity Water Sewage = 3 M
$15 Million
Infrastructure costs for the 20 MW and 400 MW cases was ratioed
from this breakdown
At this conceptual level costs are order-of-magnitude In a Phase
II program these infrastructure costs can be developed in detail
32389
Page 3
15 Contract Mining Alternatives
Page 4-11 Mine Operation
Based on Bechtels evaluation of the mine contractors price as found in Section 15 of the Mining Report it was concluded that
the mine contractors price does not include costs for such things
as developing the mine with a box-cut ramp haul roads
developing an area for the waste material maintaining the
haulroads constructing the mine services facilities diversion
ditches sedimentation ponds water well crushing the oil shale
pre-mixing the oil shale at the mine and other items associated
with operating a mine to support a power plant If it is proven
that the mine contractors price includes cost for the above
mentioned scope of work in additi-n to drill blast load and
haul then the contractors price can be used but in the meantime
the all inclusive cost developed by Bechtel should be used
Contract Mining appears to be attractive for the smaller size
plants but not for the larger commercial scale operation Some
third party must provide the necessary capital for trucks
loading mining machines etc under a contract arrangement
16 Reassessment due to Dinar value change needs further study and can
not be evaluated given present budget limitations If average
labor rate of $300hr still valid then little change involve with
study
If deemed necessary reexamination of project economics can be
done in Phase IIwhen funded
17 Costs in this study are based on recent similar Bechtel experience
on Mount Poso project and on Montana I project The Mount Poso
project is a 50 MW unit firing coal in a Pyropower boiler The
Montana I project is a 35 MW unit firing coal in a Keeler Dorr
Oliver FBC boiler utilizing dry cooling
32389
Page 4
18 The Pyropower quote of $186000000 to futnish and erect the steam
generator stack and baghouse has been adjusted to include
engineering construction indirect cost etc to be consistant
with the rest of the costs shown in Table 65 p 6-10 No
further adjustment for location was made
19 Equity funding has the lowest priority of payoff in case of a
liquidation and carries greater risk Hence a higher rate of
return is needed to attract these funds Debt funding is a first
mortgage and has first priority for payoff in case of liquidation
and carries less risk Hence it requires lower rate of return
than equity funding
The risk taking equity owner will ask for greater interest rate
to make funds available The only way to minimize this expense is
to find a loaning agency willing to provide 90 or perhaps 95 of
the investment cost It is likely that banks will require some
minimum equity participation
This Prefeasibility Study was not based on a non-profit utility
operation
Even though JEA is a non-profit organization its service
contributors are profit making groups It is visualized that the
Jordan Oil Shale Co (JOSCO) will be a stand alone business
enterprise servicing JEA under long term contract To secure
funding for the proposed project JOSCO will need attractive
enough contract terms to attract both equity and debt capital
110 Additional work is needed to develop the requested information
This work can be preformed as part of the Phase II program
111 Bechtel includes contingency in all of its estimates to cover
error emissions and unforeseen items within the defined scope of
the project The level of contingency is dependent upon the
amount of scope definition For a prefeasible study such as this
15 contingency is lower than normal
32389
Page 5
112 Tables 89 through 816 include a present value calculation to
establish the relative benefit for a shale project vs coal and
oil
113 The variable maintenance cost of 1 millsKWH has been adjusted for CFB plants with an additional $200000 per year or 06 millsKWH
This yields the following
Variable Maintenance - 10 millsKWH
CFB Adjustment - 06
Fixed Maintenance Cost - 40
Total Cost 56 MillsKWH
114 Page 4-29
The royalty costs are included in the weighted average oil shale
costs for the 50 megawatt plant
Page 4-8
Shale fuel costs include return on equity and royalty These are
two separate cost items Royalty is the last item mentioned in
the sentence and it therefore reads as royalty and not return on
royalty
Page 4-31 gives rates used by Bechtel based on our calculations
using the referenced procedures
DebtEquity Capital Charge Rate
5050 153
8020 139
Table 69 displays the calculation of the 153 capital charge
rate (Line 7 of Table 69 is not used in the calculation and
should be deleted)
32389
Page 6
116 No water purchase charge from the Water Authority was added to the
operating expense based on the statement that no resource costs
will be charged
$020 per 1000 gallons is rule of thumb for USA installations in
absence of client data
Boiler make up water (p4-17) is treated in a demineralizer
train If deemed necessary comparison with reverse osmosis
process can be performed in Phase II
Water requirements were estimated to be
Cubic Metres Per Year
20 MW 50 MW 400 MW
Mine amp Shale Processing 455000 761000 773000
Power Block 3000 6000 42000
Infrastructure 80000 140000 448000
Total 538000 907000 1263000
117 Annual average operating costs shown on Table 6-1 are in error
Financing Option 5050 8020
Cost Shown 56606 48945
Corrected Cost 60396 53236
Average mining and shale processing costs are developed year by
year in the Mining Report Appendix 5 Table 12-10
32389
Page 7
118 We would be interested in receiving the breakdown of these current
power cost figures (ie capital charges fuel cost number of
operators etc) Further economic analysis employing these
figures can be developed in Phase II
119 Manpower requirements for the three case studies were estimated as
fol lows
Mining amp Shale Processing
Power Block
Operations
Maintenance
Management
20 MW 50 MW 400 MW
75 163 396
54 78 175
46 73 455
10 10 10
185 324 1036
Page 14-4 of the Mine Report is for mine and shale processing
only It should be noted that most of these manpower requirements
involved new jobs for Jordanian people
120 At the April 1988 Amman Meeting it was agreed that the following
costs would be omitted
o Permits and Licenses
o Local Taxes
o Import Taxes
If necessary such costs can be developed and added into a revised
economic analysis as part of the Phase II program
121 6 average inflation rate is the figure recommended by Bechtel
based on USA conditions for use in long term economic analyses of
new power ventures
32389
Page 8
122 This matter is referred to ORNL who prepared a rate of return
analysis
Bechtels conclusion is based on computed busbar costscumulative
benefits compared to alternate fuels in the timeframe 1995 to 2000
Relative Busbar Power Cost Net 25 Year
Mills per KWH Benefits - Million US$
Sultani Oil Shale 71-83 Base Cost
Imported Coal
$50tonne 68-88 778
$70tonne 78-107 2531
Imported Oil
$17Bbl 56-76 (18) $24Bbl 61-96 1810
The above results are based on a capacity factor of 75 which is
considered to be a reasonable target for a new plant over its 25 year
life The average selling price of 6 cents per KWH cited in the
questionnaire is based on existing plant costs which may not include
all cost elements of new capacity evaluated in this study
32389
Page 9
TECHNICAL COMMENTS
21 See answer to Item 116
Total power plant raw wate consumption rates and annual
consumptions including the water requirements for wetting ash at the truck loading p int within the power plant are given in Tables 43 and 44 for 50 MW unit and Tables 53 and 54 for 20 MW unit
The raw water requirements for 4x0 MW plant were factored
excepting the mine where a revised mine pldn is employed to reduce water request The quantities shown on these tables exclude raw
water requirements for housing complex mine and ash wetting if
required at the ash disposal site
Total power plant requirements shown in the above referred tables
are
50 MW 20 MW
Rate gpm 207 102 (See Drawing M004)
Annual Use
Gallons 1400000 675000
Cooling tower blowndown supplemented with raw water is used for
wetting ash at the truck loading point within the power plant Raw water quantities attributable for ash wetting at the power
truck loading point are
50 MW 20 MW
Rate gpm 75 325
Annual Use
Gallons 500000 215000
These quantities are included in the quantities shown in
the above referred tables
32389
Page 10
22 We recognize the POTENTIAL for leaching toxic compounds from the
spent ash However this matter is not yet defined well enough to
recommend specific action steps The Prefeasibility Study page
7-12 recommends creation of a ground water dispersion model to
determine whether more specific contaminated water mitigation
plans are needed It is anticipated that the leachate rate will
be low and that aquifer dispersion will keep problem compounds
bel3w health standards thresholds
23 Noted
We have not received up to date resource study material which
defines 50 billion tons resource base Please furnish
The resource base at Sultani alone is adequate to support two 400
MW power projects capacity subject water availability The
2-million cubic metre per year water allowance for oilshale will
limit development to about 600 MW
24 Selection of a combustion temperature is a balance between carbon
combustion efficiency and heat loss due carbonate decomposition
For purposes of the Prefeasibility Study we have opted for high
combustion efficiency At lower efficiency larger shale
mineprocessing plants will be needed
25 Bottom ash is cooled by water exchange before discharge
Cooling water is supplied to the ash screw coolers as specified by
Pyropower See Drawing MOO5 2140 gpm flow for 50 MW and 860 gpm
flow for 20 MW Heat removed by the cooling water from the ash
screw coolers is dissipated to atmosphere via a wet cooling
tower Pyropower should indicate the temperature of the ash
discharged to be 5OOF
32389
Page 11
Initially we had considered using a heat exchanger to cool the ash
and improve the cycle efficiency Considering low cost of fuel
the additional capital costs and the system complexities it was
decided not to employ such heat recovery systems for this project
26 The suggested alternates were looked at briefly and the potential
for wind blown air pollution from the ash disposal areas are too
great to warrant dry disposal unless GO(] and World Bank are
willing to accept such a potential problem Wetting the ash is
tne only practical solution Hopefully some cementation will
occur helping to reduce future leaching potential
27 JEA requirements are noted This is a conceptual study not a
final design Optimal design analysis can be performed during
Phase II
2829
JEA requirements are noted and can be incorporated into the Phase
II design
210 The transformer size is adequate for base load operation A
higher capacity can be considered at the final design stage if the
Client prefers
211 From our experience it does not appear to be economical to
provide additional dry cooling towers to take care of maximum
ambient temperatures which may prevail only for a short period of
time in a year To study this an annual dry bulb temperature
duration curve is required Also adding additional dry cooling
towers will change the plant performance It should also be noted
that the dry cooling towers are very expensive and the size should
be selected carefly considering performance and cost and not on the basis of maximum ambient temperatures This can be studied
during Phase II
32389
Page 12
212 The plant gross output varies with condenser pressure
Condenser
Pressure Design 55 in HgA Annual Ave 35 in HgA
Unit Size MW 20 50 4xlO0 20 50 4xlO0
Gross Output MW 234 593 496 2415 607 TBD
Net Output MW 1975 501 400 205 515 TBD
To be developed in Phase II
Output for 4x100 MW is estimated by others
213 The fan power consumption of the CFB boiler is about 30 to 35 of
the total auxiliary power The fan power consumption of the dry
cooling tower is about 20 to 25 of the total auxiliary power
214 Table 1-1 does not include plant net output Therefore do not
understand the comment
215 Commercial operating experience with coal fueled CFBC units in LISA
and Europe has been uniformly good showing high on stream
availability in early years (See Table 2-6 which reports on
Pyropower experience)
We expect operations with high ash content fuel like oilshale will
have unique scale up problems such as
o Solid handling in and out
o Internal solids circulation
o Erosioncorrosion steam generator intervals
o Heat recovery from bottom ash
Consequently we are recommending these items be worked out in a
single 50 MW prototype
32389
Page 13
216 Maximum dry cooling is used in this study A small wet cooling
tower is used on circulating service water system
217 Horizontal condensate pump is adequate with dry cooling tower and it is cheaper Vertical condensate pumps with cans can be
considered in the final design if required
218 A concrete shell brick lined flue stack will be larger in diameter and costs more than a steel lined stack Brick lined stack can be
considered in the final design
219 Demineralized water tank capacity for 50 MW is 76 cu meters or 20000 gallons not 1000 cu meters For 20 MW plant it is 38 cu
meters or 10000 gallons
220 It is US practice to use an average continuous blowdown rate of
1 and maximum biowdown rate of 3 for this type of plants
221 This can be studied during Phase II
222 Same as 221
223 Same as 221
224 The recommended action plan calls for continuing support studies covering the referenced items Additional effort is needed to
further define these matters and confirm the conceptual plan
The next step is to develop an outline for a project plan including
o Work Scope
o Schedule
o Budget
accommodate the increase in the number of employees and
equipment Truck bays to accommodate the 136 tonne trucks
will be added The truck bays used for the 77 tonne
trucks will be used for the maintenance of other
equipment The warehouse change house training room
offices and cafeteria will be expanded accordingly
6025 Mining and Processing Economics
Details of the oil shale mining and processing plant
economics for the 400 MW plant are included in the Mining
Report (Appendix 5) These details are of the same
magnitude as prepared for the 20 MW and 50 MW plants
The summary of the cash flow analysis for the mine and
shale processing plant is presented in Table 6-1
Table 6-1
SUMMARY OF 400 MW PLANT OIL SHALE MINING AND PROCESSING COSTS
5050 Debt-Equity 8020 Debt-Equity
US $1000 US $1000
Capital Cost
Mine Development 30915 30915
Mine Equipment 66012 66012
Process Plant Facilities 50889 50889
Spare Parts 5000 5000
Working Capital 10000 10000
Capi tal ized Interest
During Construction 24423 39075
TOTAL 187239 201891
Operating Costs and Other Costs
Annual Cost 60386 53236
Product Mined and Processed
Annual Tonnes x 1000 7783 7783
Unit Cost
US $Tonne (weighted average)
US $l06Btu (weighted average) 776
156
684
138
Year 12 costs taken as 25 year average
6-6
-Au
Table 610 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
- FCC plant sizes equivalent to proposed power application
Prefeasibility Study Oil Shale Fueled Power Generation
VOO94GEampJRI26
i
PYROFLOW UNITS IN THE US
COLORADOUTE IOYA STATE UNIV UNIV OFNUCLA CO NORTHERNAMES IA BF GOODRICH110 1o0MW(a) 2x170000 Ibhr HENRYILCEDAR FALLS IA 120000 Ibhr GENERALGULF OILu EiN P MOTORSSbtUpStart-UIL 1987 O A 1I N000 TC
NORT10 PONTIACH B MIRANCHWV00000 lbhr
CORN PRODUCTSSM NORTH-CAROLINA STOCKTOD CA
400000 lbbhl t
RUMF RD ME
CEMENT CO CALIF PORTLAND-COLTON CA
190000 Iblhr Start-Up 1985 TRUMTFTWN NYU
3I75ERTOWN N
etar t-Up loss ACE COGENERATIONCABI
TRONA CA Oper t~on l -Start-UP 1990 ~ rt upz 091Start-up loss Start-up PNeLAI 1991
MTKESFICOENERATIO-N1
BASFIELDp Start-uStar-Up WESTCA9 199otgoUp 1 MAHONEV PA|00000 Ibhr A Oz 2X365000 Ibhr
SETtr-Ups 188B CHAT TANOOGA TN
G ULF OIL EXPLORATION 8ta-rt-u) 1085BAKERSFIELD NORTH BRANCHCA SPRING GROVE PANORTH BRANCH WV 400000 IbhtOperational 19835 5 0 0 I b h 9 0 0 0 Iblh r- tart-Upi 1991 S t r - U p s l e s s
SOUTHEAST PAPER MFG CO UNIVOF NORTH CAROLINArDUBLIN GA UHAPEL HILL NO400000 IbhrStart-Ups logo Start-Ups2X250O000 1loseIbhr B
- Withdrawing ash from combustor - Withdrawing fly ash
a Internal solids circulation of the steam generator
m Erosioncorrosion of steam generatorinternals
Heat recovery from bottom ash
U Operation with low calorific-value fuel
Prefeasblity Study O Shari Fueled Power Generation
VOO7AI 27
Impact of Scale-Up
Project Size
20 MW
50 MW
100 MW
50 MW boiler in 100 MW plant
Potential Risk
Design Scale-upOperation of to 100 MW Initial Plant Plant
Low Significant
Modest Modest
High Low for duplicate units
Modest Low for duplicate units
Prefeasibility Study Oil Shaje Fueled Power Generation
VOO71-4GEAL4n2
i
Conclusions
Defined risk of CFBC boiler is acceptable
U Operating experience with commercial CFBC boilers built and under construction will strengthen confidencelevel and minimize risk for a plant built in 1995
SPrefeasibility Study Oil Shale Fueled Power Generation
V007GHAAE29
ENVIRONMENTAL ASSESSMENT
a Mine and shale processing
- Fugitive dust emissions
- Noise levels
- Leachability of disposal piles
Power plant
- Fugitive dust emissions
- Gaseous emissions
- Noise levels
- Water effluents
U Conclusions
Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel
Prefeasibility Study Oil Shale Fueled Power Generalon
- Coaloil prices will be at least 15 greater after 1995
- Discovery of indigenous conventional fuel resources is inadequate for power plant purposes
Prefeasibility Study
Oil Shale Fueled Power Generation
VOO) IDWFO
Feasibility(Contd)
N Suitable financing will be available
- For $200 million 50 MW prototypeproject
- For $1000 million 400 MW commercial project
Government of Jordan will make basic commitments
- Long-term power purchase agreement
- Long-term access to Sultani shale deposit
Adequate water and manpower resources
- Attractive tax incentives
Prefeasibility Study
Oil Shale Fueled Power Generaion
VO bull1DUJJRO 6
Timeliness
U Timely development of Jordan oil shale needs prompt action to create - Additional definitive information
- Suitable business plan
Prefeasibility Study
Oil Shale Fueled Power Generation
VooI DUJo 7
i
Expansion Conditions
U Continued expansion of powergeneration from oil shale in Jordan depends on water availability
Prospects for power export or importand domestic load growth will affect size of the needed shale-to-power program
Prefeasibility Sudy
Oil Shale Fueled Power Generation
yOWl lVuJO
Environmental Impacts
N Environmental impacts of shale development will be minimal
Prefeasibility Study Oi Shale Fueled Power Generation
i
Development Advantages
Will create significant new jobopportunities in Jordan
Will avoidreduce foreign exchangelosses for expanding alternate fuel imports
Prefeasibility Study
Oil Shale Fueled Power Generation
VOOIIULL tO
Recommended Action Plan
N Basic recommendation
N Conceptual development schedule
U Project development plan
Key plan elements
N Funding requirements
Prefeasibility Study Oil Shale Fueled Power Generation
VOO4II )U OII
i
Basic Recommendation
N Expand efforts to develop an oil shaleshyfueled power generation program at the Sultani deposit
- Conduct required supporting studies
- Define facilities costs and business plans
- Obtain project funding
Prefeasibility Study
Oil Shale Fueled Power Generation
VON I II)ILL 12
C
Conceptual DevelopmentSchedule
1989-1990
- Conduct supporting studies - Define costsbusiness plans for 50
MW prototype and 400 MW commercial projects
- Develop project financing
N 1990-1993 - Build and operate the prototype project
N 1994-1996 - Expand the 50 MW prototype to 100 MW scale
U 1996-2000 - Expand the project to 400 MW scale
N 2000-2005 - Build a second 400 MW commercial project if needed
i 1 Prefeasiblity Study
dOil Shale Fueled Power Generation
VW IMLITO 13
Conceptual Development Plan
Months
1 Project development plan - Define project
costs1busness plans
-24 -12 0 12 24 36 48 60 72 84 96 108 120
2 Secure funding
3 Build and operate 50 MW prototype
Dergn and procurement
Mine development
Plant construction
Startup and testing
Operations
L- -
4 Expand prototype to 100 MW
Design and procurement
bullConstruction
Startup
5 Expand project to 400 MW
2nd 100 MW unit
3rd100 MW unit
i 44
4th 100 MW unit -
O Project dacision point
i Prefeasib~ity Study Oil Shale Fueled Power Generation
17958562aJocdanV 3-14-89 rsO
18
Phase I - ProjectDevelopment Plan
n Program development
Seminar workshop on prefeasibilitystudy Oate project development plan woek scope schedule arid budget
U Carry out project planning program
- Conduct continuing support studies - Test Sultani shale in existing FBC
- Firm up designs and specifications
- Update costs and economic analysis
- Develop business plans and requirements
Explore project funding alternatives
i Prefeasibility Study
Oil Shale Fueled Power Generation
VO MItUOR 14 -0
Key Plan Elements
N Project feasibility analysis
- Firm up designs and equipmentspecifications for all facilities
- Update cost estimates based on preliminary designs and specifications
Explore arrangements for contract mining and mine development
Update forecasts for demand growthand for retirements of older generating capacity
- Create updated economic analysis
Preleasibility StudyO1 Shae Fueled Power Generation
VOO1IOLWRI
Key Plan Elements (Contd)
Business entity requirement
- Explore optionsconditions for a new company to managebuildoperate the project
- Explore optionsconditions for obtaining a concession agreement for Sultani development
Explore optionsconditions for water rights commitment
Prefeasibility Study Oil Shale Fueled Power Generation
VMIOIA)lj 16S
i
Key Plan Elements (Contd)
U Continuing supporting studies
- Combustion tests (additional pilot tests for design and warranty purposes contract for large-scale burn operations in existing plants if appropriate)
- Additional core drilling and core analysis
- Oil shale crushing tests
- Spent ash leaching tests
- Geotechnical data base including soils analysis
- Environmental baseline data
Prefeasibility Study O Shae Fueled Power Generation
VMMMUldMOA
Steps Required to Develop an Oil Shale-to-Power Project
Create a development business plan - Schedule - Decision tree
Develop a work scope and budget for the development plan program including - Firming up designsspecificationscosts
- Developing business entity requirements - Continuing support studies
Carry out development plan program
Assemble all planning results in a report for discussion with financial institutions
Explore project finance opportunities
Finalize business arrangements
Implement prototype project
i Prefeasibility Study
Oil Shale Fueled Power Generation
VM1-11UJROLI
MARCH 15 JEA QUESTIONS (M S ARAFAH) ON PREFEASIBILITY
STUDY DRAFT REPORT
Rt
DIR EScBSULIVAN PHD OFJCEop~BUREAU FOR SCIENCE AND~TECHNOLOGYAGENCY - --FOR INTERNATIONAL DEVELOPMhINTSWASHINGON DC x20523---------4
4 -
-SUBJ E CT - -C O H~ E T 4N l
Dr Mr sullivan ------shy
c-rommnents We ~efr-preaereorPla -tobYou lete dted Jan 91989 regardn~i4po4t P ea e1 f i nd y ubel ow our -e ot r XcOrcerned Jordanian deipartments
- --A ar o~nnYu Y o turjlt~ lt K
4 C~mments
~1 N i gFIN I~fANDECONOMIC1COIMEN S -
It sidicaed that Beohtel and US AIDWash ingtonj~4- re ojy nen ing that E 2hould und ertake the n e tshyihaisAre ~our c leometprogram n order shye-t im~ ate d f n t v design and budget cost
4Al1so Lthe study ncal--ttsutnilndcaei~ A-1 A thas ~ l 1 be eeded idb~~~~~ rn o ei t n i la itheMWa~-~5s~ 4
hrPro hehgemetTh trOfT ses~fnr4 BOT)Vmanu- a n-mnf~cure 4 r~j or contra c4-or ivoIlveiintijn I 4 4investmnt ude smi ~w 2 Zha tev e r --~4~prce e ec r it v p4~ f JA gertiy geeated-at 4 JEA 3 a l b u y ~the same average~~ A
~jithia oncot in4 ordrtan ecpoemic asess thespePower generatjoon J ordan3 oi sha I eroic c inr~etJordan 4
2P ge i1- 1 Aj iit eu that OPin he atocontr~ct 4with owner4 ofext3ing (oconstriiction r(FB rml-t
qu i of S 11 t to test large tonnagen j es StaniUti n d ajIe -for se veralIQf 31 hi
evrEAPreferpilot qr the dP 1prt7n -that the4mPIt
andi to(7 he instalI 1e 2 310 A
_
JODN ELECTRICITYAUTHORIT LL
Dac
operated in Jordan i n or~der~~t ~n nuex~on mnining crushing and haidi igQhre~ and sash Maeia nd aSootoget enough olr ndaita needed for einolre
CEBbole~ -i s~
ccordance with Jordaian oil shale
large to~ bfig
1 3 le 1-2 Page 1-7 Cost Of Pwer~i It i S menti-oned that the conmecial oil hle~ lt~project (4 X1OOmw) 1is ninacompetative roqt~range-~while table 12 indicates thattcost of-pow Ais~mill
q kwiihcii r 1
average wih i ii -much higher ihantheshy-ost of ~Power gnrtofomJEA therimaPower s ta tions Please~ indicate on what basi o ~~ shave-~made your-statement
PK
14 Pae 2 Sction 4-0sIt 1nlkly that theChousing and off- -site infrastructur-ommnity fakilitieR) to be onsidered for both the demo and prototyp prjcs oeoverwe~4 hnk that their~c_6t is raterojects Mo
iwcv~- age -1 1 Mine O(perationIIt is indicate~d that mining cot eevdfoMine contractor~ are ficomiplee h
r and iyudi-t~con qidder contract mnn opio fr4 the min4 cmflt2ng are reIanddrepres~ent the real costs derived from Phspat miin contractors in
lestfor the eo rPooypuat in order tlt7
P I eadenote tha detthe new exchangerate ofthJraian~ Di~nner you may add 20j6 Kto the quoted
1 6 P Ias e consider the followin ecn hage_
171- The new exchange ra teof tUSD=54o0 fils1 72-W2 The new~ aerage tariff for selIn~electricityhas decrreased to 120 8 f ilIsicwh
17- Page 1-7 TbIe 1-2 W bev th tthe cap ita1 cot for the pwhokand forthe min n d ash hMnd1ing equipen
P B~2Anaor a -Tl 8156152 8176 1Q MYf -t -Now 520 t 1U
JDNEECRICIT AU-RA L14lLiL
2 ~are very high We suggest~ thta You rerconsie (- telowerus e~+d accuracy est a rangethan +30
Page4-22 Table 4-5weno0ti ced( that- PyroPowe ha ddeta(IiacCst fori the bo1ilerlocation and terha dutdetlease isxtr fo~ l C~ io~ s~ e~~ 1a~ a if and indicate theonldjusted ~percentagefor construction foin Jordan
19 Page-7 Table 11-2 -Yo aeue ihrinterest rate on Equity thatn on1DehI~laseinclude~ adetaied explanation of thisrr -tni kepin in miUndie JEA is1thaIt a non profit~ shyorgaiztion unik oher private UJSA utility~in ktation
~-~110- Regarding shy
the ra4ital Rt fthe project it is~requesed tobre k it intdo foreignMeanwhile cthe nd lorcal c-osfoeigptario i nt-re3t~shol becnierdo-h
rr n ontiondonnotopdbon the 9 cnieelocal portion~onth
1-1- 237~Pa
oningeny 9tooi s high~~ a lower 4value -should be~
4~ gt ~112- -Tbles t1-1 -8-8~ inclu~de t~he c~alculationscuultie nt enefits for of Th shyunttypes l i4s difeen geeatnmrer likely tocluae
-~ Q~ J7present vk1u for tenet tthe~benefits in feralterntives -t-oa s the
49
ehliyoi shale
Wea gree with you9 tha t th e percentage used ~ an for thenua~l 0 ~amp-M rahr CFBo ndsomewha~t highervrate be n ededma y for a C B l n Me n h l ~ a e r
indir e ta~ts the -estimatedma i variablec st i ddition t he fi-xed-9i 1 mislkih We --
thinktttiis too lowK -5
shy
1-14- e 4-29
opprza tion-o to The o i1s h1 costs-nc I deAbo 1h
Pa10 mman ormTSI62 a
IB I
JORD N EtECTICI1~ 4 E~)~Is-s
Date ib-_
~ ~riii~g~nd~o9~ru~hng h~tnlin cot~u~tv yo
i Dae Jnryit
1ts c 7 4-
i smiig iniand fh co I eY
susendi ca tI t icag th t1 ~an~approximate 15 ~pita L tYII I (-~a~ge or he owe bl ockj f aniitjes isof +the capthe)t~ial7cpi~lrharge Uoratelformny SI~Uj(uiity installa~tions~ whle page 6-1T9 talJshyit is mentioned that~ the Capital rate pe-r JEA isshyi5~PeaseJustify this~matter since~w o
i16- Pae 6-1 6
1 I4~t is mentioned that the costs of 4process Water are ~ 4 ~0 2$1 000 gallons
r~j~lt IHave~You considered additionalvalue ofbying waterfrom~ the Wa ters Aito i ~or ditoa cost~f o revrseoqoesplant if ground water is used
~~ I1 7- Table 6-1 Page 6-6 Please explain how did You come ou ihteoil~ shale miniing and proces~sing uit~Icost
ltII~I~ 8- Please note 1 t hatj the average JEA~productinr ot frmthermal I power stationsr (Istationbus-barCOSt)i sbewen 6 3-17 3 fils 4kwh You may use this~
l4~ 19-i For ~4 X 100~AMW Plat iti etindo pag e14-4 VolI 11 that4 at tota I of W42 14 epoye W II eemplo~yer] And on page 69yo1Iiti mentioned that a~ tot 1 f1 ~p yeI iNbe enp1oyed a
is~ high asrmetitexeds100personorthe ~41X100~MWh~~j nsatnpPrlae
I 1 The 4 following iftemns are a sumed to1 be excluded from theraPi ta 1 cot xoI
120-1 Perits I icen es 7
1_207~3 Imprt ~xe on s7pare par ts -and c(7orfmurab -ma~teria Is
04f4 4
~4 R j4 4
D4
~ ~ ~ AIf eS taxesq in acrac ihteJraand regulations should be considered aw
21- p1ea4s e indic ate Your Ju t f c io r us ga 6
44122- Table 977App 5Page4 9-1 4L IK Car1Yiniae that the hIRR of the 4 Otplantis rather unattractive (66)most
-( Cns1er4 ngthe logical base 4csek c pwhen cii 6OL
average sell~ing prc CkhampDEratio L801~2O~Aoreover4M the ne siellin prcwh o JEA ati theamptime~ Abeing os4ltp n~ot exceed 4 Ckwh~-However Ipage 1shy~ and 14 0 T indicate that ecnms for a commeri
S4A4scale joil 4 shale projc ~
appear Piomisig-nug o4Ywarrant continued dee fgfluht 4 feaibiit 4tudy wihil cost sevea~lili
do ar~sf Plas lear wether the ~x step jqs~$j~~lt 4
gtt 9o be considered arCcording4to jthe 4unattractiveresul to mentioned in IRR7 Table 97 gt4
a C4 44fET2 4 144-4444 P a g 1 T b6 l
htte~We ~ ~ ae~ rqieetfrteX ~ noie ~~ ~ 444 MW un t44 r te4l w w e o p r d i th e w t r n rre u f4m or4444~ the4444 54M4rto y e Pg~A~44EHiveL det ile an l A44
s o awa er c n um t a4r f rofsho in P6Io erT
e ch 2 50 M W aPln wa e d 41004 MW4 1 consumption_____________
ma4~2 k e u p houin~44 p A44 4444444 C O 4ltI4
a nd a sh et in etc 4 2 4 1 -24 P a g e4 2 - 1 A P P 5
4Yo 4_ j1 4 4~h444 N44 44
1gro nd tce t hir fthe w bern coqir mna t efora4e 4X10A M 444444 4 r i n to 4 4 4lo w w ehA 7 n 2 cinCie h rh4 n ttthh1eb -e 4 44t Of3 E4O
ea h n~ ffl 4 4Jl44 4 4444 4giv
6 ig re sofrat4 de in cl ar f w w at5 c hrw pe o
s h b 444 o t h e g nd L 44 h u i n C
r 4ne a4 t44 e L(704 2 4 p ae) 2 - o Au P dn 5ai 7~e r 44 I Y (1t 44a
ve7 rn e qu 1saharvthe y
and n~~~o speci~~~l4 p n l nh i n t x
r ~rA M e d r o t eu n 8 1 wTtl t t h
- c re e N I wo6
~ n n a i n a t d h l7 A PP6 gt
J
S2~3- Page 2-4 ~ ~ It ~is i
that oil eindicated the- sha le r our~ Cesin Jordan are 10 billion tons -The anulp e reere maiy exeed 50 4 billion tons ~
~ 24- 4Page~2 -l1 iujntr We beiv thtCBcmuto~ep i s high and~alSo
~~ ~ -2 ~~ Page 4-1~6 j - shy
Please~~ indicates your procedure to cool the omn ashand atwa icagd-eprtr
A Have you~ considered~ additional he~at exchanger topcool th ash and to imrve h cycleef ficiency
-~2~6 Page 4-16 It s~ indicated that ash from each silo i Amixed19 ~with~fabout 20 waterKb weight to minimize generation of dust~during trnprtto to mine and disposalHave you~ coniidered other 4lternativeto
~ ~eliminate dustiiig -and avoid use ofwat r uring it ransportationi such as~ using closed trucks or closed
of ~fans conUMnPo wihrlaintthe total plant auiir poe osupin 1~21- Table 5_-3 and I ~
Th~~ is- somneere c6ntradiction regardingplnneotpu~t in both am tables 21-~ Tabl~e 1-33
We noticed tha~t yourall9 cacacapac t fatro75 tion ae asdnWe thilt ~that 7capacityshyfacto is tobo high for- an oil shale fired plant duketo lack of existing simila~r ~plants handl~~~firing oil adshale ~K
216~ The study iniae thtawet~coigtower wi11~used Actually a b
dry cooling should be consideda5ini ~HTP S inZ atomnmz so water rnumption4the cycle~ efficiency willbe reducedHenre YO33~reconsider calculating the cyclefficiy
U~~~~~ codnt umconsidered ofhorizontal -aretypethe~ the vertical cian type can alsobeh considered
shy ~ ~ ~ I~~
2~2 Kconcrete shy
shjell stepl fltstack is onidereconcrete shell brick flue Rt c ~s beCaconsidered3V
2-19~- Deminiraized water~ tank3 capacity~ is -76 ui(meterThe recommnended tank cameter- ui tyi 00cbc
220Designconditions Pa~ge (4-74)te5 hat bow 3down percentage splusmn ~fomrpra til re i hou I be 3~)~
PoD Z 2 m a ad~ - e 5 1 2 iJS~ ~ p A f amp ~ ~ y1
4
JO R ECTICITY AUTHORTIT 4L
~ 4
Date~
t etats ttthe quantityof s i S ~1 000Tons ra Sthis tuntity 11- be transporited for severIy --to tu ofI pit a~te torg P KM ra~erm Spower plIatS about 12 midilidoni CUIA(- met ryea
h e ndd mp e he (d u p in i n L
area wil evric power plant6t Please zn1 a te~tiv s tudY for dumping th r~ a enoug
-from the power plantr~~h~
S 2- Please provide deald-ifrat ao etbaaiedrawing hwn TH11 R thaU and~pV ra~te takcing illto o 6it v- consumptionn _uig themrining equipment
alternate~ study 0o Jine operation for 1 shiftday Vand twoshifts day -lt
224- Conceptua~l pflR 1 for mi ing anusdtransportation of oil- shale a 0 dmj of hs f u r therV examinedh iV~sdpatI ho u1d be
orderj to poe~ehicalq and~eoomca1 fesblt of t his operation
SYour are requested te) study and consider all- above - iPoin s at your earliest in rder -to be peete y oiAnimain on March 29-301989 peetdb~o 4 n
S9incerly-You S
WDIRECTORGENERAL -
I~ CCMR WLINTON ~vs
5N
Pa D~t~IoAmmn -Jordtn -Tel 815615 20 Bl76 15 -19j A VINO- AFf TY
MARCH 21 RESPONSE TO JEA QUESTIONS
Bechtel Power Corporation Engineers - Constructors
Fifty Beale Street San Francisco California Mail Address P 0 Box 3965 San Franclco CA 94119
March 21 1989
Mr M S Arafah Director General Jordan Electricity Authority PO Box 2310 Amman Jordan
Subject Jordan Oil Shale Prefeasibility Study
Dear Mr Arafah
Your letter of 15 March 1989 with comments on the Oil Shale to Power Prefeasibility Study draft report has been referred to me for reply
The attached responses to each item in the reference letter follows the order submitted
Also attached are three revised pages for the draft report - Volume I
Page 6-1 Page 6-21 Page 6-23
Please copy these revised pages into the report previously sent to you
We plan to review this material with JEA during the March 2930 and April 1 meetings in Amman
rsuVertrul yours
W Linton Project Manager
WHLdc
Attachments Questionnaire Response Three revised pages
cc C J Aulisio R R Buta G D Gould T J Wilbanks
32389
Page 1
RESPONSE TO MARCH 15 1989 QUESTIONAIRE
OIL SHALE TO POWER PREFEASIBILITY STUDY
This study examines economic prospects in terms of a 1995-2000 timeframe
FIRANCIAL AND ECONOMIC COMMENTS
11 It is likely that a BOT deal can be structured at present JEA
generation costs for either 20 MW or 50 MW size units if GOJ is
willing to subsidize the incremental power generation cost
Furthermore these incremental costs can be recovered during the 25
year operation of a Commercial Scale Project
12 A 3rd Party Test was proposed as an alternate means to raising
$100+ for an independent JEA sponsored 20 MW Demonstration
program
13 71 millsKWH for Shale Power
VS
JEA 1987 costs
Purchased Power 17 filsKWH = 51 mills
Produced Power 1360 filsKWH = 41 mills
19952000 Costs - Expected to be 30 to 40 higher and in line
with the cost estimate presented in this study
It also is important to recognize that the busbar cost of power
generated by any new power source can not be compared directly
with the cost of existing older installed capacity because of the
lower capital cost component of the latter (See enclosed Figure
1-1 which demonstrates how total capital carrying costs decline as
the investment is paid off) Any new capacity whether coal oil
or oil shale will be an unreasonable disadvantage compared with
costs for existing older capacity
l
024
o2
0De return
E 016Total carrying charge
012 qu return
S -008
ety taxes and n rcw vshy000 X 0 5 10 15 20 25
Figure 1-1 Year-by-year Carrying Charge Components for 15-yearTax Recovery Period
1-7
30
32389
Page 2
14 Infrastructure Cost
Total People
OperatorFamilies Installed Cost
20 MW $10000000 185700 $54000Operator
50 MW 15000000 3241200 46000Operator
400 MW 45000000 10364000 43000Operator
Factored allowance for grass roots desert installation
including housing and community facilities was developed as
follows for the 50 MW case study
Infrastructure
50 MW
Family Housing 200 30K = $ 6 Million
Bachelor Housing 100 20K = 2 M
HospitalClinic (8 Beds) 11 M
SchoolMosque I1 M
Stores Services amp Recreation = 2 M
Facilities
Roads Electricity Water Sewage = 3 M
$15 Million
Infrastructure costs for the 20 MW and 400 MW cases was ratioed
from this breakdown
At this conceptual level costs are order-of-magnitude In a Phase
II program these infrastructure costs can be developed in detail
32389
Page 3
15 Contract Mining Alternatives
Page 4-11 Mine Operation
Based on Bechtels evaluation of the mine contractors price as found in Section 15 of the Mining Report it was concluded that
the mine contractors price does not include costs for such things
as developing the mine with a box-cut ramp haul roads
developing an area for the waste material maintaining the
haulroads constructing the mine services facilities diversion
ditches sedimentation ponds water well crushing the oil shale
pre-mixing the oil shale at the mine and other items associated
with operating a mine to support a power plant If it is proven
that the mine contractors price includes cost for the above
mentioned scope of work in additi-n to drill blast load and
haul then the contractors price can be used but in the meantime
the all inclusive cost developed by Bechtel should be used
Contract Mining appears to be attractive for the smaller size
plants but not for the larger commercial scale operation Some
third party must provide the necessary capital for trucks
loading mining machines etc under a contract arrangement
16 Reassessment due to Dinar value change needs further study and can
not be evaluated given present budget limitations If average
labor rate of $300hr still valid then little change involve with
study
If deemed necessary reexamination of project economics can be
done in Phase IIwhen funded
17 Costs in this study are based on recent similar Bechtel experience
on Mount Poso project and on Montana I project The Mount Poso
project is a 50 MW unit firing coal in a Pyropower boiler The
Montana I project is a 35 MW unit firing coal in a Keeler Dorr
Oliver FBC boiler utilizing dry cooling
32389
Page 4
18 The Pyropower quote of $186000000 to futnish and erect the steam
generator stack and baghouse has been adjusted to include
engineering construction indirect cost etc to be consistant
with the rest of the costs shown in Table 65 p 6-10 No
further adjustment for location was made
19 Equity funding has the lowest priority of payoff in case of a
liquidation and carries greater risk Hence a higher rate of
return is needed to attract these funds Debt funding is a first
mortgage and has first priority for payoff in case of liquidation
and carries less risk Hence it requires lower rate of return
than equity funding
The risk taking equity owner will ask for greater interest rate
to make funds available The only way to minimize this expense is
to find a loaning agency willing to provide 90 or perhaps 95 of
the investment cost It is likely that banks will require some
minimum equity participation
This Prefeasibility Study was not based on a non-profit utility
operation
Even though JEA is a non-profit organization its service
contributors are profit making groups It is visualized that the
Jordan Oil Shale Co (JOSCO) will be a stand alone business
enterprise servicing JEA under long term contract To secure
funding for the proposed project JOSCO will need attractive
enough contract terms to attract both equity and debt capital
110 Additional work is needed to develop the requested information
This work can be preformed as part of the Phase II program
111 Bechtel includes contingency in all of its estimates to cover
error emissions and unforeseen items within the defined scope of
the project The level of contingency is dependent upon the
amount of scope definition For a prefeasible study such as this
15 contingency is lower than normal
32389
Page 5
112 Tables 89 through 816 include a present value calculation to
establish the relative benefit for a shale project vs coal and
oil
113 The variable maintenance cost of 1 millsKWH has been adjusted for CFB plants with an additional $200000 per year or 06 millsKWH
This yields the following
Variable Maintenance - 10 millsKWH
CFB Adjustment - 06
Fixed Maintenance Cost - 40
Total Cost 56 MillsKWH
114 Page 4-29
The royalty costs are included in the weighted average oil shale
costs for the 50 megawatt plant
Page 4-8
Shale fuel costs include return on equity and royalty These are
two separate cost items Royalty is the last item mentioned in
the sentence and it therefore reads as royalty and not return on
royalty
Page 4-31 gives rates used by Bechtel based on our calculations
using the referenced procedures
DebtEquity Capital Charge Rate
5050 153
8020 139
Table 69 displays the calculation of the 153 capital charge
rate (Line 7 of Table 69 is not used in the calculation and
should be deleted)
32389
Page 6
116 No water purchase charge from the Water Authority was added to the
operating expense based on the statement that no resource costs
will be charged
$020 per 1000 gallons is rule of thumb for USA installations in
absence of client data
Boiler make up water (p4-17) is treated in a demineralizer
train If deemed necessary comparison with reverse osmosis
process can be performed in Phase II
Water requirements were estimated to be
Cubic Metres Per Year
20 MW 50 MW 400 MW
Mine amp Shale Processing 455000 761000 773000
Power Block 3000 6000 42000
Infrastructure 80000 140000 448000
Total 538000 907000 1263000
117 Annual average operating costs shown on Table 6-1 are in error
Financing Option 5050 8020
Cost Shown 56606 48945
Corrected Cost 60396 53236
Average mining and shale processing costs are developed year by
year in the Mining Report Appendix 5 Table 12-10
32389
Page 7
118 We would be interested in receiving the breakdown of these current
power cost figures (ie capital charges fuel cost number of
operators etc) Further economic analysis employing these
figures can be developed in Phase II
119 Manpower requirements for the three case studies were estimated as
fol lows
Mining amp Shale Processing
Power Block
Operations
Maintenance
Management
20 MW 50 MW 400 MW
75 163 396
54 78 175
46 73 455
10 10 10
185 324 1036
Page 14-4 of the Mine Report is for mine and shale processing
only It should be noted that most of these manpower requirements
involved new jobs for Jordanian people
120 At the April 1988 Amman Meeting it was agreed that the following
costs would be omitted
o Permits and Licenses
o Local Taxes
o Import Taxes
If necessary such costs can be developed and added into a revised
economic analysis as part of the Phase II program
121 6 average inflation rate is the figure recommended by Bechtel
based on USA conditions for use in long term economic analyses of
new power ventures
32389
Page 8
122 This matter is referred to ORNL who prepared a rate of return
analysis
Bechtels conclusion is based on computed busbar costscumulative
benefits compared to alternate fuels in the timeframe 1995 to 2000
Relative Busbar Power Cost Net 25 Year
Mills per KWH Benefits - Million US$
Sultani Oil Shale 71-83 Base Cost
Imported Coal
$50tonne 68-88 778
$70tonne 78-107 2531
Imported Oil
$17Bbl 56-76 (18) $24Bbl 61-96 1810
The above results are based on a capacity factor of 75 which is
considered to be a reasonable target for a new plant over its 25 year
life The average selling price of 6 cents per KWH cited in the
questionnaire is based on existing plant costs which may not include
all cost elements of new capacity evaluated in this study
32389
Page 9
TECHNICAL COMMENTS
21 See answer to Item 116
Total power plant raw wate consumption rates and annual
consumptions including the water requirements for wetting ash at the truck loading p int within the power plant are given in Tables 43 and 44 for 50 MW unit and Tables 53 and 54 for 20 MW unit
The raw water requirements for 4x0 MW plant were factored
excepting the mine where a revised mine pldn is employed to reduce water request The quantities shown on these tables exclude raw
water requirements for housing complex mine and ash wetting if
required at the ash disposal site
Total power plant requirements shown in the above referred tables
are
50 MW 20 MW
Rate gpm 207 102 (See Drawing M004)
Annual Use
Gallons 1400000 675000
Cooling tower blowndown supplemented with raw water is used for
wetting ash at the truck loading point within the power plant Raw water quantities attributable for ash wetting at the power
truck loading point are
50 MW 20 MW
Rate gpm 75 325
Annual Use
Gallons 500000 215000
These quantities are included in the quantities shown in
the above referred tables
32389
Page 10
22 We recognize the POTENTIAL for leaching toxic compounds from the
spent ash However this matter is not yet defined well enough to
recommend specific action steps The Prefeasibility Study page
7-12 recommends creation of a ground water dispersion model to
determine whether more specific contaminated water mitigation
plans are needed It is anticipated that the leachate rate will
be low and that aquifer dispersion will keep problem compounds
bel3w health standards thresholds
23 Noted
We have not received up to date resource study material which
defines 50 billion tons resource base Please furnish
The resource base at Sultani alone is adequate to support two 400
MW power projects capacity subject water availability The
2-million cubic metre per year water allowance for oilshale will
limit development to about 600 MW
24 Selection of a combustion temperature is a balance between carbon
combustion efficiency and heat loss due carbonate decomposition
For purposes of the Prefeasibility Study we have opted for high
combustion efficiency At lower efficiency larger shale
mineprocessing plants will be needed
25 Bottom ash is cooled by water exchange before discharge
Cooling water is supplied to the ash screw coolers as specified by
Pyropower See Drawing MOO5 2140 gpm flow for 50 MW and 860 gpm
flow for 20 MW Heat removed by the cooling water from the ash
screw coolers is dissipated to atmosphere via a wet cooling
tower Pyropower should indicate the temperature of the ash
discharged to be 5OOF
32389
Page 11
Initially we had considered using a heat exchanger to cool the ash
and improve the cycle efficiency Considering low cost of fuel
the additional capital costs and the system complexities it was
decided not to employ such heat recovery systems for this project
26 The suggested alternates were looked at briefly and the potential
for wind blown air pollution from the ash disposal areas are too
great to warrant dry disposal unless GO(] and World Bank are
willing to accept such a potential problem Wetting the ash is
tne only practical solution Hopefully some cementation will
occur helping to reduce future leaching potential
27 JEA requirements are noted This is a conceptual study not a
final design Optimal design analysis can be performed during
Phase II
2829
JEA requirements are noted and can be incorporated into the Phase
II design
210 The transformer size is adequate for base load operation A
higher capacity can be considered at the final design stage if the
Client prefers
211 From our experience it does not appear to be economical to
provide additional dry cooling towers to take care of maximum
ambient temperatures which may prevail only for a short period of
time in a year To study this an annual dry bulb temperature
duration curve is required Also adding additional dry cooling
towers will change the plant performance It should also be noted
that the dry cooling towers are very expensive and the size should
be selected carefly considering performance and cost and not on the basis of maximum ambient temperatures This can be studied
during Phase II
32389
Page 12
212 The plant gross output varies with condenser pressure
Condenser
Pressure Design 55 in HgA Annual Ave 35 in HgA
Unit Size MW 20 50 4xlO0 20 50 4xlO0
Gross Output MW 234 593 496 2415 607 TBD
Net Output MW 1975 501 400 205 515 TBD
To be developed in Phase II
Output for 4x100 MW is estimated by others
213 The fan power consumption of the CFB boiler is about 30 to 35 of
the total auxiliary power The fan power consumption of the dry
cooling tower is about 20 to 25 of the total auxiliary power
214 Table 1-1 does not include plant net output Therefore do not
understand the comment
215 Commercial operating experience with coal fueled CFBC units in LISA
and Europe has been uniformly good showing high on stream
availability in early years (See Table 2-6 which reports on
Pyropower experience)
We expect operations with high ash content fuel like oilshale will
have unique scale up problems such as
o Solid handling in and out
o Internal solids circulation
o Erosioncorrosion steam generator intervals
o Heat recovery from bottom ash
Consequently we are recommending these items be worked out in a
single 50 MW prototype
32389
Page 13
216 Maximum dry cooling is used in this study A small wet cooling
tower is used on circulating service water system
217 Horizontal condensate pump is adequate with dry cooling tower and it is cheaper Vertical condensate pumps with cans can be
considered in the final design if required
218 A concrete shell brick lined flue stack will be larger in diameter and costs more than a steel lined stack Brick lined stack can be
considered in the final design
219 Demineralized water tank capacity for 50 MW is 76 cu meters or 20000 gallons not 1000 cu meters For 20 MW plant it is 38 cu
meters or 10000 gallons
220 It is US practice to use an average continuous blowdown rate of
1 and maximum biowdown rate of 3 for this type of plants
221 This can be studied during Phase II
222 Same as 221
223 Same as 221
224 The recommended action plan calls for continuing support studies covering the referenced items Additional effort is needed to
further define these matters and confirm the conceptual plan
The next step is to develop an outline for a project plan including
o Work Scope
o Schedule
o Budget
accommodate the increase in the number of employees and
equipment Truck bays to accommodate the 136 tonne trucks
will be added The truck bays used for the 77 tonne
trucks will be used for the maintenance of other
equipment The warehouse change house training room
offices and cafeteria will be expanded accordingly
6025 Mining and Processing Economics
Details of the oil shale mining and processing plant
economics for the 400 MW plant are included in the Mining
Report (Appendix 5) These details are of the same
magnitude as prepared for the 20 MW and 50 MW plants
The summary of the cash flow analysis for the mine and
shale processing plant is presented in Table 6-1
Table 6-1
SUMMARY OF 400 MW PLANT OIL SHALE MINING AND PROCESSING COSTS
5050 Debt-Equity 8020 Debt-Equity
US $1000 US $1000
Capital Cost
Mine Development 30915 30915
Mine Equipment 66012 66012
Process Plant Facilities 50889 50889
Spare Parts 5000 5000
Working Capital 10000 10000
Capi tal ized Interest
During Construction 24423 39075
TOTAL 187239 201891
Operating Costs and Other Costs
Annual Cost 60386 53236
Product Mined and Processed
Annual Tonnes x 1000 7783 7783
Unit Cost
US $Tonne (weighted average)
US $l06Btu (weighted average) 776
156
684
138
Year 12 costs taken as 25 year average
6-6
-Au
Table 610 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
- FCC plant sizes equivalent to proposed power application
Prefeasibility Study Oil Shale Fueled Power Generation
VOO94GEampJRI26
i
PYROFLOW UNITS IN THE US
COLORADOUTE IOYA STATE UNIV UNIV OFNUCLA CO NORTHERNAMES IA BF GOODRICH110 1o0MW(a) 2x170000 Ibhr HENRYILCEDAR FALLS IA 120000 Ibhr GENERALGULF OILu EiN P MOTORSSbtUpStart-UIL 1987 O A 1I N000 TC
NORT10 PONTIACH B MIRANCHWV00000 lbhr
CORN PRODUCTSSM NORTH-CAROLINA STOCKTOD CA
400000 lbbhl t
RUMF RD ME
CEMENT CO CALIF PORTLAND-COLTON CA
190000 Iblhr Start-Up 1985 TRUMTFTWN NYU
3I75ERTOWN N
etar t-Up loss ACE COGENERATIONCABI
TRONA CA Oper t~on l -Start-UP 1990 ~ rt upz 091Start-up loss Start-up PNeLAI 1991
MTKESFICOENERATIO-N1
BASFIELDp Start-uStar-Up WESTCA9 199otgoUp 1 MAHONEV PA|00000 Ibhr A Oz 2X365000 Ibhr
SETtr-Ups 188B CHAT TANOOGA TN
G ULF OIL EXPLORATION 8ta-rt-u) 1085BAKERSFIELD NORTH BRANCHCA SPRING GROVE PANORTH BRANCH WV 400000 IbhtOperational 19835 5 0 0 I b h 9 0 0 0 Iblh r- tart-Upi 1991 S t r - U p s l e s s
SOUTHEAST PAPER MFG CO UNIVOF NORTH CAROLINArDUBLIN GA UHAPEL HILL NO400000 IbhrStart-Ups logo Start-Ups2X250O000 1loseIbhr B
- Withdrawing ash from combustor - Withdrawing fly ash
a Internal solids circulation of the steam generator
m Erosioncorrosion of steam generatorinternals
Heat recovery from bottom ash
U Operation with low calorific-value fuel
Prefeasblity Study O Shari Fueled Power Generation
VOO7AI 27
Impact of Scale-Up
Project Size
20 MW
50 MW
100 MW
50 MW boiler in 100 MW plant
Potential Risk
Design Scale-upOperation of to 100 MW Initial Plant Plant
Low Significant
Modest Modest
High Low for duplicate units
Modest Low for duplicate units
Prefeasibility Study Oil Shaje Fueled Power Generation
VOO71-4GEAL4n2
i
Conclusions
Defined risk of CFBC boiler is acceptable
U Operating experience with commercial CFBC boilers built and under construction will strengthen confidencelevel and minimize risk for a plant built in 1995
SPrefeasibility Study Oil Shale Fueled Power Generation
V007GHAAE29
ENVIRONMENTAL ASSESSMENT
a Mine and shale processing
- Fugitive dust emissions
- Noise levels
- Leachability of disposal piles
Power plant
- Fugitive dust emissions
- Gaseous emissions
- Noise levels
- Water effluents
U Conclusions
Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel
Prefeasibility Study Oil Shale Fueled Power Generalon
- Coaloil prices will be at least 15 greater after 1995
- Discovery of indigenous conventional fuel resources is inadequate for power plant purposes
Prefeasibility Study
Oil Shale Fueled Power Generation
VOO) IDWFO
Feasibility(Contd)
N Suitable financing will be available
- For $200 million 50 MW prototypeproject
- For $1000 million 400 MW commercial project
Government of Jordan will make basic commitments
- Long-term power purchase agreement
- Long-term access to Sultani shale deposit
Adequate water and manpower resources
- Attractive tax incentives
Prefeasibility Study
Oil Shale Fueled Power Generaion
VO bull1DUJJRO 6
Timeliness
U Timely development of Jordan oil shale needs prompt action to create - Additional definitive information
- Suitable business plan
Prefeasibility Study
Oil Shale Fueled Power Generation
VooI DUJo 7
i
Expansion Conditions
U Continued expansion of powergeneration from oil shale in Jordan depends on water availability
Prospects for power export or importand domestic load growth will affect size of the needed shale-to-power program
Prefeasibility Sudy
Oil Shale Fueled Power Generation
yOWl lVuJO
Environmental Impacts
N Environmental impacts of shale development will be minimal
Prefeasibility Study Oi Shale Fueled Power Generation
i
Development Advantages
Will create significant new jobopportunities in Jordan
Will avoidreduce foreign exchangelosses for expanding alternate fuel imports
Prefeasibility Study
Oil Shale Fueled Power Generation
VOOIIULL tO
Recommended Action Plan
N Basic recommendation
N Conceptual development schedule
U Project development plan
Key plan elements
N Funding requirements
Prefeasibility Study Oil Shale Fueled Power Generation
VOO4II )U OII
i
Basic Recommendation
N Expand efforts to develop an oil shaleshyfueled power generation program at the Sultani deposit
- Conduct required supporting studies
- Define facilities costs and business plans
- Obtain project funding
Prefeasibility Study
Oil Shale Fueled Power Generation
VON I II)ILL 12
C
Conceptual DevelopmentSchedule
1989-1990
- Conduct supporting studies - Define costsbusiness plans for 50
MW prototype and 400 MW commercial projects
- Develop project financing
N 1990-1993 - Build and operate the prototype project
N 1994-1996 - Expand the 50 MW prototype to 100 MW scale
U 1996-2000 - Expand the project to 400 MW scale
N 2000-2005 - Build a second 400 MW commercial project if needed
i 1 Prefeasiblity Study
dOil Shale Fueled Power Generation
VW IMLITO 13
Conceptual Development Plan
Months
1 Project development plan - Define project
costs1busness plans
-24 -12 0 12 24 36 48 60 72 84 96 108 120
2 Secure funding
3 Build and operate 50 MW prototype
Dergn and procurement
Mine development
Plant construction
Startup and testing
Operations
L- -
4 Expand prototype to 100 MW
Design and procurement
bullConstruction
Startup
5 Expand project to 400 MW
2nd 100 MW unit
3rd100 MW unit
i 44
4th 100 MW unit -
O Project dacision point
i Prefeasib~ity Study Oil Shale Fueled Power Generation
17958562aJocdanV 3-14-89 rsO
18
Phase I - ProjectDevelopment Plan
n Program development
Seminar workshop on prefeasibilitystudy Oate project development plan woek scope schedule arid budget
U Carry out project planning program
- Conduct continuing support studies - Test Sultani shale in existing FBC
- Firm up designs and specifications
- Update costs and economic analysis
- Develop business plans and requirements
Explore project funding alternatives
i Prefeasibility Study
Oil Shale Fueled Power Generation
VO MItUOR 14 -0
Key Plan Elements
N Project feasibility analysis
- Firm up designs and equipmentspecifications for all facilities
- Update cost estimates based on preliminary designs and specifications
Explore arrangements for contract mining and mine development
Update forecasts for demand growthand for retirements of older generating capacity
- Create updated economic analysis
Preleasibility StudyO1 Shae Fueled Power Generation
VOO1IOLWRI
Key Plan Elements (Contd)
Business entity requirement
- Explore optionsconditions for a new company to managebuildoperate the project
- Explore optionsconditions for obtaining a concession agreement for Sultani development
Explore optionsconditions for water rights commitment
Prefeasibility Study Oil Shale Fueled Power Generation
VMIOIA)lj 16S
i
Key Plan Elements (Contd)
U Continuing supporting studies
- Combustion tests (additional pilot tests for design and warranty purposes contract for large-scale burn operations in existing plants if appropriate)
- Additional core drilling and core analysis
- Oil shale crushing tests
- Spent ash leaching tests
- Geotechnical data base including soils analysis
- Environmental baseline data
Prefeasibility Study O Shae Fueled Power Generation
VMMMUldMOA
Steps Required to Develop an Oil Shale-to-Power Project
Create a development business plan - Schedule - Decision tree
Develop a work scope and budget for the development plan program including - Firming up designsspecificationscosts
- Developing business entity requirements - Continuing support studies
Carry out development plan program
Assemble all planning results in a report for discussion with financial institutions
Explore project finance opportunities
Finalize business arrangements
Implement prototype project
i Prefeasibility Study
Oil Shale Fueled Power Generation
VM1-11UJROLI
MARCH 15 JEA QUESTIONS (M S ARAFAH) ON PREFEASIBILITY
STUDY DRAFT REPORT
Rt
DIR EScBSULIVAN PHD OFJCEop~BUREAU FOR SCIENCE AND~TECHNOLOGYAGENCY - --FOR INTERNATIONAL DEVELOPMhINTSWASHINGON DC x20523---------4
4 -
-SUBJ E CT - -C O H~ E T 4N l
Dr Mr sullivan ------shy
c-rommnents We ~efr-preaereorPla -tobYou lete dted Jan 91989 regardn~i4po4t P ea e1 f i nd y ubel ow our -e ot r XcOrcerned Jordanian deipartments
- --A ar o~nnYu Y o turjlt~ lt K
4 C~mments
~1 N i gFIN I~fANDECONOMIC1COIMEN S -
It sidicaed that Beohtel and US AIDWash ingtonj~4- re ojy nen ing that E 2hould und ertake the n e tshyihaisAre ~our c leometprogram n order shye-t im~ ate d f n t v design and budget cost
4Al1so Lthe study ncal--ttsutnilndcaei~ A-1 A thas ~ l 1 be eeded idb~~~~~ rn o ei t n i la itheMWa~-~5s~ 4
hrPro hehgemetTh trOfT ses~fnr4 BOT)Vmanu- a n-mnf~cure 4 r~j or contra c4-or ivoIlveiintijn I 4 4investmnt ude smi ~w 2 Zha tev e r --~4~prce e ec r it v p4~ f JA gertiy geeated-at 4 JEA 3 a l b u y ~the same average~~ A
~jithia oncot in4 ordrtan ecpoemic asess thespePower generatjoon J ordan3 oi sha I eroic c inr~etJordan 4
2P ge i1- 1 Aj iit eu that OPin he atocontr~ct 4with owner4 ofext3ing (oconstriiction r(FB rml-t
qu i of S 11 t to test large tonnagen j es StaniUti n d ajIe -for se veralIQf 31 hi
evrEAPreferpilot qr the dP 1prt7n -that the4mPIt
andi to(7 he instalI 1e 2 310 A
_
JODN ELECTRICITYAUTHORIT LL
Dac
operated in Jordan i n or~der~~t ~n nuex~on mnining crushing and haidi igQhre~ and sash Maeia nd aSootoget enough olr ndaita needed for einolre
CEBbole~ -i s~
ccordance with Jordaian oil shale
large to~ bfig
1 3 le 1-2 Page 1-7 Cost Of Pwer~i It i S menti-oned that the conmecial oil hle~ lt~project (4 X1OOmw) 1is ninacompetative roqt~range-~while table 12 indicates thattcost of-pow Ais~mill
q kwiihcii r 1
average wih i ii -much higher ihantheshy-ost of ~Power gnrtofomJEA therimaPower s ta tions Please~ indicate on what basi o ~~ shave-~made your-statement
PK
14 Pae 2 Sction 4-0sIt 1nlkly that theChousing and off- -site infrastructur-ommnity fakilitieR) to be onsidered for both the demo and prototyp prjcs oeoverwe~4 hnk that their~c_6t is raterojects Mo
iwcv~- age -1 1 Mine O(perationIIt is indicate~d that mining cot eevdfoMine contractor~ are ficomiplee h
r and iyudi-t~con qidder contract mnn opio fr4 the min4 cmflt2ng are reIanddrepres~ent the real costs derived from Phspat miin contractors in
lestfor the eo rPooypuat in order tlt7
P I eadenote tha detthe new exchangerate ofthJraian~ Di~nner you may add 20j6 Kto the quoted
1 6 P Ias e consider the followin ecn hage_
171- The new exchange ra teof tUSD=54o0 fils1 72-W2 The new~ aerage tariff for selIn~electricityhas decrreased to 120 8 f ilIsicwh
17- Page 1-7 TbIe 1-2 W bev th tthe cap ita1 cot for the pwhokand forthe min n d ash hMnd1ing equipen
P B~2Anaor a -Tl 8156152 8176 1Q MYf -t -Now 520 t 1U
JDNEECRICIT AU-RA L14lLiL
2 ~are very high We suggest~ thta You rerconsie (- telowerus e~+d accuracy est a rangethan +30
Page4-22 Table 4-5weno0ti ced( that- PyroPowe ha ddeta(IiacCst fori the bo1ilerlocation and terha dutdetlease isxtr fo~ l C~ io~ s~ e~~ 1a~ a if and indicate theonldjusted ~percentagefor construction foin Jordan
19 Page-7 Table 11-2 -Yo aeue ihrinterest rate on Equity thatn on1DehI~laseinclude~ adetaied explanation of thisrr -tni kepin in miUndie JEA is1thaIt a non profit~ shyorgaiztion unik oher private UJSA utility~in ktation
~-~110- Regarding shy
the ra4ital Rt fthe project it is~requesed tobre k it intdo foreignMeanwhile cthe nd lorcal c-osfoeigptario i nt-re3t~shol becnierdo-h
rr n ontiondonnotopdbon the 9 cnieelocal portion~onth
1-1- 237~Pa
oningeny 9tooi s high~~ a lower 4value -should be~
4~ gt ~112- -Tbles t1-1 -8-8~ inclu~de t~he c~alculationscuultie nt enefits for of Th shyunttypes l i4s difeen geeatnmrer likely tocluae
-~ Q~ J7present vk1u for tenet tthe~benefits in feralterntives -t-oa s the
49
ehliyoi shale
Wea gree with you9 tha t th e percentage used ~ an for thenua~l 0 ~amp-M rahr CFBo ndsomewha~t highervrate be n ededma y for a C B l n Me n h l ~ a e r
indir e ta~ts the -estimatedma i variablec st i ddition t he fi-xed-9i 1 mislkih We --
thinktttiis too lowK -5
shy
1-14- e 4-29
opprza tion-o to The o i1s h1 costs-nc I deAbo 1h
Pa10 mman ormTSI62 a
IB I
JORD N EtECTICI1~ 4 E~)~Is-s
Date ib-_
~ ~riii~g~nd~o9~ru~hng h~tnlin cot~u~tv yo
i Dae Jnryit
1ts c 7 4-
i smiig iniand fh co I eY
susendi ca tI t icag th t1 ~an~approximate 15 ~pita L tYII I (-~a~ge or he owe bl ockj f aniitjes isof +the capthe)t~ial7cpi~lrharge Uoratelformny SI~Uj(uiity installa~tions~ whle page 6-1T9 talJshyit is mentioned that~ the Capital rate pe-r JEA isshyi5~PeaseJustify this~matter since~w o
i16- Pae 6-1 6
1 I4~t is mentioned that the costs of 4process Water are ~ 4 ~0 2$1 000 gallons
r~j~lt IHave~You considered additionalvalue ofbying waterfrom~ the Wa ters Aito i ~or ditoa cost~f o revrseoqoesplant if ground water is used
~~ I1 7- Table 6-1 Page 6-6 Please explain how did You come ou ihteoil~ shale miniing and proces~sing uit~Icost
ltII~I~ 8- Please note 1 t hatj the average JEA~productinr ot frmthermal I power stationsr (Istationbus-barCOSt)i sbewen 6 3-17 3 fils 4kwh You may use this~
l4~ 19-i For ~4 X 100~AMW Plat iti etindo pag e14-4 VolI 11 that4 at tota I of W42 14 epoye W II eemplo~yer] And on page 69yo1Iiti mentioned that a~ tot 1 f1 ~p yeI iNbe enp1oyed a
is~ high asrmetitexeds100personorthe ~41X100~MWh~~j nsatnpPrlae
I 1 The 4 following iftemns are a sumed to1 be excluded from theraPi ta 1 cot xoI
120-1 Perits I icen es 7
1_207~3 Imprt ~xe on s7pare par ts -and c(7orfmurab -ma~teria Is
04f4 4
~4 R j4 4
D4
~ ~ ~ AIf eS taxesq in acrac ihteJraand regulations should be considered aw
21- p1ea4s e indic ate Your Ju t f c io r us ga 6
44122- Table 977App 5Page4 9-1 4L IK Car1Yiniae that the hIRR of the 4 Otplantis rather unattractive (66)most
-( Cns1er4 ngthe logical base 4csek c pwhen cii 6OL
average sell~ing prc CkhampDEratio L801~2O~Aoreover4M the ne siellin prcwh o JEA ati theamptime~ Abeing os4ltp n~ot exceed 4 Ckwh~-However Ipage 1shy~ and 14 0 T indicate that ecnms for a commeri
S4A4scale joil 4 shale projc ~
appear Piomisig-nug o4Ywarrant continued dee fgfluht 4 feaibiit 4tudy wihil cost sevea~lili
do ar~sf Plas lear wether the ~x step jqs~$j~~lt 4
gtt 9o be considered arCcording4to jthe 4unattractiveresul to mentioned in IRR7 Table 97 gt4
a C4 44fET2 4 144-4444 P a g 1 T b6 l
htte~We ~ ~ ae~ rqieetfrteX ~ noie ~~ ~ 444 MW un t44 r te4l w w e o p r d i th e w t r n rre u f4m or4444~ the4444 54M4rto y e Pg~A~44EHiveL det ile an l A44
s o awa er c n um t a4r f rofsho in P6Io erT
e ch 2 50 M W aPln wa e d 41004 MW4 1 consumption_____________
ma4~2 k e u p houin~44 p A44 4444444 C O 4ltI4
a nd a sh et in etc 4 2 4 1 -24 P a g e4 2 - 1 A P P 5
4Yo 4_ j1 4 4~h444 N44 44
1gro nd tce t hir fthe w bern coqir mna t efora4e 4X10A M 444444 4 r i n to 4 4 4lo w w ehA 7 n 2 cinCie h rh4 n ttthh1eb -e 4 44t Of3 E4O
ea h n~ ffl 4 4Jl44 4 4444 4giv
6 ig re sofrat4 de in cl ar f w w at5 c hrw pe o
s h b 444 o t h e g nd L 44 h u i n C
r 4ne a4 t44 e L(704 2 4 p ae) 2 - o Au P dn 5ai 7~e r 44 I Y (1t 44a
ve7 rn e qu 1saharvthe y
and n~~~o speci~~~l4 p n l nh i n t x
r ~rA M e d r o t eu n 8 1 wTtl t t h
- c re e N I wo6
~ n n a i n a t d h l7 A PP6 gt
J
S2~3- Page 2-4 ~ ~ It ~is i
that oil eindicated the- sha le r our~ Cesin Jordan are 10 billion tons -The anulp e reere maiy exeed 50 4 billion tons ~
~ 24- 4Page~2 -l1 iujntr We beiv thtCBcmuto~ep i s high and~alSo
~~ ~ -2 ~~ Page 4-1~6 j - shy
Please~~ indicates your procedure to cool the omn ashand atwa icagd-eprtr
A Have you~ considered~ additional he~at exchanger topcool th ash and to imrve h cycleef ficiency
-~2~6 Page 4-16 It s~ indicated that ash from each silo i Amixed19 ~with~fabout 20 waterKb weight to minimize generation of dust~during trnprtto to mine and disposalHave you~ coniidered other 4lternativeto
~ ~eliminate dustiiig -and avoid use ofwat r uring it ransportationi such as~ using closed trucks or closed
of ~fans conUMnPo wihrlaintthe total plant auiir poe osupin 1~21- Table 5_-3 and I ~
Th~~ is- somneere c6ntradiction regardingplnneotpu~t in both am tables 21-~ Tabl~e 1-33
We noticed tha~t yourall9 cacacapac t fatro75 tion ae asdnWe thilt ~that 7capacityshyfacto is tobo high for- an oil shale fired plant duketo lack of existing simila~r ~plants handl~~~firing oil adshale ~K
216~ The study iniae thtawet~coigtower wi11~used Actually a b
dry cooling should be consideda5ini ~HTP S inZ atomnmz so water rnumption4the cycle~ efficiency willbe reducedHenre YO33~reconsider calculating the cyclefficiy
U~~~~~ codnt umconsidered ofhorizontal -aretypethe~ the vertical cian type can alsobeh considered
shy ~ ~ ~ I~~
2~2 Kconcrete shy
shjell stepl fltstack is onidereconcrete shell brick flue Rt c ~s beCaconsidered3V
2-19~- Deminiraized water~ tank3 capacity~ is -76 ui(meterThe recommnended tank cameter- ui tyi 00cbc
220Designconditions Pa~ge (4-74)te5 hat bow 3down percentage splusmn ~fomrpra til re i hou I be 3~)~
PoD Z 2 m a ad~ - e 5 1 2 iJS~ ~ p A f amp ~ ~ y1
4
JO R ECTICITY AUTHORTIT 4L
~ 4
Date~
t etats ttthe quantityof s i S ~1 000Tons ra Sthis tuntity 11- be transporited for severIy --to tu ofI pit a~te torg P KM ra~erm Spower plIatS about 12 midilidoni CUIA(- met ryea
h e ndd mp e he (d u p in i n L
area wil evric power plant6t Please zn1 a te~tiv s tudY for dumping th r~ a enoug
-from the power plantr~~h~
S 2- Please provide deald-ifrat ao etbaaiedrawing hwn TH11 R thaU and~pV ra~te takcing illto o 6it v- consumptionn _uig themrining equipment
alternate~ study 0o Jine operation for 1 shiftday Vand twoshifts day -lt
224- Conceptua~l pflR 1 for mi ing anusdtransportation of oil- shale a 0 dmj of hs f u r therV examinedh iV~sdpatI ho u1d be
orderj to poe~ehicalq and~eoomca1 fesblt of t his operation
SYour are requested te) study and consider all- above - iPoin s at your earliest in rder -to be peete y oiAnimain on March 29-301989 peetdb~o 4 n
S9incerly-You S
WDIRECTORGENERAL -
I~ CCMR WLINTON ~vs
5N
Pa D~t~IoAmmn -Jordtn -Tel 815615 20 Bl76 15 -19j A VINO- AFf TY
MARCH 21 RESPONSE TO JEA QUESTIONS
Bechtel Power Corporation Engineers - Constructors
Fifty Beale Street San Francisco California Mail Address P 0 Box 3965 San Franclco CA 94119
March 21 1989
Mr M S Arafah Director General Jordan Electricity Authority PO Box 2310 Amman Jordan
Subject Jordan Oil Shale Prefeasibility Study
Dear Mr Arafah
Your letter of 15 March 1989 with comments on the Oil Shale to Power Prefeasibility Study draft report has been referred to me for reply
The attached responses to each item in the reference letter follows the order submitted
Also attached are three revised pages for the draft report - Volume I
Page 6-1 Page 6-21 Page 6-23
Please copy these revised pages into the report previously sent to you
We plan to review this material with JEA during the March 2930 and April 1 meetings in Amman
rsuVertrul yours
W Linton Project Manager
WHLdc
Attachments Questionnaire Response Three revised pages
cc C J Aulisio R R Buta G D Gould T J Wilbanks
32389
Page 1
RESPONSE TO MARCH 15 1989 QUESTIONAIRE
OIL SHALE TO POWER PREFEASIBILITY STUDY
This study examines economic prospects in terms of a 1995-2000 timeframe
FIRANCIAL AND ECONOMIC COMMENTS
11 It is likely that a BOT deal can be structured at present JEA
generation costs for either 20 MW or 50 MW size units if GOJ is
willing to subsidize the incremental power generation cost
Furthermore these incremental costs can be recovered during the 25
year operation of a Commercial Scale Project
12 A 3rd Party Test was proposed as an alternate means to raising
$100+ for an independent JEA sponsored 20 MW Demonstration
program
13 71 millsKWH for Shale Power
VS
JEA 1987 costs
Purchased Power 17 filsKWH = 51 mills
Produced Power 1360 filsKWH = 41 mills
19952000 Costs - Expected to be 30 to 40 higher and in line
with the cost estimate presented in this study
It also is important to recognize that the busbar cost of power
generated by any new power source can not be compared directly
with the cost of existing older installed capacity because of the
lower capital cost component of the latter (See enclosed Figure
1-1 which demonstrates how total capital carrying costs decline as
the investment is paid off) Any new capacity whether coal oil
or oil shale will be an unreasonable disadvantage compared with
costs for existing older capacity
l
024
o2
0De return
E 016Total carrying charge
012 qu return
S -008
ety taxes and n rcw vshy000 X 0 5 10 15 20 25
Figure 1-1 Year-by-year Carrying Charge Components for 15-yearTax Recovery Period
1-7
30
32389
Page 2
14 Infrastructure Cost
Total People
OperatorFamilies Installed Cost
20 MW $10000000 185700 $54000Operator
50 MW 15000000 3241200 46000Operator
400 MW 45000000 10364000 43000Operator
Factored allowance for grass roots desert installation
including housing and community facilities was developed as
follows for the 50 MW case study
Infrastructure
50 MW
Family Housing 200 30K = $ 6 Million
Bachelor Housing 100 20K = 2 M
HospitalClinic (8 Beds) 11 M
SchoolMosque I1 M
Stores Services amp Recreation = 2 M
Facilities
Roads Electricity Water Sewage = 3 M
$15 Million
Infrastructure costs for the 20 MW and 400 MW cases was ratioed
from this breakdown
At this conceptual level costs are order-of-magnitude In a Phase
II program these infrastructure costs can be developed in detail
32389
Page 3
15 Contract Mining Alternatives
Page 4-11 Mine Operation
Based on Bechtels evaluation of the mine contractors price as found in Section 15 of the Mining Report it was concluded that
the mine contractors price does not include costs for such things
as developing the mine with a box-cut ramp haul roads
developing an area for the waste material maintaining the
haulroads constructing the mine services facilities diversion
ditches sedimentation ponds water well crushing the oil shale
pre-mixing the oil shale at the mine and other items associated
with operating a mine to support a power plant If it is proven
that the mine contractors price includes cost for the above
mentioned scope of work in additi-n to drill blast load and
haul then the contractors price can be used but in the meantime
the all inclusive cost developed by Bechtel should be used
Contract Mining appears to be attractive for the smaller size
plants but not for the larger commercial scale operation Some
third party must provide the necessary capital for trucks
loading mining machines etc under a contract arrangement
16 Reassessment due to Dinar value change needs further study and can
not be evaluated given present budget limitations If average
labor rate of $300hr still valid then little change involve with
study
If deemed necessary reexamination of project economics can be
done in Phase IIwhen funded
17 Costs in this study are based on recent similar Bechtel experience
on Mount Poso project and on Montana I project The Mount Poso
project is a 50 MW unit firing coal in a Pyropower boiler The
Montana I project is a 35 MW unit firing coal in a Keeler Dorr
Oliver FBC boiler utilizing dry cooling
32389
Page 4
18 The Pyropower quote of $186000000 to futnish and erect the steam
generator stack and baghouse has been adjusted to include
engineering construction indirect cost etc to be consistant
with the rest of the costs shown in Table 65 p 6-10 No
further adjustment for location was made
19 Equity funding has the lowest priority of payoff in case of a
liquidation and carries greater risk Hence a higher rate of
return is needed to attract these funds Debt funding is a first
mortgage and has first priority for payoff in case of liquidation
and carries less risk Hence it requires lower rate of return
than equity funding
The risk taking equity owner will ask for greater interest rate
to make funds available The only way to minimize this expense is
to find a loaning agency willing to provide 90 or perhaps 95 of
the investment cost It is likely that banks will require some
minimum equity participation
This Prefeasibility Study was not based on a non-profit utility
operation
Even though JEA is a non-profit organization its service
contributors are profit making groups It is visualized that the
Jordan Oil Shale Co (JOSCO) will be a stand alone business
enterprise servicing JEA under long term contract To secure
funding for the proposed project JOSCO will need attractive
enough contract terms to attract both equity and debt capital
110 Additional work is needed to develop the requested information
This work can be preformed as part of the Phase II program
111 Bechtel includes contingency in all of its estimates to cover
error emissions and unforeseen items within the defined scope of
the project The level of contingency is dependent upon the
amount of scope definition For a prefeasible study such as this
15 contingency is lower than normal
32389
Page 5
112 Tables 89 through 816 include a present value calculation to
establish the relative benefit for a shale project vs coal and
oil
113 The variable maintenance cost of 1 millsKWH has been adjusted for CFB plants with an additional $200000 per year or 06 millsKWH
This yields the following
Variable Maintenance - 10 millsKWH
CFB Adjustment - 06
Fixed Maintenance Cost - 40
Total Cost 56 MillsKWH
114 Page 4-29
The royalty costs are included in the weighted average oil shale
costs for the 50 megawatt plant
Page 4-8
Shale fuel costs include return on equity and royalty These are
two separate cost items Royalty is the last item mentioned in
the sentence and it therefore reads as royalty and not return on
royalty
Page 4-31 gives rates used by Bechtel based on our calculations
using the referenced procedures
DebtEquity Capital Charge Rate
5050 153
8020 139
Table 69 displays the calculation of the 153 capital charge
rate (Line 7 of Table 69 is not used in the calculation and
should be deleted)
32389
Page 6
116 No water purchase charge from the Water Authority was added to the
operating expense based on the statement that no resource costs
will be charged
$020 per 1000 gallons is rule of thumb for USA installations in
absence of client data
Boiler make up water (p4-17) is treated in a demineralizer
train If deemed necessary comparison with reverse osmosis
process can be performed in Phase II
Water requirements were estimated to be
Cubic Metres Per Year
20 MW 50 MW 400 MW
Mine amp Shale Processing 455000 761000 773000
Power Block 3000 6000 42000
Infrastructure 80000 140000 448000
Total 538000 907000 1263000
117 Annual average operating costs shown on Table 6-1 are in error
Financing Option 5050 8020
Cost Shown 56606 48945
Corrected Cost 60396 53236
Average mining and shale processing costs are developed year by
year in the Mining Report Appendix 5 Table 12-10
32389
Page 7
118 We would be interested in receiving the breakdown of these current
power cost figures (ie capital charges fuel cost number of
operators etc) Further economic analysis employing these
figures can be developed in Phase II
119 Manpower requirements for the three case studies were estimated as
fol lows
Mining amp Shale Processing
Power Block
Operations
Maintenance
Management
20 MW 50 MW 400 MW
75 163 396
54 78 175
46 73 455
10 10 10
185 324 1036
Page 14-4 of the Mine Report is for mine and shale processing
only It should be noted that most of these manpower requirements
involved new jobs for Jordanian people
120 At the April 1988 Amman Meeting it was agreed that the following
costs would be omitted
o Permits and Licenses
o Local Taxes
o Import Taxes
If necessary such costs can be developed and added into a revised
economic analysis as part of the Phase II program
121 6 average inflation rate is the figure recommended by Bechtel
based on USA conditions for use in long term economic analyses of
new power ventures
32389
Page 8
122 This matter is referred to ORNL who prepared a rate of return
analysis
Bechtels conclusion is based on computed busbar costscumulative
benefits compared to alternate fuels in the timeframe 1995 to 2000
Relative Busbar Power Cost Net 25 Year
Mills per KWH Benefits - Million US$
Sultani Oil Shale 71-83 Base Cost
Imported Coal
$50tonne 68-88 778
$70tonne 78-107 2531
Imported Oil
$17Bbl 56-76 (18) $24Bbl 61-96 1810
The above results are based on a capacity factor of 75 which is
considered to be a reasonable target for a new plant over its 25 year
life The average selling price of 6 cents per KWH cited in the
questionnaire is based on existing plant costs which may not include
all cost elements of new capacity evaluated in this study
32389
Page 9
TECHNICAL COMMENTS
21 See answer to Item 116
Total power plant raw wate consumption rates and annual
consumptions including the water requirements for wetting ash at the truck loading p int within the power plant are given in Tables 43 and 44 for 50 MW unit and Tables 53 and 54 for 20 MW unit
The raw water requirements for 4x0 MW plant were factored
excepting the mine where a revised mine pldn is employed to reduce water request The quantities shown on these tables exclude raw
water requirements for housing complex mine and ash wetting if
required at the ash disposal site
Total power plant requirements shown in the above referred tables
are
50 MW 20 MW
Rate gpm 207 102 (See Drawing M004)
Annual Use
Gallons 1400000 675000
Cooling tower blowndown supplemented with raw water is used for
wetting ash at the truck loading point within the power plant Raw water quantities attributable for ash wetting at the power
truck loading point are
50 MW 20 MW
Rate gpm 75 325
Annual Use
Gallons 500000 215000
These quantities are included in the quantities shown in
the above referred tables
32389
Page 10
22 We recognize the POTENTIAL for leaching toxic compounds from the
spent ash However this matter is not yet defined well enough to
recommend specific action steps The Prefeasibility Study page
7-12 recommends creation of a ground water dispersion model to
determine whether more specific contaminated water mitigation
plans are needed It is anticipated that the leachate rate will
be low and that aquifer dispersion will keep problem compounds
bel3w health standards thresholds
23 Noted
We have not received up to date resource study material which
defines 50 billion tons resource base Please furnish
The resource base at Sultani alone is adequate to support two 400
MW power projects capacity subject water availability The
2-million cubic metre per year water allowance for oilshale will
limit development to about 600 MW
24 Selection of a combustion temperature is a balance between carbon
combustion efficiency and heat loss due carbonate decomposition
For purposes of the Prefeasibility Study we have opted for high
combustion efficiency At lower efficiency larger shale
mineprocessing plants will be needed
25 Bottom ash is cooled by water exchange before discharge
Cooling water is supplied to the ash screw coolers as specified by
Pyropower See Drawing MOO5 2140 gpm flow for 50 MW and 860 gpm
flow for 20 MW Heat removed by the cooling water from the ash
screw coolers is dissipated to atmosphere via a wet cooling
tower Pyropower should indicate the temperature of the ash
discharged to be 5OOF
32389
Page 11
Initially we had considered using a heat exchanger to cool the ash
and improve the cycle efficiency Considering low cost of fuel
the additional capital costs and the system complexities it was
decided not to employ such heat recovery systems for this project
26 The suggested alternates were looked at briefly and the potential
for wind blown air pollution from the ash disposal areas are too
great to warrant dry disposal unless GO(] and World Bank are
willing to accept such a potential problem Wetting the ash is
tne only practical solution Hopefully some cementation will
occur helping to reduce future leaching potential
27 JEA requirements are noted This is a conceptual study not a
final design Optimal design analysis can be performed during
Phase II
2829
JEA requirements are noted and can be incorporated into the Phase
II design
210 The transformer size is adequate for base load operation A
higher capacity can be considered at the final design stage if the
Client prefers
211 From our experience it does not appear to be economical to
provide additional dry cooling towers to take care of maximum
ambient temperatures which may prevail only for a short period of
time in a year To study this an annual dry bulb temperature
duration curve is required Also adding additional dry cooling
towers will change the plant performance It should also be noted
that the dry cooling towers are very expensive and the size should
be selected carefly considering performance and cost and not on the basis of maximum ambient temperatures This can be studied
during Phase II
32389
Page 12
212 The plant gross output varies with condenser pressure
Condenser
Pressure Design 55 in HgA Annual Ave 35 in HgA
Unit Size MW 20 50 4xlO0 20 50 4xlO0
Gross Output MW 234 593 496 2415 607 TBD
Net Output MW 1975 501 400 205 515 TBD
To be developed in Phase II
Output for 4x100 MW is estimated by others
213 The fan power consumption of the CFB boiler is about 30 to 35 of
the total auxiliary power The fan power consumption of the dry
cooling tower is about 20 to 25 of the total auxiliary power
214 Table 1-1 does not include plant net output Therefore do not
understand the comment
215 Commercial operating experience with coal fueled CFBC units in LISA
and Europe has been uniformly good showing high on stream
availability in early years (See Table 2-6 which reports on
Pyropower experience)
We expect operations with high ash content fuel like oilshale will
have unique scale up problems such as
o Solid handling in and out
o Internal solids circulation
o Erosioncorrosion steam generator intervals
o Heat recovery from bottom ash
Consequently we are recommending these items be worked out in a
single 50 MW prototype
32389
Page 13
216 Maximum dry cooling is used in this study A small wet cooling
tower is used on circulating service water system
217 Horizontal condensate pump is adequate with dry cooling tower and it is cheaper Vertical condensate pumps with cans can be
considered in the final design if required
218 A concrete shell brick lined flue stack will be larger in diameter and costs more than a steel lined stack Brick lined stack can be
considered in the final design
219 Demineralized water tank capacity for 50 MW is 76 cu meters or 20000 gallons not 1000 cu meters For 20 MW plant it is 38 cu
meters or 10000 gallons
220 It is US practice to use an average continuous blowdown rate of
1 and maximum biowdown rate of 3 for this type of plants
221 This can be studied during Phase II
222 Same as 221
223 Same as 221
224 The recommended action plan calls for continuing support studies covering the referenced items Additional effort is needed to
further define these matters and confirm the conceptual plan
The next step is to develop an outline for a project plan including
o Work Scope
o Schedule
o Budget
accommodate the increase in the number of employees and
equipment Truck bays to accommodate the 136 tonne trucks
will be added The truck bays used for the 77 tonne
trucks will be used for the maintenance of other
equipment The warehouse change house training room
offices and cafeteria will be expanded accordingly
6025 Mining and Processing Economics
Details of the oil shale mining and processing plant
economics for the 400 MW plant are included in the Mining
Report (Appendix 5) These details are of the same
magnitude as prepared for the 20 MW and 50 MW plants
The summary of the cash flow analysis for the mine and
shale processing plant is presented in Table 6-1
Table 6-1
SUMMARY OF 400 MW PLANT OIL SHALE MINING AND PROCESSING COSTS
5050 Debt-Equity 8020 Debt-Equity
US $1000 US $1000
Capital Cost
Mine Development 30915 30915
Mine Equipment 66012 66012
Process Plant Facilities 50889 50889
Spare Parts 5000 5000
Working Capital 10000 10000
Capi tal ized Interest
During Construction 24423 39075
TOTAL 187239 201891
Operating Costs and Other Costs
Annual Cost 60386 53236
Product Mined and Processed
Annual Tonnes x 1000 7783 7783
Unit Cost
US $Tonne (weighted average)
US $l06Btu (weighted average) 776
156
684
138
Year 12 costs taken as 25 year average
6-6
-Au
Table 610 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
- FCC plant sizes equivalent to proposed power application
Prefeasibility Study Oil Shale Fueled Power Generation
VOO94GEampJRI26
i
PYROFLOW UNITS IN THE US
COLORADOUTE IOYA STATE UNIV UNIV OFNUCLA CO NORTHERNAMES IA BF GOODRICH110 1o0MW(a) 2x170000 Ibhr HENRYILCEDAR FALLS IA 120000 Ibhr GENERALGULF OILu EiN P MOTORSSbtUpStart-UIL 1987 O A 1I N000 TC
NORT10 PONTIACH B MIRANCHWV00000 lbhr
CORN PRODUCTSSM NORTH-CAROLINA STOCKTOD CA
400000 lbbhl t
RUMF RD ME
CEMENT CO CALIF PORTLAND-COLTON CA
190000 Iblhr Start-Up 1985 TRUMTFTWN NYU
3I75ERTOWN N
etar t-Up loss ACE COGENERATIONCABI
TRONA CA Oper t~on l -Start-UP 1990 ~ rt upz 091Start-up loss Start-up PNeLAI 1991
MTKESFICOENERATIO-N1
BASFIELDp Start-uStar-Up WESTCA9 199otgoUp 1 MAHONEV PA|00000 Ibhr A Oz 2X365000 Ibhr
SETtr-Ups 188B CHAT TANOOGA TN
G ULF OIL EXPLORATION 8ta-rt-u) 1085BAKERSFIELD NORTH BRANCHCA SPRING GROVE PANORTH BRANCH WV 400000 IbhtOperational 19835 5 0 0 I b h 9 0 0 0 Iblh r- tart-Upi 1991 S t r - U p s l e s s
SOUTHEAST PAPER MFG CO UNIVOF NORTH CAROLINArDUBLIN GA UHAPEL HILL NO400000 IbhrStart-Ups logo Start-Ups2X250O000 1loseIbhr B
- Withdrawing ash from combustor - Withdrawing fly ash
a Internal solids circulation of the steam generator
m Erosioncorrosion of steam generatorinternals
Heat recovery from bottom ash
U Operation with low calorific-value fuel
Prefeasblity Study O Shari Fueled Power Generation
VOO7AI 27
Impact of Scale-Up
Project Size
20 MW
50 MW
100 MW
50 MW boiler in 100 MW plant
Potential Risk
Design Scale-upOperation of to 100 MW Initial Plant Plant
Low Significant
Modest Modest
High Low for duplicate units
Modest Low for duplicate units
Prefeasibility Study Oil Shaje Fueled Power Generation
VOO71-4GEAL4n2
i
Conclusions
Defined risk of CFBC boiler is acceptable
U Operating experience with commercial CFBC boilers built and under construction will strengthen confidencelevel and minimize risk for a plant built in 1995
SPrefeasibility Study Oil Shale Fueled Power Generation
V007GHAAE29
ENVIRONMENTAL ASSESSMENT
a Mine and shale processing
- Fugitive dust emissions
- Noise levels
- Leachability of disposal piles
Power plant
- Fugitive dust emissions
- Gaseous emissions
- Noise levels
- Water effluents
U Conclusions
Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel
Prefeasibility Study Oil Shale Fueled Power Generalon
- Coaloil prices will be at least 15 greater after 1995
- Discovery of indigenous conventional fuel resources is inadequate for power plant purposes
Prefeasibility Study
Oil Shale Fueled Power Generation
VOO) IDWFO
Feasibility(Contd)
N Suitable financing will be available
- For $200 million 50 MW prototypeproject
- For $1000 million 400 MW commercial project
Government of Jordan will make basic commitments
- Long-term power purchase agreement
- Long-term access to Sultani shale deposit
Adequate water and manpower resources
- Attractive tax incentives
Prefeasibility Study
Oil Shale Fueled Power Generaion
VO bull1DUJJRO 6
Timeliness
U Timely development of Jordan oil shale needs prompt action to create - Additional definitive information
- Suitable business plan
Prefeasibility Study
Oil Shale Fueled Power Generation
VooI DUJo 7
i
Expansion Conditions
U Continued expansion of powergeneration from oil shale in Jordan depends on water availability
Prospects for power export or importand domestic load growth will affect size of the needed shale-to-power program
Prefeasibility Sudy
Oil Shale Fueled Power Generation
yOWl lVuJO
Environmental Impacts
N Environmental impacts of shale development will be minimal
Prefeasibility Study Oi Shale Fueled Power Generation
i
Development Advantages
Will create significant new jobopportunities in Jordan
Will avoidreduce foreign exchangelosses for expanding alternate fuel imports
Prefeasibility Study
Oil Shale Fueled Power Generation
VOOIIULL tO
Recommended Action Plan
N Basic recommendation
N Conceptual development schedule
U Project development plan
Key plan elements
N Funding requirements
Prefeasibility Study Oil Shale Fueled Power Generation
VOO4II )U OII
i
Basic Recommendation
N Expand efforts to develop an oil shaleshyfueled power generation program at the Sultani deposit
- Conduct required supporting studies
- Define facilities costs and business plans
- Obtain project funding
Prefeasibility Study
Oil Shale Fueled Power Generation
VON I II)ILL 12
C
Conceptual DevelopmentSchedule
1989-1990
- Conduct supporting studies - Define costsbusiness plans for 50
MW prototype and 400 MW commercial projects
- Develop project financing
N 1990-1993 - Build and operate the prototype project
N 1994-1996 - Expand the 50 MW prototype to 100 MW scale
U 1996-2000 - Expand the project to 400 MW scale
N 2000-2005 - Build a second 400 MW commercial project if needed
i 1 Prefeasiblity Study
dOil Shale Fueled Power Generation
VW IMLITO 13
Conceptual Development Plan
Months
1 Project development plan - Define project
costs1busness plans
-24 -12 0 12 24 36 48 60 72 84 96 108 120
2 Secure funding
3 Build and operate 50 MW prototype
Dergn and procurement
Mine development
Plant construction
Startup and testing
Operations
L- -
4 Expand prototype to 100 MW
Design and procurement
bullConstruction
Startup
5 Expand project to 400 MW
2nd 100 MW unit
3rd100 MW unit
i 44
4th 100 MW unit -
O Project dacision point
i Prefeasib~ity Study Oil Shale Fueled Power Generation
17958562aJocdanV 3-14-89 rsO
18
Phase I - ProjectDevelopment Plan
n Program development
Seminar workshop on prefeasibilitystudy Oate project development plan woek scope schedule arid budget
U Carry out project planning program
- Conduct continuing support studies - Test Sultani shale in existing FBC
- Firm up designs and specifications
- Update costs and economic analysis
- Develop business plans and requirements
Explore project funding alternatives
i Prefeasibility Study
Oil Shale Fueled Power Generation
VO MItUOR 14 -0
Key Plan Elements
N Project feasibility analysis
- Firm up designs and equipmentspecifications for all facilities
- Update cost estimates based on preliminary designs and specifications
Explore arrangements for contract mining and mine development
Update forecasts for demand growthand for retirements of older generating capacity
- Create updated economic analysis
Preleasibility StudyO1 Shae Fueled Power Generation
VOO1IOLWRI
Key Plan Elements (Contd)
Business entity requirement
- Explore optionsconditions for a new company to managebuildoperate the project
- Explore optionsconditions for obtaining a concession agreement for Sultani development
Explore optionsconditions for water rights commitment
Prefeasibility Study Oil Shale Fueled Power Generation
VMIOIA)lj 16S
i
Key Plan Elements (Contd)
U Continuing supporting studies
- Combustion tests (additional pilot tests for design and warranty purposes contract for large-scale burn operations in existing plants if appropriate)
- Additional core drilling and core analysis
- Oil shale crushing tests
- Spent ash leaching tests
- Geotechnical data base including soils analysis
- Environmental baseline data
Prefeasibility Study O Shae Fueled Power Generation
VMMMUldMOA
Steps Required to Develop an Oil Shale-to-Power Project
Create a development business plan - Schedule - Decision tree
Develop a work scope and budget for the development plan program including - Firming up designsspecificationscosts
- Developing business entity requirements - Continuing support studies
Carry out development plan program
Assemble all planning results in a report for discussion with financial institutions
Explore project finance opportunities
Finalize business arrangements
Implement prototype project
i Prefeasibility Study
Oil Shale Fueled Power Generation
VM1-11UJROLI
MARCH 15 JEA QUESTIONS (M S ARAFAH) ON PREFEASIBILITY
STUDY DRAFT REPORT
Rt
DIR EScBSULIVAN PHD OFJCEop~BUREAU FOR SCIENCE AND~TECHNOLOGYAGENCY - --FOR INTERNATIONAL DEVELOPMhINTSWASHINGON DC x20523---------4
4 -
-SUBJ E CT - -C O H~ E T 4N l
Dr Mr sullivan ------shy
c-rommnents We ~efr-preaereorPla -tobYou lete dted Jan 91989 regardn~i4po4t P ea e1 f i nd y ubel ow our -e ot r XcOrcerned Jordanian deipartments
- --A ar o~nnYu Y o turjlt~ lt K
4 C~mments
~1 N i gFIN I~fANDECONOMIC1COIMEN S -
It sidicaed that Beohtel and US AIDWash ingtonj~4- re ojy nen ing that E 2hould und ertake the n e tshyihaisAre ~our c leometprogram n order shye-t im~ ate d f n t v design and budget cost
4Al1so Lthe study ncal--ttsutnilndcaei~ A-1 A thas ~ l 1 be eeded idb~~~~~ rn o ei t n i la itheMWa~-~5s~ 4
hrPro hehgemetTh trOfT ses~fnr4 BOT)Vmanu- a n-mnf~cure 4 r~j or contra c4-or ivoIlveiintijn I 4 4investmnt ude smi ~w 2 Zha tev e r --~4~prce e ec r it v p4~ f JA gertiy geeated-at 4 JEA 3 a l b u y ~the same average~~ A
~jithia oncot in4 ordrtan ecpoemic asess thespePower generatjoon J ordan3 oi sha I eroic c inr~etJordan 4
2P ge i1- 1 Aj iit eu that OPin he atocontr~ct 4with owner4 ofext3ing (oconstriiction r(FB rml-t
qu i of S 11 t to test large tonnagen j es StaniUti n d ajIe -for se veralIQf 31 hi
evrEAPreferpilot qr the dP 1prt7n -that the4mPIt
andi to(7 he instalI 1e 2 310 A
_
JODN ELECTRICITYAUTHORIT LL
Dac
operated in Jordan i n or~der~~t ~n nuex~on mnining crushing and haidi igQhre~ and sash Maeia nd aSootoget enough olr ndaita needed for einolre
CEBbole~ -i s~
ccordance with Jordaian oil shale
large to~ bfig
1 3 le 1-2 Page 1-7 Cost Of Pwer~i It i S menti-oned that the conmecial oil hle~ lt~project (4 X1OOmw) 1is ninacompetative roqt~range-~while table 12 indicates thattcost of-pow Ais~mill
q kwiihcii r 1
average wih i ii -much higher ihantheshy-ost of ~Power gnrtofomJEA therimaPower s ta tions Please~ indicate on what basi o ~~ shave-~made your-statement
PK
14 Pae 2 Sction 4-0sIt 1nlkly that theChousing and off- -site infrastructur-ommnity fakilitieR) to be onsidered for both the demo and prototyp prjcs oeoverwe~4 hnk that their~c_6t is raterojects Mo
iwcv~- age -1 1 Mine O(perationIIt is indicate~d that mining cot eevdfoMine contractor~ are ficomiplee h
r and iyudi-t~con qidder contract mnn opio fr4 the min4 cmflt2ng are reIanddrepres~ent the real costs derived from Phspat miin contractors in
lestfor the eo rPooypuat in order tlt7
P I eadenote tha detthe new exchangerate ofthJraian~ Di~nner you may add 20j6 Kto the quoted
1 6 P Ias e consider the followin ecn hage_
171- The new exchange ra teof tUSD=54o0 fils1 72-W2 The new~ aerage tariff for selIn~electricityhas decrreased to 120 8 f ilIsicwh
17- Page 1-7 TbIe 1-2 W bev th tthe cap ita1 cot for the pwhokand forthe min n d ash hMnd1ing equipen
P B~2Anaor a -Tl 8156152 8176 1Q MYf -t -Now 520 t 1U
JDNEECRICIT AU-RA L14lLiL
2 ~are very high We suggest~ thta You rerconsie (- telowerus e~+d accuracy est a rangethan +30
Page4-22 Table 4-5weno0ti ced( that- PyroPowe ha ddeta(IiacCst fori the bo1ilerlocation and terha dutdetlease isxtr fo~ l C~ io~ s~ e~~ 1a~ a if and indicate theonldjusted ~percentagefor construction foin Jordan
19 Page-7 Table 11-2 -Yo aeue ihrinterest rate on Equity thatn on1DehI~laseinclude~ adetaied explanation of thisrr -tni kepin in miUndie JEA is1thaIt a non profit~ shyorgaiztion unik oher private UJSA utility~in ktation
~-~110- Regarding shy
the ra4ital Rt fthe project it is~requesed tobre k it intdo foreignMeanwhile cthe nd lorcal c-osfoeigptario i nt-re3t~shol becnierdo-h
rr n ontiondonnotopdbon the 9 cnieelocal portion~onth
1-1- 237~Pa
oningeny 9tooi s high~~ a lower 4value -should be~
4~ gt ~112- -Tbles t1-1 -8-8~ inclu~de t~he c~alculationscuultie nt enefits for of Th shyunttypes l i4s difeen geeatnmrer likely tocluae
-~ Q~ J7present vk1u for tenet tthe~benefits in feralterntives -t-oa s the
49
ehliyoi shale
Wea gree with you9 tha t th e percentage used ~ an for thenua~l 0 ~amp-M rahr CFBo ndsomewha~t highervrate be n ededma y for a C B l n Me n h l ~ a e r
indir e ta~ts the -estimatedma i variablec st i ddition t he fi-xed-9i 1 mislkih We --
thinktttiis too lowK -5
shy
1-14- e 4-29
opprza tion-o to The o i1s h1 costs-nc I deAbo 1h
Pa10 mman ormTSI62 a
IB I
JORD N EtECTICI1~ 4 E~)~Is-s
Date ib-_
~ ~riii~g~nd~o9~ru~hng h~tnlin cot~u~tv yo
i Dae Jnryit
1ts c 7 4-
i smiig iniand fh co I eY
susendi ca tI t icag th t1 ~an~approximate 15 ~pita L tYII I (-~a~ge or he owe bl ockj f aniitjes isof +the capthe)t~ial7cpi~lrharge Uoratelformny SI~Uj(uiity installa~tions~ whle page 6-1T9 talJshyit is mentioned that~ the Capital rate pe-r JEA isshyi5~PeaseJustify this~matter since~w o
i16- Pae 6-1 6
1 I4~t is mentioned that the costs of 4process Water are ~ 4 ~0 2$1 000 gallons
r~j~lt IHave~You considered additionalvalue ofbying waterfrom~ the Wa ters Aito i ~or ditoa cost~f o revrseoqoesplant if ground water is used
~~ I1 7- Table 6-1 Page 6-6 Please explain how did You come ou ihteoil~ shale miniing and proces~sing uit~Icost
ltII~I~ 8- Please note 1 t hatj the average JEA~productinr ot frmthermal I power stationsr (Istationbus-barCOSt)i sbewen 6 3-17 3 fils 4kwh You may use this~
l4~ 19-i For ~4 X 100~AMW Plat iti etindo pag e14-4 VolI 11 that4 at tota I of W42 14 epoye W II eemplo~yer] And on page 69yo1Iiti mentioned that a~ tot 1 f1 ~p yeI iNbe enp1oyed a
is~ high asrmetitexeds100personorthe ~41X100~MWh~~j nsatnpPrlae
I 1 The 4 following iftemns are a sumed to1 be excluded from theraPi ta 1 cot xoI
120-1 Perits I icen es 7
1_207~3 Imprt ~xe on s7pare par ts -and c(7orfmurab -ma~teria Is
04f4 4
~4 R j4 4
D4
~ ~ ~ AIf eS taxesq in acrac ihteJraand regulations should be considered aw
21- p1ea4s e indic ate Your Ju t f c io r us ga 6
44122- Table 977App 5Page4 9-1 4L IK Car1Yiniae that the hIRR of the 4 Otplantis rather unattractive (66)most
-( Cns1er4 ngthe logical base 4csek c pwhen cii 6OL
average sell~ing prc CkhampDEratio L801~2O~Aoreover4M the ne siellin prcwh o JEA ati theamptime~ Abeing os4ltp n~ot exceed 4 Ckwh~-However Ipage 1shy~ and 14 0 T indicate that ecnms for a commeri
S4A4scale joil 4 shale projc ~
appear Piomisig-nug o4Ywarrant continued dee fgfluht 4 feaibiit 4tudy wihil cost sevea~lili
do ar~sf Plas lear wether the ~x step jqs~$j~~lt 4
gtt 9o be considered arCcording4to jthe 4unattractiveresul to mentioned in IRR7 Table 97 gt4
a C4 44fET2 4 144-4444 P a g 1 T b6 l
htte~We ~ ~ ae~ rqieetfrteX ~ noie ~~ ~ 444 MW un t44 r te4l w w e o p r d i th e w t r n rre u f4m or4444~ the4444 54M4rto y e Pg~A~44EHiveL det ile an l A44
s o awa er c n um t a4r f rofsho in P6Io erT
e ch 2 50 M W aPln wa e d 41004 MW4 1 consumption_____________
ma4~2 k e u p houin~44 p A44 4444444 C O 4ltI4
a nd a sh et in etc 4 2 4 1 -24 P a g e4 2 - 1 A P P 5
4Yo 4_ j1 4 4~h444 N44 44
1gro nd tce t hir fthe w bern coqir mna t efora4e 4X10A M 444444 4 r i n to 4 4 4lo w w ehA 7 n 2 cinCie h rh4 n ttthh1eb -e 4 44t Of3 E4O
ea h n~ ffl 4 4Jl44 4 4444 4giv
6 ig re sofrat4 de in cl ar f w w at5 c hrw pe o
s h b 444 o t h e g nd L 44 h u i n C
r 4ne a4 t44 e L(704 2 4 p ae) 2 - o Au P dn 5ai 7~e r 44 I Y (1t 44a
ve7 rn e qu 1saharvthe y
and n~~~o speci~~~l4 p n l nh i n t x
r ~rA M e d r o t eu n 8 1 wTtl t t h
- c re e N I wo6
~ n n a i n a t d h l7 A PP6 gt
J
S2~3- Page 2-4 ~ ~ It ~is i
that oil eindicated the- sha le r our~ Cesin Jordan are 10 billion tons -The anulp e reere maiy exeed 50 4 billion tons ~
~ 24- 4Page~2 -l1 iujntr We beiv thtCBcmuto~ep i s high and~alSo
~~ ~ -2 ~~ Page 4-1~6 j - shy
Please~~ indicates your procedure to cool the omn ashand atwa icagd-eprtr
A Have you~ considered~ additional he~at exchanger topcool th ash and to imrve h cycleef ficiency
-~2~6 Page 4-16 It s~ indicated that ash from each silo i Amixed19 ~with~fabout 20 waterKb weight to minimize generation of dust~during trnprtto to mine and disposalHave you~ coniidered other 4lternativeto
~ ~eliminate dustiiig -and avoid use ofwat r uring it ransportationi such as~ using closed trucks or closed
of ~fans conUMnPo wihrlaintthe total plant auiir poe osupin 1~21- Table 5_-3 and I ~
Th~~ is- somneere c6ntradiction regardingplnneotpu~t in both am tables 21-~ Tabl~e 1-33
We noticed tha~t yourall9 cacacapac t fatro75 tion ae asdnWe thilt ~that 7capacityshyfacto is tobo high for- an oil shale fired plant duketo lack of existing simila~r ~plants handl~~~firing oil adshale ~K
216~ The study iniae thtawet~coigtower wi11~used Actually a b
dry cooling should be consideda5ini ~HTP S inZ atomnmz so water rnumption4the cycle~ efficiency willbe reducedHenre YO33~reconsider calculating the cyclefficiy
U~~~~~ codnt umconsidered ofhorizontal -aretypethe~ the vertical cian type can alsobeh considered
shy ~ ~ ~ I~~
2~2 Kconcrete shy
shjell stepl fltstack is onidereconcrete shell brick flue Rt c ~s beCaconsidered3V
2-19~- Deminiraized water~ tank3 capacity~ is -76 ui(meterThe recommnended tank cameter- ui tyi 00cbc
220Designconditions Pa~ge (4-74)te5 hat bow 3down percentage splusmn ~fomrpra til re i hou I be 3~)~
PoD Z 2 m a ad~ - e 5 1 2 iJS~ ~ p A f amp ~ ~ y1
4
JO R ECTICITY AUTHORTIT 4L
~ 4
Date~
t etats ttthe quantityof s i S ~1 000Tons ra Sthis tuntity 11- be transporited for severIy --to tu ofI pit a~te torg P KM ra~erm Spower plIatS about 12 midilidoni CUIA(- met ryea
h e ndd mp e he (d u p in i n L
area wil evric power plant6t Please zn1 a te~tiv s tudY for dumping th r~ a enoug
-from the power plantr~~h~
S 2- Please provide deald-ifrat ao etbaaiedrawing hwn TH11 R thaU and~pV ra~te takcing illto o 6it v- consumptionn _uig themrining equipment
alternate~ study 0o Jine operation for 1 shiftday Vand twoshifts day -lt
224- Conceptua~l pflR 1 for mi ing anusdtransportation of oil- shale a 0 dmj of hs f u r therV examinedh iV~sdpatI ho u1d be
orderj to poe~ehicalq and~eoomca1 fesblt of t his operation
SYour are requested te) study and consider all- above - iPoin s at your earliest in rder -to be peete y oiAnimain on March 29-301989 peetdb~o 4 n
S9incerly-You S
WDIRECTORGENERAL -
I~ CCMR WLINTON ~vs
5N
Pa D~t~IoAmmn -Jordtn -Tel 815615 20 Bl76 15 -19j A VINO- AFf TY
MARCH 21 RESPONSE TO JEA QUESTIONS
Bechtel Power Corporation Engineers - Constructors
Fifty Beale Street San Francisco California Mail Address P 0 Box 3965 San Franclco CA 94119
March 21 1989
Mr M S Arafah Director General Jordan Electricity Authority PO Box 2310 Amman Jordan
Subject Jordan Oil Shale Prefeasibility Study
Dear Mr Arafah
Your letter of 15 March 1989 with comments on the Oil Shale to Power Prefeasibility Study draft report has been referred to me for reply
The attached responses to each item in the reference letter follows the order submitted
Also attached are three revised pages for the draft report - Volume I
Page 6-1 Page 6-21 Page 6-23
Please copy these revised pages into the report previously sent to you
We plan to review this material with JEA during the March 2930 and April 1 meetings in Amman
rsuVertrul yours
W Linton Project Manager
WHLdc
Attachments Questionnaire Response Three revised pages
cc C J Aulisio R R Buta G D Gould T J Wilbanks
32389
Page 1
RESPONSE TO MARCH 15 1989 QUESTIONAIRE
OIL SHALE TO POWER PREFEASIBILITY STUDY
This study examines economic prospects in terms of a 1995-2000 timeframe
FIRANCIAL AND ECONOMIC COMMENTS
11 It is likely that a BOT deal can be structured at present JEA
generation costs for either 20 MW or 50 MW size units if GOJ is
willing to subsidize the incremental power generation cost
Furthermore these incremental costs can be recovered during the 25
year operation of a Commercial Scale Project
12 A 3rd Party Test was proposed as an alternate means to raising
$100+ for an independent JEA sponsored 20 MW Demonstration
program
13 71 millsKWH for Shale Power
VS
JEA 1987 costs
Purchased Power 17 filsKWH = 51 mills
Produced Power 1360 filsKWH = 41 mills
19952000 Costs - Expected to be 30 to 40 higher and in line
with the cost estimate presented in this study
It also is important to recognize that the busbar cost of power
generated by any new power source can not be compared directly
with the cost of existing older installed capacity because of the
lower capital cost component of the latter (See enclosed Figure
1-1 which demonstrates how total capital carrying costs decline as
the investment is paid off) Any new capacity whether coal oil
or oil shale will be an unreasonable disadvantage compared with
costs for existing older capacity
l
024
o2
0De return
E 016Total carrying charge
012 qu return
S -008
ety taxes and n rcw vshy000 X 0 5 10 15 20 25
Figure 1-1 Year-by-year Carrying Charge Components for 15-yearTax Recovery Period
1-7
30
32389
Page 2
14 Infrastructure Cost
Total People
OperatorFamilies Installed Cost
20 MW $10000000 185700 $54000Operator
50 MW 15000000 3241200 46000Operator
400 MW 45000000 10364000 43000Operator
Factored allowance for grass roots desert installation
including housing and community facilities was developed as
follows for the 50 MW case study
Infrastructure
50 MW
Family Housing 200 30K = $ 6 Million
Bachelor Housing 100 20K = 2 M
HospitalClinic (8 Beds) 11 M
SchoolMosque I1 M
Stores Services amp Recreation = 2 M
Facilities
Roads Electricity Water Sewage = 3 M
$15 Million
Infrastructure costs for the 20 MW and 400 MW cases was ratioed
from this breakdown
At this conceptual level costs are order-of-magnitude In a Phase
II program these infrastructure costs can be developed in detail
32389
Page 3
15 Contract Mining Alternatives
Page 4-11 Mine Operation
Based on Bechtels evaluation of the mine contractors price as found in Section 15 of the Mining Report it was concluded that
the mine contractors price does not include costs for such things
as developing the mine with a box-cut ramp haul roads
developing an area for the waste material maintaining the
haulroads constructing the mine services facilities diversion
ditches sedimentation ponds water well crushing the oil shale
pre-mixing the oil shale at the mine and other items associated
with operating a mine to support a power plant If it is proven
that the mine contractors price includes cost for the above
mentioned scope of work in additi-n to drill blast load and
haul then the contractors price can be used but in the meantime
the all inclusive cost developed by Bechtel should be used
Contract Mining appears to be attractive for the smaller size
plants but not for the larger commercial scale operation Some
third party must provide the necessary capital for trucks
loading mining machines etc under a contract arrangement
16 Reassessment due to Dinar value change needs further study and can
not be evaluated given present budget limitations If average
labor rate of $300hr still valid then little change involve with
study
If deemed necessary reexamination of project economics can be
done in Phase IIwhen funded
17 Costs in this study are based on recent similar Bechtel experience
on Mount Poso project and on Montana I project The Mount Poso
project is a 50 MW unit firing coal in a Pyropower boiler The
Montana I project is a 35 MW unit firing coal in a Keeler Dorr
Oliver FBC boiler utilizing dry cooling
32389
Page 4
18 The Pyropower quote of $186000000 to futnish and erect the steam
generator stack and baghouse has been adjusted to include
engineering construction indirect cost etc to be consistant
with the rest of the costs shown in Table 65 p 6-10 No
further adjustment for location was made
19 Equity funding has the lowest priority of payoff in case of a
liquidation and carries greater risk Hence a higher rate of
return is needed to attract these funds Debt funding is a first
mortgage and has first priority for payoff in case of liquidation
and carries less risk Hence it requires lower rate of return
than equity funding
The risk taking equity owner will ask for greater interest rate
to make funds available The only way to minimize this expense is
to find a loaning agency willing to provide 90 or perhaps 95 of
the investment cost It is likely that banks will require some
minimum equity participation
This Prefeasibility Study was not based on a non-profit utility
operation
Even though JEA is a non-profit organization its service
contributors are profit making groups It is visualized that the
Jordan Oil Shale Co (JOSCO) will be a stand alone business
enterprise servicing JEA under long term contract To secure
funding for the proposed project JOSCO will need attractive
enough contract terms to attract both equity and debt capital
110 Additional work is needed to develop the requested information
This work can be preformed as part of the Phase II program
111 Bechtel includes contingency in all of its estimates to cover
error emissions and unforeseen items within the defined scope of
the project The level of contingency is dependent upon the
amount of scope definition For a prefeasible study such as this
15 contingency is lower than normal
32389
Page 5
112 Tables 89 through 816 include a present value calculation to
establish the relative benefit for a shale project vs coal and
oil
113 The variable maintenance cost of 1 millsKWH has been adjusted for CFB plants with an additional $200000 per year or 06 millsKWH
This yields the following
Variable Maintenance - 10 millsKWH
CFB Adjustment - 06
Fixed Maintenance Cost - 40
Total Cost 56 MillsKWH
114 Page 4-29
The royalty costs are included in the weighted average oil shale
costs for the 50 megawatt plant
Page 4-8
Shale fuel costs include return on equity and royalty These are
two separate cost items Royalty is the last item mentioned in
the sentence and it therefore reads as royalty and not return on
royalty
Page 4-31 gives rates used by Bechtel based on our calculations
using the referenced procedures
DebtEquity Capital Charge Rate
5050 153
8020 139
Table 69 displays the calculation of the 153 capital charge
rate (Line 7 of Table 69 is not used in the calculation and
should be deleted)
32389
Page 6
116 No water purchase charge from the Water Authority was added to the
operating expense based on the statement that no resource costs
will be charged
$020 per 1000 gallons is rule of thumb for USA installations in
absence of client data
Boiler make up water (p4-17) is treated in a demineralizer
train If deemed necessary comparison with reverse osmosis
process can be performed in Phase II
Water requirements were estimated to be
Cubic Metres Per Year
20 MW 50 MW 400 MW
Mine amp Shale Processing 455000 761000 773000
Power Block 3000 6000 42000
Infrastructure 80000 140000 448000
Total 538000 907000 1263000
117 Annual average operating costs shown on Table 6-1 are in error
Financing Option 5050 8020
Cost Shown 56606 48945
Corrected Cost 60396 53236
Average mining and shale processing costs are developed year by
year in the Mining Report Appendix 5 Table 12-10
32389
Page 7
118 We would be interested in receiving the breakdown of these current
power cost figures (ie capital charges fuel cost number of
operators etc) Further economic analysis employing these
figures can be developed in Phase II
119 Manpower requirements for the three case studies were estimated as
fol lows
Mining amp Shale Processing
Power Block
Operations
Maintenance
Management
20 MW 50 MW 400 MW
75 163 396
54 78 175
46 73 455
10 10 10
185 324 1036
Page 14-4 of the Mine Report is for mine and shale processing
only It should be noted that most of these manpower requirements
involved new jobs for Jordanian people
120 At the April 1988 Amman Meeting it was agreed that the following
costs would be omitted
o Permits and Licenses
o Local Taxes
o Import Taxes
If necessary such costs can be developed and added into a revised
economic analysis as part of the Phase II program
121 6 average inflation rate is the figure recommended by Bechtel
based on USA conditions for use in long term economic analyses of
new power ventures
32389
Page 8
122 This matter is referred to ORNL who prepared a rate of return
analysis
Bechtels conclusion is based on computed busbar costscumulative
benefits compared to alternate fuels in the timeframe 1995 to 2000
Relative Busbar Power Cost Net 25 Year
Mills per KWH Benefits - Million US$
Sultani Oil Shale 71-83 Base Cost
Imported Coal
$50tonne 68-88 778
$70tonne 78-107 2531
Imported Oil
$17Bbl 56-76 (18) $24Bbl 61-96 1810
The above results are based on a capacity factor of 75 which is
considered to be a reasonable target for a new plant over its 25 year
life The average selling price of 6 cents per KWH cited in the
questionnaire is based on existing plant costs which may not include
all cost elements of new capacity evaluated in this study
32389
Page 9
TECHNICAL COMMENTS
21 See answer to Item 116
Total power plant raw wate consumption rates and annual
consumptions including the water requirements for wetting ash at the truck loading p int within the power plant are given in Tables 43 and 44 for 50 MW unit and Tables 53 and 54 for 20 MW unit
The raw water requirements for 4x0 MW plant were factored
excepting the mine where a revised mine pldn is employed to reduce water request The quantities shown on these tables exclude raw
water requirements for housing complex mine and ash wetting if
required at the ash disposal site
Total power plant requirements shown in the above referred tables
are
50 MW 20 MW
Rate gpm 207 102 (See Drawing M004)
Annual Use
Gallons 1400000 675000
Cooling tower blowndown supplemented with raw water is used for
wetting ash at the truck loading point within the power plant Raw water quantities attributable for ash wetting at the power
truck loading point are
50 MW 20 MW
Rate gpm 75 325
Annual Use
Gallons 500000 215000
These quantities are included in the quantities shown in
the above referred tables
32389
Page 10
22 We recognize the POTENTIAL for leaching toxic compounds from the
spent ash However this matter is not yet defined well enough to
recommend specific action steps The Prefeasibility Study page
7-12 recommends creation of a ground water dispersion model to
determine whether more specific contaminated water mitigation
plans are needed It is anticipated that the leachate rate will
be low and that aquifer dispersion will keep problem compounds
bel3w health standards thresholds
23 Noted
We have not received up to date resource study material which
defines 50 billion tons resource base Please furnish
The resource base at Sultani alone is adequate to support two 400
MW power projects capacity subject water availability The
2-million cubic metre per year water allowance for oilshale will
limit development to about 600 MW
24 Selection of a combustion temperature is a balance between carbon
combustion efficiency and heat loss due carbonate decomposition
For purposes of the Prefeasibility Study we have opted for high
combustion efficiency At lower efficiency larger shale
mineprocessing plants will be needed
25 Bottom ash is cooled by water exchange before discharge
Cooling water is supplied to the ash screw coolers as specified by
Pyropower See Drawing MOO5 2140 gpm flow for 50 MW and 860 gpm
flow for 20 MW Heat removed by the cooling water from the ash
screw coolers is dissipated to atmosphere via a wet cooling
tower Pyropower should indicate the temperature of the ash
discharged to be 5OOF
32389
Page 11
Initially we had considered using a heat exchanger to cool the ash
and improve the cycle efficiency Considering low cost of fuel
the additional capital costs and the system complexities it was
decided not to employ such heat recovery systems for this project
26 The suggested alternates were looked at briefly and the potential
for wind blown air pollution from the ash disposal areas are too
great to warrant dry disposal unless GO(] and World Bank are
willing to accept such a potential problem Wetting the ash is
tne only practical solution Hopefully some cementation will
occur helping to reduce future leaching potential
27 JEA requirements are noted This is a conceptual study not a
final design Optimal design analysis can be performed during
Phase II
2829
JEA requirements are noted and can be incorporated into the Phase
II design
210 The transformer size is adequate for base load operation A
higher capacity can be considered at the final design stage if the
Client prefers
211 From our experience it does not appear to be economical to
provide additional dry cooling towers to take care of maximum
ambient temperatures which may prevail only for a short period of
time in a year To study this an annual dry bulb temperature
duration curve is required Also adding additional dry cooling
towers will change the plant performance It should also be noted
that the dry cooling towers are very expensive and the size should
be selected carefly considering performance and cost and not on the basis of maximum ambient temperatures This can be studied
during Phase II
32389
Page 12
212 The plant gross output varies with condenser pressure
Condenser
Pressure Design 55 in HgA Annual Ave 35 in HgA
Unit Size MW 20 50 4xlO0 20 50 4xlO0
Gross Output MW 234 593 496 2415 607 TBD
Net Output MW 1975 501 400 205 515 TBD
To be developed in Phase II
Output for 4x100 MW is estimated by others
213 The fan power consumption of the CFB boiler is about 30 to 35 of
the total auxiliary power The fan power consumption of the dry
cooling tower is about 20 to 25 of the total auxiliary power
214 Table 1-1 does not include plant net output Therefore do not
understand the comment
215 Commercial operating experience with coal fueled CFBC units in LISA
and Europe has been uniformly good showing high on stream
availability in early years (See Table 2-6 which reports on
Pyropower experience)
We expect operations with high ash content fuel like oilshale will
have unique scale up problems such as
o Solid handling in and out
o Internal solids circulation
o Erosioncorrosion steam generator intervals
o Heat recovery from bottom ash
Consequently we are recommending these items be worked out in a
single 50 MW prototype
32389
Page 13
216 Maximum dry cooling is used in this study A small wet cooling
tower is used on circulating service water system
217 Horizontal condensate pump is adequate with dry cooling tower and it is cheaper Vertical condensate pumps with cans can be
considered in the final design if required
218 A concrete shell brick lined flue stack will be larger in diameter and costs more than a steel lined stack Brick lined stack can be
considered in the final design
219 Demineralized water tank capacity for 50 MW is 76 cu meters or 20000 gallons not 1000 cu meters For 20 MW plant it is 38 cu
meters or 10000 gallons
220 It is US practice to use an average continuous blowdown rate of
1 and maximum biowdown rate of 3 for this type of plants
221 This can be studied during Phase II
222 Same as 221
223 Same as 221
224 The recommended action plan calls for continuing support studies covering the referenced items Additional effort is needed to
further define these matters and confirm the conceptual plan
The next step is to develop an outline for a project plan including
o Work Scope
o Schedule
o Budget
accommodate the increase in the number of employees and
equipment Truck bays to accommodate the 136 tonne trucks
will be added The truck bays used for the 77 tonne
trucks will be used for the maintenance of other
equipment The warehouse change house training room
offices and cafeteria will be expanded accordingly
6025 Mining and Processing Economics
Details of the oil shale mining and processing plant
economics for the 400 MW plant are included in the Mining
Report (Appendix 5) These details are of the same
magnitude as prepared for the 20 MW and 50 MW plants
The summary of the cash flow analysis for the mine and
shale processing plant is presented in Table 6-1
Table 6-1
SUMMARY OF 400 MW PLANT OIL SHALE MINING AND PROCESSING COSTS
5050 Debt-Equity 8020 Debt-Equity
US $1000 US $1000
Capital Cost
Mine Development 30915 30915
Mine Equipment 66012 66012
Process Plant Facilities 50889 50889
Spare Parts 5000 5000
Working Capital 10000 10000
Capi tal ized Interest
During Construction 24423 39075
TOTAL 187239 201891
Operating Costs and Other Costs
Annual Cost 60386 53236
Product Mined and Processed
Annual Tonnes x 1000 7783 7783
Unit Cost
US $Tonne (weighted average)
US $l06Btu (weighted average) 776
156
684
138
Year 12 costs taken as 25 year average
6-6
-Au
Table 610 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
- FCC plant sizes equivalent to proposed power application
Prefeasibility Study Oil Shale Fueled Power Generation
VOO94GEampJRI26
i
PYROFLOW UNITS IN THE US
COLORADOUTE IOYA STATE UNIV UNIV OFNUCLA CO NORTHERNAMES IA BF GOODRICH110 1o0MW(a) 2x170000 Ibhr HENRYILCEDAR FALLS IA 120000 Ibhr GENERALGULF OILu EiN P MOTORSSbtUpStart-UIL 1987 O A 1I N000 TC
NORT10 PONTIACH B MIRANCHWV00000 lbhr
CORN PRODUCTSSM NORTH-CAROLINA STOCKTOD CA
400000 lbbhl t
RUMF RD ME
CEMENT CO CALIF PORTLAND-COLTON CA
190000 Iblhr Start-Up 1985 TRUMTFTWN NYU
3I75ERTOWN N
etar t-Up loss ACE COGENERATIONCABI
TRONA CA Oper t~on l -Start-UP 1990 ~ rt upz 091Start-up loss Start-up PNeLAI 1991
MTKESFICOENERATIO-N1
BASFIELDp Start-uStar-Up WESTCA9 199otgoUp 1 MAHONEV PA|00000 Ibhr A Oz 2X365000 Ibhr
SETtr-Ups 188B CHAT TANOOGA TN
G ULF OIL EXPLORATION 8ta-rt-u) 1085BAKERSFIELD NORTH BRANCHCA SPRING GROVE PANORTH BRANCH WV 400000 IbhtOperational 19835 5 0 0 I b h 9 0 0 0 Iblh r- tart-Upi 1991 S t r - U p s l e s s
SOUTHEAST PAPER MFG CO UNIVOF NORTH CAROLINArDUBLIN GA UHAPEL HILL NO400000 IbhrStart-Ups logo Start-Ups2X250O000 1loseIbhr B
- Withdrawing ash from combustor - Withdrawing fly ash
a Internal solids circulation of the steam generator
m Erosioncorrosion of steam generatorinternals
Heat recovery from bottom ash
U Operation with low calorific-value fuel
Prefeasblity Study O Shari Fueled Power Generation
VOO7AI 27
Impact of Scale-Up
Project Size
20 MW
50 MW
100 MW
50 MW boiler in 100 MW plant
Potential Risk
Design Scale-upOperation of to 100 MW Initial Plant Plant
Low Significant
Modest Modest
High Low for duplicate units
Modest Low for duplicate units
Prefeasibility Study Oil Shaje Fueled Power Generation
VOO71-4GEAL4n2
i
Conclusions
Defined risk of CFBC boiler is acceptable
U Operating experience with commercial CFBC boilers built and under construction will strengthen confidencelevel and minimize risk for a plant built in 1995
SPrefeasibility Study Oil Shale Fueled Power Generation
V007GHAAE29
ENVIRONMENTAL ASSESSMENT
a Mine and shale processing
- Fugitive dust emissions
- Noise levels
- Leachability of disposal piles
Power plant
- Fugitive dust emissions
- Gaseous emissions
- Noise levels
- Water effluents
U Conclusions
Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel
Prefeasibility Study Oil Shale Fueled Power Generalon
- Coaloil prices will be at least 15 greater after 1995
- Discovery of indigenous conventional fuel resources is inadequate for power plant purposes
Prefeasibility Study
Oil Shale Fueled Power Generation
VOO) IDWFO
Feasibility(Contd)
N Suitable financing will be available
- For $200 million 50 MW prototypeproject
- For $1000 million 400 MW commercial project
Government of Jordan will make basic commitments
- Long-term power purchase agreement
- Long-term access to Sultani shale deposit
Adequate water and manpower resources
- Attractive tax incentives
Prefeasibility Study
Oil Shale Fueled Power Generaion
VO bull1DUJJRO 6
Timeliness
U Timely development of Jordan oil shale needs prompt action to create - Additional definitive information
- Suitable business plan
Prefeasibility Study
Oil Shale Fueled Power Generation
VooI DUJo 7
i
Expansion Conditions
U Continued expansion of powergeneration from oil shale in Jordan depends on water availability
Prospects for power export or importand domestic load growth will affect size of the needed shale-to-power program
Prefeasibility Sudy
Oil Shale Fueled Power Generation
yOWl lVuJO
Environmental Impacts
N Environmental impacts of shale development will be minimal
Prefeasibility Study Oi Shale Fueled Power Generation
i
Development Advantages
Will create significant new jobopportunities in Jordan
Will avoidreduce foreign exchangelosses for expanding alternate fuel imports
Prefeasibility Study
Oil Shale Fueled Power Generation
VOOIIULL tO
Recommended Action Plan
N Basic recommendation
N Conceptual development schedule
U Project development plan
Key plan elements
N Funding requirements
Prefeasibility Study Oil Shale Fueled Power Generation
VOO4II )U OII
i
Basic Recommendation
N Expand efforts to develop an oil shaleshyfueled power generation program at the Sultani deposit
- Conduct required supporting studies
- Define facilities costs and business plans
- Obtain project funding
Prefeasibility Study
Oil Shale Fueled Power Generation
VON I II)ILL 12
C
Conceptual DevelopmentSchedule
1989-1990
- Conduct supporting studies - Define costsbusiness plans for 50
MW prototype and 400 MW commercial projects
- Develop project financing
N 1990-1993 - Build and operate the prototype project
N 1994-1996 - Expand the 50 MW prototype to 100 MW scale
U 1996-2000 - Expand the project to 400 MW scale
N 2000-2005 - Build a second 400 MW commercial project if needed
i 1 Prefeasiblity Study
dOil Shale Fueled Power Generation
VW IMLITO 13
Conceptual Development Plan
Months
1 Project development plan - Define project
costs1busness plans
-24 -12 0 12 24 36 48 60 72 84 96 108 120
2 Secure funding
3 Build and operate 50 MW prototype
Dergn and procurement
Mine development
Plant construction
Startup and testing
Operations
L- -
4 Expand prototype to 100 MW
Design and procurement
bullConstruction
Startup
5 Expand project to 400 MW
2nd 100 MW unit
3rd100 MW unit
i 44
4th 100 MW unit -
O Project dacision point
i Prefeasib~ity Study Oil Shale Fueled Power Generation
17958562aJocdanV 3-14-89 rsO
18
Phase I - ProjectDevelopment Plan
n Program development
Seminar workshop on prefeasibilitystudy Oate project development plan woek scope schedule arid budget
U Carry out project planning program
- Conduct continuing support studies - Test Sultani shale in existing FBC
- Firm up designs and specifications
- Update costs and economic analysis
- Develop business plans and requirements
Explore project funding alternatives
i Prefeasibility Study
Oil Shale Fueled Power Generation
VO MItUOR 14 -0
Key Plan Elements
N Project feasibility analysis
- Firm up designs and equipmentspecifications for all facilities
- Update cost estimates based on preliminary designs and specifications
Explore arrangements for contract mining and mine development
Update forecasts for demand growthand for retirements of older generating capacity
- Create updated economic analysis
Preleasibility StudyO1 Shae Fueled Power Generation
VOO1IOLWRI
Key Plan Elements (Contd)
Business entity requirement
- Explore optionsconditions for a new company to managebuildoperate the project
- Explore optionsconditions for obtaining a concession agreement for Sultani development
Explore optionsconditions for water rights commitment
Prefeasibility Study Oil Shale Fueled Power Generation
VMIOIA)lj 16S
i
Key Plan Elements (Contd)
U Continuing supporting studies
- Combustion tests (additional pilot tests for design and warranty purposes contract for large-scale burn operations in existing plants if appropriate)
- Additional core drilling and core analysis
- Oil shale crushing tests
- Spent ash leaching tests
- Geotechnical data base including soils analysis
- Environmental baseline data
Prefeasibility Study O Shae Fueled Power Generation
VMMMUldMOA
Steps Required to Develop an Oil Shale-to-Power Project
Create a development business plan - Schedule - Decision tree
Develop a work scope and budget for the development plan program including - Firming up designsspecificationscosts
- Developing business entity requirements - Continuing support studies
Carry out development plan program
Assemble all planning results in a report for discussion with financial institutions
Explore project finance opportunities
Finalize business arrangements
Implement prototype project
i Prefeasibility Study
Oil Shale Fueled Power Generation
VM1-11UJROLI
MARCH 15 JEA QUESTIONS (M S ARAFAH) ON PREFEASIBILITY
STUDY DRAFT REPORT
Rt
DIR EScBSULIVAN PHD OFJCEop~BUREAU FOR SCIENCE AND~TECHNOLOGYAGENCY - --FOR INTERNATIONAL DEVELOPMhINTSWASHINGON DC x20523---------4
4 -
-SUBJ E CT - -C O H~ E T 4N l
Dr Mr sullivan ------shy
c-rommnents We ~efr-preaereorPla -tobYou lete dted Jan 91989 regardn~i4po4t P ea e1 f i nd y ubel ow our -e ot r XcOrcerned Jordanian deipartments
- --A ar o~nnYu Y o turjlt~ lt K
4 C~mments
~1 N i gFIN I~fANDECONOMIC1COIMEN S -
It sidicaed that Beohtel and US AIDWash ingtonj~4- re ojy nen ing that E 2hould und ertake the n e tshyihaisAre ~our c leometprogram n order shye-t im~ ate d f n t v design and budget cost
4Al1so Lthe study ncal--ttsutnilndcaei~ A-1 A thas ~ l 1 be eeded idb~~~~~ rn o ei t n i la itheMWa~-~5s~ 4
hrPro hehgemetTh trOfT ses~fnr4 BOT)Vmanu- a n-mnf~cure 4 r~j or contra c4-or ivoIlveiintijn I 4 4investmnt ude smi ~w 2 Zha tev e r --~4~prce e ec r it v p4~ f JA gertiy geeated-at 4 JEA 3 a l b u y ~the same average~~ A
~jithia oncot in4 ordrtan ecpoemic asess thespePower generatjoon J ordan3 oi sha I eroic c inr~etJordan 4
2P ge i1- 1 Aj iit eu that OPin he atocontr~ct 4with owner4 ofext3ing (oconstriiction r(FB rml-t
qu i of S 11 t to test large tonnagen j es StaniUti n d ajIe -for se veralIQf 31 hi
evrEAPreferpilot qr the dP 1prt7n -that the4mPIt
andi to(7 he instalI 1e 2 310 A
_
JODN ELECTRICITYAUTHORIT LL
Dac
operated in Jordan i n or~der~~t ~n nuex~on mnining crushing and haidi igQhre~ and sash Maeia nd aSootoget enough olr ndaita needed for einolre
CEBbole~ -i s~
ccordance with Jordaian oil shale
large to~ bfig
1 3 le 1-2 Page 1-7 Cost Of Pwer~i It i S menti-oned that the conmecial oil hle~ lt~project (4 X1OOmw) 1is ninacompetative roqt~range-~while table 12 indicates thattcost of-pow Ais~mill
q kwiihcii r 1
average wih i ii -much higher ihantheshy-ost of ~Power gnrtofomJEA therimaPower s ta tions Please~ indicate on what basi o ~~ shave-~made your-statement
PK
14 Pae 2 Sction 4-0sIt 1nlkly that theChousing and off- -site infrastructur-ommnity fakilitieR) to be onsidered for both the demo and prototyp prjcs oeoverwe~4 hnk that their~c_6t is raterojects Mo
iwcv~- age -1 1 Mine O(perationIIt is indicate~d that mining cot eevdfoMine contractor~ are ficomiplee h
r and iyudi-t~con qidder contract mnn opio fr4 the min4 cmflt2ng are reIanddrepres~ent the real costs derived from Phspat miin contractors in
lestfor the eo rPooypuat in order tlt7
P I eadenote tha detthe new exchangerate ofthJraian~ Di~nner you may add 20j6 Kto the quoted
1 6 P Ias e consider the followin ecn hage_
171- The new exchange ra teof tUSD=54o0 fils1 72-W2 The new~ aerage tariff for selIn~electricityhas decrreased to 120 8 f ilIsicwh
17- Page 1-7 TbIe 1-2 W bev th tthe cap ita1 cot for the pwhokand forthe min n d ash hMnd1ing equipen
P B~2Anaor a -Tl 8156152 8176 1Q MYf -t -Now 520 t 1U
JDNEECRICIT AU-RA L14lLiL
2 ~are very high We suggest~ thta You rerconsie (- telowerus e~+d accuracy est a rangethan +30
Page4-22 Table 4-5weno0ti ced( that- PyroPowe ha ddeta(IiacCst fori the bo1ilerlocation and terha dutdetlease isxtr fo~ l C~ io~ s~ e~~ 1a~ a if and indicate theonldjusted ~percentagefor construction foin Jordan
19 Page-7 Table 11-2 -Yo aeue ihrinterest rate on Equity thatn on1DehI~laseinclude~ adetaied explanation of thisrr -tni kepin in miUndie JEA is1thaIt a non profit~ shyorgaiztion unik oher private UJSA utility~in ktation
~-~110- Regarding shy
the ra4ital Rt fthe project it is~requesed tobre k it intdo foreignMeanwhile cthe nd lorcal c-osfoeigptario i nt-re3t~shol becnierdo-h
rr n ontiondonnotopdbon the 9 cnieelocal portion~onth
1-1- 237~Pa
oningeny 9tooi s high~~ a lower 4value -should be~
4~ gt ~112- -Tbles t1-1 -8-8~ inclu~de t~he c~alculationscuultie nt enefits for of Th shyunttypes l i4s difeen geeatnmrer likely tocluae
-~ Q~ J7present vk1u for tenet tthe~benefits in feralterntives -t-oa s the
49
ehliyoi shale
Wea gree with you9 tha t th e percentage used ~ an for thenua~l 0 ~amp-M rahr CFBo ndsomewha~t highervrate be n ededma y for a C B l n Me n h l ~ a e r
indir e ta~ts the -estimatedma i variablec st i ddition t he fi-xed-9i 1 mislkih We --
thinktttiis too lowK -5
shy
1-14- e 4-29
opprza tion-o to The o i1s h1 costs-nc I deAbo 1h
Pa10 mman ormTSI62 a
IB I
JORD N EtECTICI1~ 4 E~)~Is-s
Date ib-_
~ ~riii~g~nd~o9~ru~hng h~tnlin cot~u~tv yo
i Dae Jnryit
1ts c 7 4-
i smiig iniand fh co I eY
susendi ca tI t icag th t1 ~an~approximate 15 ~pita L tYII I (-~a~ge or he owe bl ockj f aniitjes isof +the capthe)t~ial7cpi~lrharge Uoratelformny SI~Uj(uiity installa~tions~ whle page 6-1T9 talJshyit is mentioned that~ the Capital rate pe-r JEA isshyi5~PeaseJustify this~matter since~w o
i16- Pae 6-1 6
1 I4~t is mentioned that the costs of 4process Water are ~ 4 ~0 2$1 000 gallons
r~j~lt IHave~You considered additionalvalue ofbying waterfrom~ the Wa ters Aito i ~or ditoa cost~f o revrseoqoesplant if ground water is used
~~ I1 7- Table 6-1 Page 6-6 Please explain how did You come ou ihteoil~ shale miniing and proces~sing uit~Icost
ltII~I~ 8- Please note 1 t hatj the average JEA~productinr ot frmthermal I power stationsr (Istationbus-barCOSt)i sbewen 6 3-17 3 fils 4kwh You may use this~
l4~ 19-i For ~4 X 100~AMW Plat iti etindo pag e14-4 VolI 11 that4 at tota I of W42 14 epoye W II eemplo~yer] And on page 69yo1Iiti mentioned that a~ tot 1 f1 ~p yeI iNbe enp1oyed a
is~ high asrmetitexeds100personorthe ~41X100~MWh~~j nsatnpPrlae
I 1 The 4 following iftemns are a sumed to1 be excluded from theraPi ta 1 cot xoI
120-1 Perits I icen es 7
1_207~3 Imprt ~xe on s7pare par ts -and c(7orfmurab -ma~teria Is
04f4 4
~4 R j4 4
D4
~ ~ ~ AIf eS taxesq in acrac ihteJraand regulations should be considered aw
21- p1ea4s e indic ate Your Ju t f c io r us ga 6
44122- Table 977App 5Page4 9-1 4L IK Car1Yiniae that the hIRR of the 4 Otplantis rather unattractive (66)most
-( Cns1er4 ngthe logical base 4csek c pwhen cii 6OL
average sell~ing prc CkhampDEratio L801~2O~Aoreover4M the ne siellin prcwh o JEA ati theamptime~ Abeing os4ltp n~ot exceed 4 Ckwh~-However Ipage 1shy~ and 14 0 T indicate that ecnms for a commeri
S4A4scale joil 4 shale projc ~
appear Piomisig-nug o4Ywarrant continued dee fgfluht 4 feaibiit 4tudy wihil cost sevea~lili
do ar~sf Plas lear wether the ~x step jqs~$j~~lt 4
gtt 9o be considered arCcording4to jthe 4unattractiveresul to mentioned in IRR7 Table 97 gt4
a C4 44fET2 4 144-4444 P a g 1 T b6 l
htte~We ~ ~ ae~ rqieetfrteX ~ noie ~~ ~ 444 MW un t44 r te4l w w e o p r d i th e w t r n rre u f4m or4444~ the4444 54M4rto y e Pg~A~44EHiveL det ile an l A44
s o awa er c n um t a4r f rofsho in P6Io erT
e ch 2 50 M W aPln wa e d 41004 MW4 1 consumption_____________
ma4~2 k e u p houin~44 p A44 4444444 C O 4ltI4
a nd a sh et in etc 4 2 4 1 -24 P a g e4 2 - 1 A P P 5
4Yo 4_ j1 4 4~h444 N44 44
1gro nd tce t hir fthe w bern coqir mna t efora4e 4X10A M 444444 4 r i n to 4 4 4lo w w ehA 7 n 2 cinCie h rh4 n ttthh1eb -e 4 44t Of3 E4O
ea h n~ ffl 4 4Jl44 4 4444 4giv
6 ig re sofrat4 de in cl ar f w w at5 c hrw pe o
s h b 444 o t h e g nd L 44 h u i n C
r 4ne a4 t44 e L(704 2 4 p ae) 2 - o Au P dn 5ai 7~e r 44 I Y (1t 44a
ve7 rn e qu 1saharvthe y
and n~~~o speci~~~l4 p n l nh i n t x
r ~rA M e d r o t eu n 8 1 wTtl t t h
- c re e N I wo6
~ n n a i n a t d h l7 A PP6 gt
J
S2~3- Page 2-4 ~ ~ It ~is i
that oil eindicated the- sha le r our~ Cesin Jordan are 10 billion tons -The anulp e reere maiy exeed 50 4 billion tons ~
~ 24- 4Page~2 -l1 iujntr We beiv thtCBcmuto~ep i s high and~alSo
~~ ~ -2 ~~ Page 4-1~6 j - shy
Please~~ indicates your procedure to cool the omn ashand atwa icagd-eprtr
A Have you~ considered~ additional he~at exchanger topcool th ash and to imrve h cycleef ficiency
-~2~6 Page 4-16 It s~ indicated that ash from each silo i Amixed19 ~with~fabout 20 waterKb weight to minimize generation of dust~during trnprtto to mine and disposalHave you~ coniidered other 4lternativeto
~ ~eliminate dustiiig -and avoid use ofwat r uring it ransportationi such as~ using closed trucks or closed
of ~fans conUMnPo wihrlaintthe total plant auiir poe osupin 1~21- Table 5_-3 and I ~
Th~~ is- somneere c6ntradiction regardingplnneotpu~t in both am tables 21-~ Tabl~e 1-33
We noticed tha~t yourall9 cacacapac t fatro75 tion ae asdnWe thilt ~that 7capacityshyfacto is tobo high for- an oil shale fired plant duketo lack of existing simila~r ~plants handl~~~firing oil adshale ~K
216~ The study iniae thtawet~coigtower wi11~used Actually a b
dry cooling should be consideda5ini ~HTP S inZ atomnmz so water rnumption4the cycle~ efficiency willbe reducedHenre YO33~reconsider calculating the cyclefficiy
U~~~~~ codnt umconsidered ofhorizontal -aretypethe~ the vertical cian type can alsobeh considered
shy ~ ~ ~ I~~
2~2 Kconcrete shy
shjell stepl fltstack is onidereconcrete shell brick flue Rt c ~s beCaconsidered3V
2-19~- Deminiraized water~ tank3 capacity~ is -76 ui(meterThe recommnended tank cameter- ui tyi 00cbc
220Designconditions Pa~ge (4-74)te5 hat bow 3down percentage splusmn ~fomrpra til re i hou I be 3~)~
PoD Z 2 m a ad~ - e 5 1 2 iJS~ ~ p A f amp ~ ~ y1
4
JO R ECTICITY AUTHORTIT 4L
~ 4
Date~
t etats ttthe quantityof s i S ~1 000Tons ra Sthis tuntity 11- be transporited for severIy --to tu ofI pit a~te torg P KM ra~erm Spower plIatS about 12 midilidoni CUIA(- met ryea
h e ndd mp e he (d u p in i n L
area wil evric power plant6t Please zn1 a te~tiv s tudY for dumping th r~ a enoug
-from the power plantr~~h~
S 2- Please provide deald-ifrat ao etbaaiedrawing hwn TH11 R thaU and~pV ra~te takcing illto o 6it v- consumptionn _uig themrining equipment
alternate~ study 0o Jine operation for 1 shiftday Vand twoshifts day -lt
224- Conceptua~l pflR 1 for mi ing anusdtransportation of oil- shale a 0 dmj of hs f u r therV examinedh iV~sdpatI ho u1d be
orderj to poe~ehicalq and~eoomca1 fesblt of t his operation
SYour are requested te) study and consider all- above - iPoin s at your earliest in rder -to be peete y oiAnimain on March 29-301989 peetdb~o 4 n
S9incerly-You S
WDIRECTORGENERAL -
I~ CCMR WLINTON ~vs
5N
Pa D~t~IoAmmn -Jordtn -Tel 815615 20 Bl76 15 -19j A VINO- AFf TY
MARCH 21 RESPONSE TO JEA QUESTIONS
Bechtel Power Corporation Engineers - Constructors
Fifty Beale Street San Francisco California Mail Address P 0 Box 3965 San Franclco CA 94119
March 21 1989
Mr M S Arafah Director General Jordan Electricity Authority PO Box 2310 Amman Jordan
Subject Jordan Oil Shale Prefeasibility Study
Dear Mr Arafah
Your letter of 15 March 1989 with comments on the Oil Shale to Power Prefeasibility Study draft report has been referred to me for reply
The attached responses to each item in the reference letter follows the order submitted
Also attached are three revised pages for the draft report - Volume I
Page 6-1 Page 6-21 Page 6-23
Please copy these revised pages into the report previously sent to you
We plan to review this material with JEA during the March 2930 and April 1 meetings in Amman
rsuVertrul yours
W Linton Project Manager
WHLdc
Attachments Questionnaire Response Three revised pages
cc C J Aulisio R R Buta G D Gould T J Wilbanks
32389
Page 1
RESPONSE TO MARCH 15 1989 QUESTIONAIRE
OIL SHALE TO POWER PREFEASIBILITY STUDY
This study examines economic prospects in terms of a 1995-2000 timeframe
FIRANCIAL AND ECONOMIC COMMENTS
11 It is likely that a BOT deal can be structured at present JEA
generation costs for either 20 MW or 50 MW size units if GOJ is
willing to subsidize the incremental power generation cost
Furthermore these incremental costs can be recovered during the 25
year operation of a Commercial Scale Project
12 A 3rd Party Test was proposed as an alternate means to raising
$100+ for an independent JEA sponsored 20 MW Demonstration
program
13 71 millsKWH for Shale Power
VS
JEA 1987 costs
Purchased Power 17 filsKWH = 51 mills
Produced Power 1360 filsKWH = 41 mills
19952000 Costs - Expected to be 30 to 40 higher and in line
with the cost estimate presented in this study
It also is important to recognize that the busbar cost of power
generated by any new power source can not be compared directly
with the cost of existing older installed capacity because of the
lower capital cost component of the latter (See enclosed Figure
1-1 which demonstrates how total capital carrying costs decline as
the investment is paid off) Any new capacity whether coal oil
or oil shale will be an unreasonable disadvantage compared with
costs for existing older capacity
l
024
o2
0De return
E 016Total carrying charge
012 qu return
S -008
ety taxes and n rcw vshy000 X 0 5 10 15 20 25
Figure 1-1 Year-by-year Carrying Charge Components for 15-yearTax Recovery Period
1-7
30
32389
Page 2
14 Infrastructure Cost
Total People
OperatorFamilies Installed Cost
20 MW $10000000 185700 $54000Operator
50 MW 15000000 3241200 46000Operator
400 MW 45000000 10364000 43000Operator
Factored allowance for grass roots desert installation
including housing and community facilities was developed as
follows for the 50 MW case study
Infrastructure
50 MW
Family Housing 200 30K = $ 6 Million
Bachelor Housing 100 20K = 2 M
HospitalClinic (8 Beds) 11 M
SchoolMosque I1 M
Stores Services amp Recreation = 2 M
Facilities
Roads Electricity Water Sewage = 3 M
$15 Million
Infrastructure costs for the 20 MW and 400 MW cases was ratioed
from this breakdown
At this conceptual level costs are order-of-magnitude In a Phase
II program these infrastructure costs can be developed in detail
32389
Page 3
15 Contract Mining Alternatives
Page 4-11 Mine Operation
Based on Bechtels evaluation of the mine contractors price as found in Section 15 of the Mining Report it was concluded that
the mine contractors price does not include costs for such things
as developing the mine with a box-cut ramp haul roads
developing an area for the waste material maintaining the
haulroads constructing the mine services facilities diversion
ditches sedimentation ponds water well crushing the oil shale
pre-mixing the oil shale at the mine and other items associated
with operating a mine to support a power plant If it is proven
that the mine contractors price includes cost for the above
mentioned scope of work in additi-n to drill blast load and
haul then the contractors price can be used but in the meantime
the all inclusive cost developed by Bechtel should be used
Contract Mining appears to be attractive for the smaller size
plants but not for the larger commercial scale operation Some
third party must provide the necessary capital for trucks
loading mining machines etc under a contract arrangement
16 Reassessment due to Dinar value change needs further study and can
not be evaluated given present budget limitations If average
labor rate of $300hr still valid then little change involve with
study
If deemed necessary reexamination of project economics can be
done in Phase IIwhen funded
17 Costs in this study are based on recent similar Bechtel experience
on Mount Poso project and on Montana I project The Mount Poso
project is a 50 MW unit firing coal in a Pyropower boiler The
Montana I project is a 35 MW unit firing coal in a Keeler Dorr
Oliver FBC boiler utilizing dry cooling
32389
Page 4
18 The Pyropower quote of $186000000 to futnish and erect the steam
generator stack and baghouse has been adjusted to include
engineering construction indirect cost etc to be consistant
with the rest of the costs shown in Table 65 p 6-10 No
further adjustment for location was made
19 Equity funding has the lowest priority of payoff in case of a
liquidation and carries greater risk Hence a higher rate of
return is needed to attract these funds Debt funding is a first
mortgage and has first priority for payoff in case of liquidation
and carries less risk Hence it requires lower rate of return
than equity funding
The risk taking equity owner will ask for greater interest rate
to make funds available The only way to minimize this expense is
to find a loaning agency willing to provide 90 or perhaps 95 of
the investment cost It is likely that banks will require some
minimum equity participation
This Prefeasibility Study was not based on a non-profit utility
operation
Even though JEA is a non-profit organization its service
contributors are profit making groups It is visualized that the
Jordan Oil Shale Co (JOSCO) will be a stand alone business
enterprise servicing JEA under long term contract To secure
funding for the proposed project JOSCO will need attractive
enough contract terms to attract both equity and debt capital
110 Additional work is needed to develop the requested information
This work can be preformed as part of the Phase II program
111 Bechtel includes contingency in all of its estimates to cover
error emissions and unforeseen items within the defined scope of
the project The level of contingency is dependent upon the
amount of scope definition For a prefeasible study such as this
15 contingency is lower than normal
32389
Page 5
112 Tables 89 through 816 include a present value calculation to
establish the relative benefit for a shale project vs coal and
oil
113 The variable maintenance cost of 1 millsKWH has been adjusted for CFB plants with an additional $200000 per year or 06 millsKWH
This yields the following
Variable Maintenance - 10 millsKWH
CFB Adjustment - 06
Fixed Maintenance Cost - 40
Total Cost 56 MillsKWH
114 Page 4-29
The royalty costs are included in the weighted average oil shale
costs for the 50 megawatt plant
Page 4-8
Shale fuel costs include return on equity and royalty These are
two separate cost items Royalty is the last item mentioned in
the sentence and it therefore reads as royalty and not return on
royalty
Page 4-31 gives rates used by Bechtel based on our calculations
using the referenced procedures
DebtEquity Capital Charge Rate
5050 153
8020 139
Table 69 displays the calculation of the 153 capital charge
rate (Line 7 of Table 69 is not used in the calculation and
should be deleted)
32389
Page 6
116 No water purchase charge from the Water Authority was added to the
operating expense based on the statement that no resource costs
will be charged
$020 per 1000 gallons is rule of thumb for USA installations in
absence of client data
Boiler make up water (p4-17) is treated in a demineralizer
train If deemed necessary comparison with reverse osmosis
process can be performed in Phase II
Water requirements were estimated to be
Cubic Metres Per Year
20 MW 50 MW 400 MW
Mine amp Shale Processing 455000 761000 773000
Power Block 3000 6000 42000
Infrastructure 80000 140000 448000
Total 538000 907000 1263000
117 Annual average operating costs shown on Table 6-1 are in error
Financing Option 5050 8020
Cost Shown 56606 48945
Corrected Cost 60396 53236
Average mining and shale processing costs are developed year by
year in the Mining Report Appendix 5 Table 12-10
32389
Page 7
118 We would be interested in receiving the breakdown of these current
power cost figures (ie capital charges fuel cost number of
operators etc) Further economic analysis employing these
figures can be developed in Phase II
119 Manpower requirements for the three case studies were estimated as
fol lows
Mining amp Shale Processing
Power Block
Operations
Maintenance
Management
20 MW 50 MW 400 MW
75 163 396
54 78 175
46 73 455
10 10 10
185 324 1036
Page 14-4 of the Mine Report is for mine and shale processing
only It should be noted that most of these manpower requirements
involved new jobs for Jordanian people
120 At the April 1988 Amman Meeting it was agreed that the following
costs would be omitted
o Permits and Licenses
o Local Taxes
o Import Taxes
If necessary such costs can be developed and added into a revised
economic analysis as part of the Phase II program
121 6 average inflation rate is the figure recommended by Bechtel
based on USA conditions for use in long term economic analyses of
new power ventures
32389
Page 8
122 This matter is referred to ORNL who prepared a rate of return
analysis
Bechtels conclusion is based on computed busbar costscumulative
benefits compared to alternate fuels in the timeframe 1995 to 2000
Relative Busbar Power Cost Net 25 Year
Mills per KWH Benefits - Million US$
Sultani Oil Shale 71-83 Base Cost
Imported Coal
$50tonne 68-88 778
$70tonne 78-107 2531
Imported Oil
$17Bbl 56-76 (18) $24Bbl 61-96 1810
The above results are based on a capacity factor of 75 which is
considered to be a reasonable target for a new plant over its 25 year
life The average selling price of 6 cents per KWH cited in the
questionnaire is based on existing plant costs which may not include
all cost elements of new capacity evaluated in this study
32389
Page 9
TECHNICAL COMMENTS
21 See answer to Item 116
Total power plant raw wate consumption rates and annual
consumptions including the water requirements for wetting ash at the truck loading p int within the power plant are given in Tables 43 and 44 for 50 MW unit and Tables 53 and 54 for 20 MW unit
The raw water requirements for 4x0 MW plant were factored
excepting the mine where a revised mine pldn is employed to reduce water request The quantities shown on these tables exclude raw
water requirements for housing complex mine and ash wetting if
required at the ash disposal site
Total power plant requirements shown in the above referred tables
are
50 MW 20 MW
Rate gpm 207 102 (See Drawing M004)
Annual Use
Gallons 1400000 675000
Cooling tower blowndown supplemented with raw water is used for
wetting ash at the truck loading point within the power plant Raw water quantities attributable for ash wetting at the power
truck loading point are
50 MW 20 MW
Rate gpm 75 325
Annual Use
Gallons 500000 215000
These quantities are included in the quantities shown in
the above referred tables
32389
Page 10
22 We recognize the POTENTIAL for leaching toxic compounds from the
spent ash However this matter is not yet defined well enough to
recommend specific action steps The Prefeasibility Study page
7-12 recommends creation of a ground water dispersion model to
determine whether more specific contaminated water mitigation
plans are needed It is anticipated that the leachate rate will
be low and that aquifer dispersion will keep problem compounds
bel3w health standards thresholds
23 Noted
We have not received up to date resource study material which
defines 50 billion tons resource base Please furnish
The resource base at Sultani alone is adequate to support two 400
MW power projects capacity subject water availability The
2-million cubic metre per year water allowance for oilshale will
limit development to about 600 MW
24 Selection of a combustion temperature is a balance between carbon
combustion efficiency and heat loss due carbonate decomposition
For purposes of the Prefeasibility Study we have opted for high
combustion efficiency At lower efficiency larger shale
mineprocessing plants will be needed
25 Bottom ash is cooled by water exchange before discharge
Cooling water is supplied to the ash screw coolers as specified by
Pyropower See Drawing MOO5 2140 gpm flow for 50 MW and 860 gpm
flow for 20 MW Heat removed by the cooling water from the ash
screw coolers is dissipated to atmosphere via a wet cooling
tower Pyropower should indicate the temperature of the ash
discharged to be 5OOF
32389
Page 11
Initially we had considered using a heat exchanger to cool the ash
and improve the cycle efficiency Considering low cost of fuel
the additional capital costs and the system complexities it was
decided not to employ such heat recovery systems for this project
26 The suggested alternates were looked at briefly and the potential
for wind blown air pollution from the ash disposal areas are too
great to warrant dry disposal unless GO(] and World Bank are
willing to accept such a potential problem Wetting the ash is
tne only practical solution Hopefully some cementation will
occur helping to reduce future leaching potential
27 JEA requirements are noted This is a conceptual study not a
final design Optimal design analysis can be performed during
Phase II
2829
JEA requirements are noted and can be incorporated into the Phase
II design
210 The transformer size is adequate for base load operation A
higher capacity can be considered at the final design stage if the
Client prefers
211 From our experience it does not appear to be economical to
provide additional dry cooling towers to take care of maximum
ambient temperatures which may prevail only for a short period of
time in a year To study this an annual dry bulb temperature
duration curve is required Also adding additional dry cooling
towers will change the plant performance It should also be noted
that the dry cooling towers are very expensive and the size should
be selected carefly considering performance and cost and not on the basis of maximum ambient temperatures This can be studied
during Phase II
32389
Page 12
212 The plant gross output varies with condenser pressure
Condenser
Pressure Design 55 in HgA Annual Ave 35 in HgA
Unit Size MW 20 50 4xlO0 20 50 4xlO0
Gross Output MW 234 593 496 2415 607 TBD
Net Output MW 1975 501 400 205 515 TBD
To be developed in Phase II
Output for 4x100 MW is estimated by others
213 The fan power consumption of the CFB boiler is about 30 to 35 of
the total auxiliary power The fan power consumption of the dry
cooling tower is about 20 to 25 of the total auxiliary power
214 Table 1-1 does not include plant net output Therefore do not
understand the comment
215 Commercial operating experience with coal fueled CFBC units in LISA
and Europe has been uniformly good showing high on stream
availability in early years (See Table 2-6 which reports on
Pyropower experience)
We expect operations with high ash content fuel like oilshale will
have unique scale up problems such as
o Solid handling in and out
o Internal solids circulation
o Erosioncorrosion steam generator intervals
o Heat recovery from bottom ash
Consequently we are recommending these items be worked out in a
single 50 MW prototype
32389
Page 13
216 Maximum dry cooling is used in this study A small wet cooling
tower is used on circulating service water system
217 Horizontal condensate pump is adequate with dry cooling tower and it is cheaper Vertical condensate pumps with cans can be
considered in the final design if required
218 A concrete shell brick lined flue stack will be larger in diameter and costs more than a steel lined stack Brick lined stack can be
considered in the final design
219 Demineralized water tank capacity for 50 MW is 76 cu meters or 20000 gallons not 1000 cu meters For 20 MW plant it is 38 cu
meters or 10000 gallons
220 It is US practice to use an average continuous blowdown rate of
1 and maximum biowdown rate of 3 for this type of plants
221 This can be studied during Phase II
222 Same as 221
223 Same as 221
224 The recommended action plan calls for continuing support studies covering the referenced items Additional effort is needed to
further define these matters and confirm the conceptual plan
The next step is to develop an outline for a project plan including
o Work Scope
o Schedule
o Budget
accommodate the increase in the number of employees and
equipment Truck bays to accommodate the 136 tonne trucks
will be added The truck bays used for the 77 tonne
trucks will be used for the maintenance of other
equipment The warehouse change house training room
offices and cafeteria will be expanded accordingly
6025 Mining and Processing Economics
Details of the oil shale mining and processing plant
economics for the 400 MW plant are included in the Mining
Report (Appendix 5) These details are of the same
magnitude as prepared for the 20 MW and 50 MW plants
The summary of the cash flow analysis for the mine and
shale processing plant is presented in Table 6-1
Table 6-1
SUMMARY OF 400 MW PLANT OIL SHALE MINING AND PROCESSING COSTS
5050 Debt-Equity 8020 Debt-Equity
US $1000 US $1000
Capital Cost
Mine Development 30915 30915
Mine Equipment 66012 66012
Process Plant Facilities 50889 50889
Spare Parts 5000 5000
Working Capital 10000 10000
Capi tal ized Interest
During Construction 24423 39075
TOTAL 187239 201891
Operating Costs and Other Costs
Annual Cost 60386 53236
Product Mined and Processed
Annual Tonnes x 1000 7783 7783
Unit Cost
US $Tonne (weighted average)
US $l06Btu (weighted average) 776
156
684
138
Year 12 costs taken as 25 year average
6-6
-Au
Table 610 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
- FCC plant sizes equivalent to proposed power application
Prefeasibility Study Oil Shale Fueled Power Generation
VOO94GEampJRI26
i
PYROFLOW UNITS IN THE US
COLORADOUTE IOYA STATE UNIV UNIV OFNUCLA CO NORTHERNAMES IA BF GOODRICH110 1o0MW(a) 2x170000 Ibhr HENRYILCEDAR FALLS IA 120000 Ibhr GENERALGULF OILu EiN P MOTORSSbtUpStart-UIL 1987 O A 1I N000 TC
NORT10 PONTIACH B MIRANCHWV00000 lbhr
CORN PRODUCTSSM NORTH-CAROLINA STOCKTOD CA
400000 lbbhl t
RUMF RD ME
CEMENT CO CALIF PORTLAND-COLTON CA
190000 Iblhr Start-Up 1985 TRUMTFTWN NYU
3I75ERTOWN N
etar t-Up loss ACE COGENERATIONCABI
TRONA CA Oper t~on l -Start-UP 1990 ~ rt upz 091Start-up loss Start-up PNeLAI 1991
MTKESFICOENERATIO-N1
BASFIELDp Start-uStar-Up WESTCA9 199otgoUp 1 MAHONEV PA|00000 Ibhr A Oz 2X365000 Ibhr
SETtr-Ups 188B CHAT TANOOGA TN
G ULF OIL EXPLORATION 8ta-rt-u) 1085BAKERSFIELD NORTH BRANCHCA SPRING GROVE PANORTH BRANCH WV 400000 IbhtOperational 19835 5 0 0 I b h 9 0 0 0 Iblh r- tart-Upi 1991 S t r - U p s l e s s
SOUTHEAST PAPER MFG CO UNIVOF NORTH CAROLINArDUBLIN GA UHAPEL HILL NO400000 IbhrStart-Ups logo Start-Ups2X250O000 1loseIbhr B
- Withdrawing ash from combustor - Withdrawing fly ash
a Internal solids circulation of the steam generator
m Erosioncorrosion of steam generatorinternals
Heat recovery from bottom ash
U Operation with low calorific-value fuel
Prefeasblity Study O Shari Fueled Power Generation
VOO7AI 27
Impact of Scale-Up
Project Size
20 MW
50 MW
100 MW
50 MW boiler in 100 MW plant
Potential Risk
Design Scale-upOperation of to 100 MW Initial Plant Plant
Low Significant
Modest Modest
High Low for duplicate units
Modest Low for duplicate units
Prefeasibility Study Oil Shaje Fueled Power Generation
VOO71-4GEAL4n2
i
Conclusions
Defined risk of CFBC boiler is acceptable
U Operating experience with commercial CFBC boilers built and under construction will strengthen confidencelevel and minimize risk for a plant built in 1995
SPrefeasibility Study Oil Shale Fueled Power Generation
V007GHAAE29
ENVIRONMENTAL ASSESSMENT
a Mine and shale processing
- Fugitive dust emissions
- Noise levels
- Leachability of disposal piles
Power plant
- Fugitive dust emissions
- Gaseous emissions
- Noise levels
- Water effluents
U Conclusions
Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel
Prefeasibility Study Oil Shale Fueled Power Generalon
- Coaloil prices will be at least 15 greater after 1995
- Discovery of indigenous conventional fuel resources is inadequate for power plant purposes
Prefeasibility Study
Oil Shale Fueled Power Generation
VOO) IDWFO
Feasibility(Contd)
N Suitable financing will be available
- For $200 million 50 MW prototypeproject
- For $1000 million 400 MW commercial project
Government of Jordan will make basic commitments
- Long-term power purchase agreement
- Long-term access to Sultani shale deposit
Adequate water and manpower resources
- Attractive tax incentives
Prefeasibility Study
Oil Shale Fueled Power Generaion
VO bull1DUJJRO 6
Timeliness
U Timely development of Jordan oil shale needs prompt action to create - Additional definitive information
- Suitable business plan
Prefeasibility Study
Oil Shale Fueled Power Generation
VooI DUJo 7
i
Expansion Conditions
U Continued expansion of powergeneration from oil shale in Jordan depends on water availability
Prospects for power export or importand domestic load growth will affect size of the needed shale-to-power program
Prefeasibility Sudy
Oil Shale Fueled Power Generation
yOWl lVuJO
Environmental Impacts
N Environmental impacts of shale development will be minimal
Prefeasibility Study Oi Shale Fueled Power Generation
i
Development Advantages
Will create significant new jobopportunities in Jordan
Will avoidreduce foreign exchangelosses for expanding alternate fuel imports
Prefeasibility Study
Oil Shale Fueled Power Generation
VOOIIULL tO
Recommended Action Plan
N Basic recommendation
N Conceptual development schedule
U Project development plan
Key plan elements
N Funding requirements
Prefeasibility Study Oil Shale Fueled Power Generation
VOO4II )U OII
i
Basic Recommendation
N Expand efforts to develop an oil shaleshyfueled power generation program at the Sultani deposit
- Conduct required supporting studies
- Define facilities costs and business plans
- Obtain project funding
Prefeasibility Study
Oil Shale Fueled Power Generation
VON I II)ILL 12
C
Conceptual DevelopmentSchedule
1989-1990
- Conduct supporting studies - Define costsbusiness plans for 50
MW prototype and 400 MW commercial projects
- Develop project financing
N 1990-1993 - Build and operate the prototype project
N 1994-1996 - Expand the 50 MW prototype to 100 MW scale
U 1996-2000 - Expand the project to 400 MW scale
N 2000-2005 - Build a second 400 MW commercial project if needed
i 1 Prefeasiblity Study
dOil Shale Fueled Power Generation
VW IMLITO 13
Conceptual Development Plan
Months
1 Project development plan - Define project
costs1busness plans
-24 -12 0 12 24 36 48 60 72 84 96 108 120
2 Secure funding
3 Build and operate 50 MW prototype
Dergn and procurement
Mine development
Plant construction
Startup and testing
Operations
L- -
4 Expand prototype to 100 MW
Design and procurement
bullConstruction
Startup
5 Expand project to 400 MW
2nd 100 MW unit
3rd100 MW unit
i 44
4th 100 MW unit -
O Project dacision point
i Prefeasib~ity Study Oil Shale Fueled Power Generation
17958562aJocdanV 3-14-89 rsO
18
Phase I - ProjectDevelopment Plan
n Program development
Seminar workshop on prefeasibilitystudy Oate project development plan woek scope schedule arid budget
U Carry out project planning program
- Conduct continuing support studies - Test Sultani shale in existing FBC
- Firm up designs and specifications
- Update costs and economic analysis
- Develop business plans and requirements
Explore project funding alternatives
i Prefeasibility Study
Oil Shale Fueled Power Generation
VO MItUOR 14 -0
Key Plan Elements
N Project feasibility analysis
- Firm up designs and equipmentspecifications for all facilities
- Update cost estimates based on preliminary designs and specifications
Explore arrangements for contract mining and mine development
Update forecasts for demand growthand for retirements of older generating capacity
- Create updated economic analysis
Preleasibility StudyO1 Shae Fueled Power Generation
VOO1IOLWRI
Key Plan Elements (Contd)
Business entity requirement
- Explore optionsconditions for a new company to managebuildoperate the project
- Explore optionsconditions for obtaining a concession agreement for Sultani development
Explore optionsconditions for water rights commitment
Prefeasibility Study Oil Shale Fueled Power Generation
VMIOIA)lj 16S
i
Key Plan Elements (Contd)
U Continuing supporting studies
- Combustion tests (additional pilot tests for design and warranty purposes contract for large-scale burn operations in existing plants if appropriate)
- Additional core drilling and core analysis
- Oil shale crushing tests
- Spent ash leaching tests
- Geotechnical data base including soils analysis
- Environmental baseline data
Prefeasibility Study O Shae Fueled Power Generation
VMMMUldMOA
Steps Required to Develop an Oil Shale-to-Power Project
Create a development business plan - Schedule - Decision tree
Develop a work scope and budget for the development plan program including - Firming up designsspecificationscosts
- Developing business entity requirements - Continuing support studies
Carry out development plan program
Assemble all planning results in a report for discussion with financial institutions
Explore project finance opportunities
Finalize business arrangements
Implement prototype project
i Prefeasibility Study
Oil Shale Fueled Power Generation
VM1-11UJROLI
MARCH 15 JEA QUESTIONS (M S ARAFAH) ON PREFEASIBILITY
STUDY DRAFT REPORT
Rt
DIR EScBSULIVAN PHD OFJCEop~BUREAU FOR SCIENCE AND~TECHNOLOGYAGENCY - --FOR INTERNATIONAL DEVELOPMhINTSWASHINGON DC x20523---------4
4 -
-SUBJ E CT - -C O H~ E T 4N l
Dr Mr sullivan ------shy
c-rommnents We ~efr-preaereorPla -tobYou lete dted Jan 91989 regardn~i4po4t P ea e1 f i nd y ubel ow our -e ot r XcOrcerned Jordanian deipartments
- --A ar o~nnYu Y o turjlt~ lt K
4 C~mments
~1 N i gFIN I~fANDECONOMIC1COIMEN S -
It sidicaed that Beohtel and US AIDWash ingtonj~4- re ojy nen ing that E 2hould und ertake the n e tshyihaisAre ~our c leometprogram n order shye-t im~ ate d f n t v design and budget cost
4Al1so Lthe study ncal--ttsutnilndcaei~ A-1 A thas ~ l 1 be eeded idb~~~~~ rn o ei t n i la itheMWa~-~5s~ 4
hrPro hehgemetTh trOfT ses~fnr4 BOT)Vmanu- a n-mnf~cure 4 r~j or contra c4-or ivoIlveiintijn I 4 4investmnt ude smi ~w 2 Zha tev e r --~4~prce e ec r it v p4~ f JA gertiy geeated-at 4 JEA 3 a l b u y ~the same average~~ A
~jithia oncot in4 ordrtan ecpoemic asess thespePower generatjoon J ordan3 oi sha I eroic c inr~etJordan 4
2P ge i1- 1 Aj iit eu that OPin he atocontr~ct 4with owner4 ofext3ing (oconstriiction r(FB rml-t
qu i of S 11 t to test large tonnagen j es StaniUti n d ajIe -for se veralIQf 31 hi
evrEAPreferpilot qr the dP 1prt7n -that the4mPIt
andi to(7 he instalI 1e 2 310 A
_
JODN ELECTRICITYAUTHORIT LL
Dac
operated in Jordan i n or~der~~t ~n nuex~on mnining crushing and haidi igQhre~ and sash Maeia nd aSootoget enough olr ndaita needed for einolre
CEBbole~ -i s~
ccordance with Jordaian oil shale
large to~ bfig
1 3 le 1-2 Page 1-7 Cost Of Pwer~i It i S menti-oned that the conmecial oil hle~ lt~project (4 X1OOmw) 1is ninacompetative roqt~range-~while table 12 indicates thattcost of-pow Ais~mill
q kwiihcii r 1
average wih i ii -much higher ihantheshy-ost of ~Power gnrtofomJEA therimaPower s ta tions Please~ indicate on what basi o ~~ shave-~made your-statement
PK
14 Pae 2 Sction 4-0sIt 1nlkly that theChousing and off- -site infrastructur-ommnity fakilitieR) to be onsidered for both the demo and prototyp prjcs oeoverwe~4 hnk that their~c_6t is raterojects Mo
iwcv~- age -1 1 Mine O(perationIIt is indicate~d that mining cot eevdfoMine contractor~ are ficomiplee h
r and iyudi-t~con qidder contract mnn opio fr4 the min4 cmflt2ng are reIanddrepres~ent the real costs derived from Phspat miin contractors in
lestfor the eo rPooypuat in order tlt7
P I eadenote tha detthe new exchangerate ofthJraian~ Di~nner you may add 20j6 Kto the quoted
1 6 P Ias e consider the followin ecn hage_
171- The new exchange ra teof tUSD=54o0 fils1 72-W2 The new~ aerage tariff for selIn~electricityhas decrreased to 120 8 f ilIsicwh
17- Page 1-7 TbIe 1-2 W bev th tthe cap ita1 cot for the pwhokand forthe min n d ash hMnd1ing equipen
P B~2Anaor a -Tl 8156152 8176 1Q MYf -t -Now 520 t 1U
JDNEECRICIT AU-RA L14lLiL
2 ~are very high We suggest~ thta You rerconsie (- telowerus e~+d accuracy est a rangethan +30
Page4-22 Table 4-5weno0ti ced( that- PyroPowe ha ddeta(IiacCst fori the bo1ilerlocation and terha dutdetlease isxtr fo~ l C~ io~ s~ e~~ 1a~ a if and indicate theonldjusted ~percentagefor construction foin Jordan
19 Page-7 Table 11-2 -Yo aeue ihrinterest rate on Equity thatn on1DehI~laseinclude~ adetaied explanation of thisrr -tni kepin in miUndie JEA is1thaIt a non profit~ shyorgaiztion unik oher private UJSA utility~in ktation
~-~110- Regarding shy
the ra4ital Rt fthe project it is~requesed tobre k it intdo foreignMeanwhile cthe nd lorcal c-osfoeigptario i nt-re3t~shol becnierdo-h
rr n ontiondonnotopdbon the 9 cnieelocal portion~onth
1-1- 237~Pa
oningeny 9tooi s high~~ a lower 4value -should be~
4~ gt ~112- -Tbles t1-1 -8-8~ inclu~de t~he c~alculationscuultie nt enefits for of Th shyunttypes l i4s difeen geeatnmrer likely tocluae
-~ Q~ J7present vk1u for tenet tthe~benefits in feralterntives -t-oa s the
49
ehliyoi shale
Wea gree with you9 tha t th e percentage used ~ an for thenua~l 0 ~amp-M rahr CFBo ndsomewha~t highervrate be n ededma y for a C B l n Me n h l ~ a e r
indir e ta~ts the -estimatedma i variablec st i ddition t he fi-xed-9i 1 mislkih We --
thinktttiis too lowK -5
shy
1-14- e 4-29
opprza tion-o to The o i1s h1 costs-nc I deAbo 1h
Pa10 mman ormTSI62 a
IB I
JORD N EtECTICI1~ 4 E~)~Is-s
Date ib-_
~ ~riii~g~nd~o9~ru~hng h~tnlin cot~u~tv yo
i Dae Jnryit
1ts c 7 4-
i smiig iniand fh co I eY
susendi ca tI t icag th t1 ~an~approximate 15 ~pita L tYII I (-~a~ge or he owe bl ockj f aniitjes isof +the capthe)t~ial7cpi~lrharge Uoratelformny SI~Uj(uiity installa~tions~ whle page 6-1T9 talJshyit is mentioned that~ the Capital rate pe-r JEA isshyi5~PeaseJustify this~matter since~w o
i16- Pae 6-1 6
1 I4~t is mentioned that the costs of 4process Water are ~ 4 ~0 2$1 000 gallons
r~j~lt IHave~You considered additionalvalue ofbying waterfrom~ the Wa ters Aito i ~or ditoa cost~f o revrseoqoesplant if ground water is used
~~ I1 7- Table 6-1 Page 6-6 Please explain how did You come ou ihteoil~ shale miniing and proces~sing uit~Icost
ltII~I~ 8- Please note 1 t hatj the average JEA~productinr ot frmthermal I power stationsr (Istationbus-barCOSt)i sbewen 6 3-17 3 fils 4kwh You may use this~
l4~ 19-i For ~4 X 100~AMW Plat iti etindo pag e14-4 VolI 11 that4 at tota I of W42 14 epoye W II eemplo~yer] And on page 69yo1Iiti mentioned that a~ tot 1 f1 ~p yeI iNbe enp1oyed a
is~ high asrmetitexeds100personorthe ~41X100~MWh~~j nsatnpPrlae
I 1 The 4 following iftemns are a sumed to1 be excluded from theraPi ta 1 cot xoI
120-1 Perits I icen es 7
1_207~3 Imprt ~xe on s7pare par ts -and c(7orfmurab -ma~teria Is
04f4 4
~4 R j4 4
D4
~ ~ ~ AIf eS taxesq in acrac ihteJraand regulations should be considered aw
21- p1ea4s e indic ate Your Ju t f c io r us ga 6
44122- Table 977App 5Page4 9-1 4L IK Car1Yiniae that the hIRR of the 4 Otplantis rather unattractive (66)most
-( Cns1er4 ngthe logical base 4csek c pwhen cii 6OL
average sell~ing prc CkhampDEratio L801~2O~Aoreover4M the ne siellin prcwh o JEA ati theamptime~ Abeing os4ltp n~ot exceed 4 Ckwh~-However Ipage 1shy~ and 14 0 T indicate that ecnms for a commeri
S4A4scale joil 4 shale projc ~
appear Piomisig-nug o4Ywarrant continued dee fgfluht 4 feaibiit 4tudy wihil cost sevea~lili
do ar~sf Plas lear wether the ~x step jqs~$j~~lt 4
gtt 9o be considered arCcording4to jthe 4unattractiveresul to mentioned in IRR7 Table 97 gt4
a C4 44fET2 4 144-4444 P a g 1 T b6 l
htte~We ~ ~ ae~ rqieetfrteX ~ noie ~~ ~ 444 MW un t44 r te4l w w e o p r d i th e w t r n rre u f4m or4444~ the4444 54M4rto y e Pg~A~44EHiveL det ile an l A44
s o awa er c n um t a4r f rofsho in P6Io erT
e ch 2 50 M W aPln wa e d 41004 MW4 1 consumption_____________
ma4~2 k e u p houin~44 p A44 4444444 C O 4ltI4
a nd a sh et in etc 4 2 4 1 -24 P a g e4 2 - 1 A P P 5
4Yo 4_ j1 4 4~h444 N44 44
1gro nd tce t hir fthe w bern coqir mna t efora4e 4X10A M 444444 4 r i n to 4 4 4lo w w ehA 7 n 2 cinCie h rh4 n ttthh1eb -e 4 44t Of3 E4O
ea h n~ ffl 4 4Jl44 4 4444 4giv
6 ig re sofrat4 de in cl ar f w w at5 c hrw pe o
s h b 444 o t h e g nd L 44 h u i n C
r 4ne a4 t44 e L(704 2 4 p ae) 2 - o Au P dn 5ai 7~e r 44 I Y (1t 44a
ve7 rn e qu 1saharvthe y
and n~~~o speci~~~l4 p n l nh i n t x
r ~rA M e d r o t eu n 8 1 wTtl t t h
- c re e N I wo6
~ n n a i n a t d h l7 A PP6 gt
J
S2~3- Page 2-4 ~ ~ It ~is i
that oil eindicated the- sha le r our~ Cesin Jordan are 10 billion tons -The anulp e reere maiy exeed 50 4 billion tons ~
~ 24- 4Page~2 -l1 iujntr We beiv thtCBcmuto~ep i s high and~alSo
~~ ~ -2 ~~ Page 4-1~6 j - shy
Please~~ indicates your procedure to cool the omn ashand atwa icagd-eprtr
A Have you~ considered~ additional he~at exchanger topcool th ash and to imrve h cycleef ficiency
-~2~6 Page 4-16 It s~ indicated that ash from each silo i Amixed19 ~with~fabout 20 waterKb weight to minimize generation of dust~during trnprtto to mine and disposalHave you~ coniidered other 4lternativeto
~ ~eliminate dustiiig -and avoid use ofwat r uring it ransportationi such as~ using closed trucks or closed
of ~fans conUMnPo wihrlaintthe total plant auiir poe osupin 1~21- Table 5_-3 and I ~
Th~~ is- somneere c6ntradiction regardingplnneotpu~t in both am tables 21-~ Tabl~e 1-33
We noticed tha~t yourall9 cacacapac t fatro75 tion ae asdnWe thilt ~that 7capacityshyfacto is tobo high for- an oil shale fired plant duketo lack of existing simila~r ~plants handl~~~firing oil adshale ~K
216~ The study iniae thtawet~coigtower wi11~used Actually a b
dry cooling should be consideda5ini ~HTP S inZ atomnmz so water rnumption4the cycle~ efficiency willbe reducedHenre YO33~reconsider calculating the cyclefficiy
U~~~~~ codnt umconsidered ofhorizontal -aretypethe~ the vertical cian type can alsobeh considered
shy ~ ~ ~ I~~
2~2 Kconcrete shy
shjell stepl fltstack is onidereconcrete shell brick flue Rt c ~s beCaconsidered3V
2-19~- Deminiraized water~ tank3 capacity~ is -76 ui(meterThe recommnended tank cameter- ui tyi 00cbc
220Designconditions Pa~ge (4-74)te5 hat bow 3down percentage splusmn ~fomrpra til re i hou I be 3~)~
PoD Z 2 m a ad~ - e 5 1 2 iJS~ ~ p A f amp ~ ~ y1
4
JO R ECTICITY AUTHORTIT 4L
~ 4
Date~
t etats ttthe quantityof s i S ~1 000Tons ra Sthis tuntity 11- be transporited for severIy --to tu ofI pit a~te torg P KM ra~erm Spower plIatS about 12 midilidoni CUIA(- met ryea
h e ndd mp e he (d u p in i n L
area wil evric power plant6t Please zn1 a te~tiv s tudY for dumping th r~ a enoug
-from the power plantr~~h~
S 2- Please provide deald-ifrat ao etbaaiedrawing hwn TH11 R thaU and~pV ra~te takcing illto o 6it v- consumptionn _uig themrining equipment
alternate~ study 0o Jine operation for 1 shiftday Vand twoshifts day -lt
224- Conceptua~l pflR 1 for mi ing anusdtransportation of oil- shale a 0 dmj of hs f u r therV examinedh iV~sdpatI ho u1d be
orderj to poe~ehicalq and~eoomca1 fesblt of t his operation
SYour are requested te) study and consider all- above - iPoin s at your earliest in rder -to be peete y oiAnimain on March 29-301989 peetdb~o 4 n
S9incerly-You S
WDIRECTORGENERAL -
I~ CCMR WLINTON ~vs
5N
Pa D~t~IoAmmn -Jordtn -Tel 815615 20 Bl76 15 -19j A VINO- AFf TY
MARCH 21 RESPONSE TO JEA QUESTIONS
Bechtel Power Corporation Engineers - Constructors
Fifty Beale Street San Francisco California Mail Address P 0 Box 3965 San Franclco CA 94119
March 21 1989
Mr M S Arafah Director General Jordan Electricity Authority PO Box 2310 Amman Jordan
Subject Jordan Oil Shale Prefeasibility Study
Dear Mr Arafah
Your letter of 15 March 1989 with comments on the Oil Shale to Power Prefeasibility Study draft report has been referred to me for reply
The attached responses to each item in the reference letter follows the order submitted
Also attached are three revised pages for the draft report - Volume I
Page 6-1 Page 6-21 Page 6-23
Please copy these revised pages into the report previously sent to you
We plan to review this material with JEA during the March 2930 and April 1 meetings in Amman
rsuVertrul yours
W Linton Project Manager
WHLdc
Attachments Questionnaire Response Three revised pages
cc C J Aulisio R R Buta G D Gould T J Wilbanks
32389
Page 1
RESPONSE TO MARCH 15 1989 QUESTIONAIRE
OIL SHALE TO POWER PREFEASIBILITY STUDY
This study examines economic prospects in terms of a 1995-2000 timeframe
FIRANCIAL AND ECONOMIC COMMENTS
11 It is likely that a BOT deal can be structured at present JEA
generation costs for either 20 MW or 50 MW size units if GOJ is
willing to subsidize the incremental power generation cost
Furthermore these incremental costs can be recovered during the 25
year operation of a Commercial Scale Project
12 A 3rd Party Test was proposed as an alternate means to raising
$100+ for an independent JEA sponsored 20 MW Demonstration
program
13 71 millsKWH for Shale Power
VS
JEA 1987 costs
Purchased Power 17 filsKWH = 51 mills
Produced Power 1360 filsKWH = 41 mills
19952000 Costs - Expected to be 30 to 40 higher and in line
with the cost estimate presented in this study
It also is important to recognize that the busbar cost of power
generated by any new power source can not be compared directly
with the cost of existing older installed capacity because of the
lower capital cost component of the latter (See enclosed Figure
1-1 which demonstrates how total capital carrying costs decline as
the investment is paid off) Any new capacity whether coal oil
or oil shale will be an unreasonable disadvantage compared with
costs for existing older capacity
l
024
o2
0De return
E 016Total carrying charge
012 qu return
S -008
ety taxes and n rcw vshy000 X 0 5 10 15 20 25
Figure 1-1 Year-by-year Carrying Charge Components for 15-yearTax Recovery Period
1-7
30
32389
Page 2
14 Infrastructure Cost
Total People
OperatorFamilies Installed Cost
20 MW $10000000 185700 $54000Operator
50 MW 15000000 3241200 46000Operator
400 MW 45000000 10364000 43000Operator
Factored allowance for grass roots desert installation
including housing and community facilities was developed as
follows for the 50 MW case study
Infrastructure
50 MW
Family Housing 200 30K = $ 6 Million
Bachelor Housing 100 20K = 2 M
HospitalClinic (8 Beds) 11 M
SchoolMosque I1 M
Stores Services amp Recreation = 2 M
Facilities
Roads Electricity Water Sewage = 3 M
$15 Million
Infrastructure costs for the 20 MW and 400 MW cases was ratioed
from this breakdown
At this conceptual level costs are order-of-magnitude In a Phase
II program these infrastructure costs can be developed in detail
32389
Page 3
15 Contract Mining Alternatives
Page 4-11 Mine Operation
Based on Bechtels evaluation of the mine contractors price as found in Section 15 of the Mining Report it was concluded that
the mine contractors price does not include costs for such things
as developing the mine with a box-cut ramp haul roads
developing an area for the waste material maintaining the
haulroads constructing the mine services facilities diversion
ditches sedimentation ponds water well crushing the oil shale
pre-mixing the oil shale at the mine and other items associated
with operating a mine to support a power plant If it is proven
that the mine contractors price includes cost for the above
mentioned scope of work in additi-n to drill blast load and
haul then the contractors price can be used but in the meantime
the all inclusive cost developed by Bechtel should be used
Contract Mining appears to be attractive for the smaller size
plants but not for the larger commercial scale operation Some
third party must provide the necessary capital for trucks
loading mining machines etc under a contract arrangement
16 Reassessment due to Dinar value change needs further study and can
not be evaluated given present budget limitations If average
labor rate of $300hr still valid then little change involve with
study
If deemed necessary reexamination of project economics can be
done in Phase IIwhen funded
17 Costs in this study are based on recent similar Bechtel experience
on Mount Poso project and on Montana I project The Mount Poso
project is a 50 MW unit firing coal in a Pyropower boiler The
Montana I project is a 35 MW unit firing coal in a Keeler Dorr
Oliver FBC boiler utilizing dry cooling
32389
Page 4
18 The Pyropower quote of $186000000 to futnish and erect the steam
generator stack and baghouse has been adjusted to include
engineering construction indirect cost etc to be consistant
with the rest of the costs shown in Table 65 p 6-10 No
further adjustment for location was made
19 Equity funding has the lowest priority of payoff in case of a
liquidation and carries greater risk Hence a higher rate of
return is needed to attract these funds Debt funding is a first
mortgage and has first priority for payoff in case of liquidation
and carries less risk Hence it requires lower rate of return
than equity funding
The risk taking equity owner will ask for greater interest rate
to make funds available The only way to minimize this expense is
to find a loaning agency willing to provide 90 or perhaps 95 of
the investment cost It is likely that banks will require some
minimum equity participation
This Prefeasibility Study was not based on a non-profit utility
operation
Even though JEA is a non-profit organization its service
contributors are profit making groups It is visualized that the
Jordan Oil Shale Co (JOSCO) will be a stand alone business
enterprise servicing JEA under long term contract To secure
funding for the proposed project JOSCO will need attractive
enough contract terms to attract both equity and debt capital
110 Additional work is needed to develop the requested information
This work can be preformed as part of the Phase II program
111 Bechtel includes contingency in all of its estimates to cover
error emissions and unforeseen items within the defined scope of
the project The level of contingency is dependent upon the
amount of scope definition For a prefeasible study such as this
15 contingency is lower than normal
32389
Page 5
112 Tables 89 through 816 include a present value calculation to
establish the relative benefit for a shale project vs coal and
oil
113 The variable maintenance cost of 1 millsKWH has been adjusted for CFB plants with an additional $200000 per year or 06 millsKWH
This yields the following
Variable Maintenance - 10 millsKWH
CFB Adjustment - 06
Fixed Maintenance Cost - 40
Total Cost 56 MillsKWH
114 Page 4-29
The royalty costs are included in the weighted average oil shale
costs for the 50 megawatt plant
Page 4-8
Shale fuel costs include return on equity and royalty These are
two separate cost items Royalty is the last item mentioned in
the sentence and it therefore reads as royalty and not return on
royalty
Page 4-31 gives rates used by Bechtel based on our calculations
using the referenced procedures
DebtEquity Capital Charge Rate
5050 153
8020 139
Table 69 displays the calculation of the 153 capital charge
rate (Line 7 of Table 69 is not used in the calculation and
should be deleted)
32389
Page 6
116 No water purchase charge from the Water Authority was added to the
operating expense based on the statement that no resource costs
will be charged
$020 per 1000 gallons is rule of thumb for USA installations in
absence of client data
Boiler make up water (p4-17) is treated in a demineralizer
train If deemed necessary comparison with reverse osmosis
process can be performed in Phase II
Water requirements were estimated to be
Cubic Metres Per Year
20 MW 50 MW 400 MW
Mine amp Shale Processing 455000 761000 773000
Power Block 3000 6000 42000
Infrastructure 80000 140000 448000
Total 538000 907000 1263000
117 Annual average operating costs shown on Table 6-1 are in error
Financing Option 5050 8020
Cost Shown 56606 48945
Corrected Cost 60396 53236
Average mining and shale processing costs are developed year by
year in the Mining Report Appendix 5 Table 12-10
32389
Page 7
118 We would be interested in receiving the breakdown of these current
power cost figures (ie capital charges fuel cost number of
operators etc) Further economic analysis employing these
figures can be developed in Phase II
119 Manpower requirements for the three case studies were estimated as
fol lows
Mining amp Shale Processing
Power Block
Operations
Maintenance
Management
20 MW 50 MW 400 MW
75 163 396
54 78 175
46 73 455
10 10 10
185 324 1036
Page 14-4 of the Mine Report is for mine and shale processing
only It should be noted that most of these manpower requirements
involved new jobs for Jordanian people
120 At the April 1988 Amman Meeting it was agreed that the following
costs would be omitted
o Permits and Licenses
o Local Taxes
o Import Taxes
If necessary such costs can be developed and added into a revised
economic analysis as part of the Phase II program
121 6 average inflation rate is the figure recommended by Bechtel
based on USA conditions for use in long term economic analyses of
new power ventures
32389
Page 8
122 This matter is referred to ORNL who prepared a rate of return
analysis
Bechtels conclusion is based on computed busbar costscumulative
benefits compared to alternate fuels in the timeframe 1995 to 2000
Relative Busbar Power Cost Net 25 Year
Mills per KWH Benefits - Million US$
Sultani Oil Shale 71-83 Base Cost
Imported Coal
$50tonne 68-88 778
$70tonne 78-107 2531
Imported Oil
$17Bbl 56-76 (18) $24Bbl 61-96 1810
The above results are based on a capacity factor of 75 which is
considered to be a reasonable target for a new plant over its 25 year
life The average selling price of 6 cents per KWH cited in the
questionnaire is based on existing plant costs which may not include
all cost elements of new capacity evaluated in this study
32389
Page 9
TECHNICAL COMMENTS
21 See answer to Item 116
Total power plant raw wate consumption rates and annual
consumptions including the water requirements for wetting ash at the truck loading p int within the power plant are given in Tables 43 and 44 for 50 MW unit and Tables 53 and 54 for 20 MW unit
The raw water requirements for 4x0 MW plant were factored
excepting the mine where a revised mine pldn is employed to reduce water request The quantities shown on these tables exclude raw
water requirements for housing complex mine and ash wetting if
required at the ash disposal site
Total power plant requirements shown in the above referred tables
are
50 MW 20 MW
Rate gpm 207 102 (See Drawing M004)
Annual Use
Gallons 1400000 675000
Cooling tower blowndown supplemented with raw water is used for
wetting ash at the truck loading point within the power plant Raw water quantities attributable for ash wetting at the power
truck loading point are
50 MW 20 MW
Rate gpm 75 325
Annual Use
Gallons 500000 215000
These quantities are included in the quantities shown in
the above referred tables
32389
Page 10
22 We recognize the POTENTIAL for leaching toxic compounds from the
spent ash However this matter is not yet defined well enough to
recommend specific action steps The Prefeasibility Study page
7-12 recommends creation of a ground water dispersion model to
determine whether more specific contaminated water mitigation
plans are needed It is anticipated that the leachate rate will
be low and that aquifer dispersion will keep problem compounds
bel3w health standards thresholds
23 Noted
We have not received up to date resource study material which
defines 50 billion tons resource base Please furnish
The resource base at Sultani alone is adequate to support two 400
MW power projects capacity subject water availability The
2-million cubic metre per year water allowance for oilshale will
limit development to about 600 MW
24 Selection of a combustion temperature is a balance between carbon
combustion efficiency and heat loss due carbonate decomposition
For purposes of the Prefeasibility Study we have opted for high
combustion efficiency At lower efficiency larger shale
mineprocessing plants will be needed
25 Bottom ash is cooled by water exchange before discharge
Cooling water is supplied to the ash screw coolers as specified by
Pyropower See Drawing MOO5 2140 gpm flow for 50 MW and 860 gpm
flow for 20 MW Heat removed by the cooling water from the ash
screw coolers is dissipated to atmosphere via a wet cooling
tower Pyropower should indicate the temperature of the ash
discharged to be 5OOF
32389
Page 11
Initially we had considered using a heat exchanger to cool the ash
and improve the cycle efficiency Considering low cost of fuel
the additional capital costs and the system complexities it was
decided not to employ such heat recovery systems for this project
26 The suggested alternates were looked at briefly and the potential
for wind blown air pollution from the ash disposal areas are too
great to warrant dry disposal unless GO(] and World Bank are
willing to accept such a potential problem Wetting the ash is
tne only practical solution Hopefully some cementation will
occur helping to reduce future leaching potential
27 JEA requirements are noted This is a conceptual study not a
final design Optimal design analysis can be performed during
Phase II
2829
JEA requirements are noted and can be incorporated into the Phase
II design
210 The transformer size is adequate for base load operation A
higher capacity can be considered at the final design stage if the
Client prefers
211 From our experience it does not appear to be economical to
provide additional dry cooling towers to take care of maximum
ambient temperatures which may prevail only for a short period of
time in a year To study this an annual dry bulb temperature
duration curve is required Also adding additional dry cooling
towers will change the plant performance It should also be noted
that the dry cooling towers are very expensive and the size should
be selected carefly considering performance and cost and not on the basis of maximum ambient temperatures This can be studied
during Phase II
32389
Page 12
212 The plant gross output varies with condenser pressure
Condenser
Pressure Design 55 in HgA Annual Ave 35 in HgA
Unit Size MW 20 50 4xlO0 20 50 4xlO0
Gross Output MW 234 593 496 2415 607 TBD
Net Output MW 1975 501 400 205 515 TBD
To be developed in Phase II
Output for 4x100 MW is estimated by others
213 The fan power consumption of the CFB boiler is about 30 to 35 of
the total auxiliary power The fan power consumption of the dry
cooling tower is about 20 to 25 of the total auxiliary power
214 Table 1-1 does not include plant net output Therefore do not
understand the comment
215 Commercial operating experience with coal fueled CFBC units in LISA
and Europe has been uniformly good showing high on stream
availability in early years (See Table 2-6 which reports on
Pyropower experience)
We expect operations with high ash content fuel like oilshale will
have unique scale up problems such as
o Solid handling in and out
o Internal solids circulation
o Erosioncorrosion steam generator intervals
o Heat recovery from bottom ash
Consequently we are recommending these items be worked out in a
single 50 MW prototype
32389
Page 13
216 Maximum dry cooling is used in this study A small wet cooling
tower is used on circulating service water system
217 Horizontal condensate pump is adequate with dry cooling tower and it is cheaper Vertical condensate pumps with cans can be
considered in the final design if required
218 A concrete shell brick lined flue stack will be larger in diameter and costs more than a steel lined stack Brick lined stack can be
considered in the final design
219 Demineralized water tank capacity for 50 MW is 76 cu meters or 20000 gallons not 1000 cu meters For 20 MW plant it is 38 cu
meters or 10000 gallons
220 It is US practice to use an average continuous blowdown rate of
1 and maximum biowdown rate of 3 for this type of plants
221 This can be studied during Phase II
222 Same as 221
223 Same as 221
224 The recommended action plan calls for continuing support studies covering the referenced items Additional effort is needed to
further define these matters and confirm the conceptual plan
The next step is to develop an outline for a project plan including
o Work Scope
o Schedule
o Budget
accommodate the increase in the number of employees and
equipment Truck bays to accommodate the 136 tonne trucks
will be added The truck bays used for the 77 tonne
trucks will be used for the maintenance of other
equipment The warehouse change house training room
offices and cafeteria will be expanded accordingly
6025 Mining and Processing Economics
Details of the oil shale mining and processing plant
economics for the 400 MW plant are included in the Mining
Report (Appendix 5) These details are of the same
magnitude as prepared for the 20 MW and 50 MW plants
The summary of the cash flow analysis for the mine and
shale processing plant is presented in Table 6-1
Table 6-1
SUMMARY OF 400 MW PLANT OIL SHALE MINING AND PROCESSING COSTS
5050 Debt-Equity 8020 Debt-Equity
US $1000 US $1000
Capital Cost
Mine Development 30915 30915
Mine Equipment 66012 66012
Process Plant Facilities 50889 50889
Spare Parts 5000 5000
Working Capital 10000 10000
Capi tal ized Interest
During Construction 24423 39075
TOTAL 187239 201891
Operating Costs and Other Costs
Annual Cost 60386 53236
Product Mined and Processed
Annual Tonnes x 1000 7783 7783
Unit Cost
US $Tonne (weighted average)
US $l06Btu (weighted average) 776
156
684
138
Year 12 costs taken as 25 year average
6-6
-Au
Table 610 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
- FCC plant sizes equivalent to proposed power application
Prefeasibility Study Oil Shale Fueled Power Generation
VOO94GEampJRI26
i
PYROFLOW UNITS IN THE US
COLORADOUTE IOYA STATE UNIV UNIV OFNUCLA CO NORTHERNAMES IA BF GOODRICH110 1o0MW(a) 2x170000 Ibhr HENRYILCEDAR FALLS IA 120000 Ibhr GENERALGULF OILu EiN P MOTORSSbtUpStart-UIL 1987 O A 1I N000 TC
NORT10 PONTIACH B MIRANCHWV00000 lbhr
CORN PRODUCTSSM NORTH-CAROLINA STOCKTOD CA
400000 lbbhl t
RUMF RD ME
CEMENT CO CALIF PORTLAND-COLTON CA
190000 Iblhr Start-Up 1985 TRUMTFTWN NYU
3I75ERTOWN N
etar t-Up loss ACE COGENERATIONCABI
TRONA CA Oper t~on l -Start-UP 1990 ~ rt upz 091Start-up loss Start-up PNeLAI 1991
MTKESFICOENERATIO-N1
BASFIELDp Start-uStar-Up WESTCA9 199otgoUp 1 MAHONEV PA|00000 Ibhr A Oz 2X365000 Ibhr
SETtr-Ups 188B CHAT TANOOGA TN
G ULF OIL EXPLORATION 8ta-rt-u) 1085BAKERSFIELD NORTH BRANCHCA SPRING GROVE PANORTH BRANCH WV 400000 IbhtOperational 19835 5 0 0 I b h 9 0 0 0 Iblh r- tart-Upi 1991 S t r - U p s l e s s
SOUTHEAST PAPER MFG CO UNIVOF NORTH CAROLINArDUBLIN GA UHAPEL HILL NO400000 IbhrStart-Ups logo Start-Ups2X250O000 1loseIbhr B
- Withdrawing ash from combustor - Withdrawing fly ash
a Internal solids circulation of the steam generator
m Erosioncorrosion of steam generatorinternals
Heat recovery from bottom ash
U Operation with low calorific-value fuel
Prefeasblity Study O Shari Fueled Power Generation
VOO7AI 27
Impact of Scale-Up
Project Size
20 MW
50 MW
100 MW
50 MW boiler in 100 MW plant
Potential Risk
Design Scale-upOperation of to 100 MW Initial Plant Plant
Low Significant
Modest Modest
High Low for duplicate units
Modest Low for duplicate units
Prefeasibility Study Oil Shaje Fueled Power Generation
VOO71-4GEAL4n2
i
Conclusions
Defined risk of CFBC boiler is acceptable
U Operating experience with commercial CFBC boilers built and under construction will strengthen confidencelevel and minimize risk for a plant built in 1995
SPrefeasibility Study Oil Shale Fueled Power Generation
V007GHAAE29
ENVIRONMENTAL ASSESSMENT
a Mine and shale processing
- Fugitive dust emissions
- Noise levels
- Leachability of disposal piles
Power plant
- Fugitive dust emissions
- Gaseous emissions
- Noise levels
- Water effluents
U Conclusions
Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel
Prefeasibility Study Oil Shale Fueled Power Generalon
- Coaloil prices will be at least 15 greater after 1995
- Discovery of indigenous conventional fuel resources is inadequate for power plant purposes
Prefeasibility Study
Oil Shale Fueled Power Generation
VOO) IDWFO
Feasibility(Contd)
N Suitable financing will be available
- For $200 million 50 MW prototypeproject
- For $1000 million 400 MW commercial project
Government of Jordan will make basic commitments
- Long-term power purchase agreement
- Long-term access to Sultani shale deposit
Adequate water and manpower resources
- Attractive tax incentives
Prefeasibility Study
Oil Shale Fueled Power Generaion
VO bull1DUJJRO 6
Timeliness
U Timely development of Jordan oil shale needs prompt action to create - Additional definitive information
- Suitable business plan
Prefeasibility Study
Oil Shale Fueled Power Generation
VooI DUJo 7
i
Expansion Conditions
U Continued expansion of powergeneration from oil shale in Jordan depends on water availability
Prospects for power export or importand domestic load growth will affect size of the needed shale-to-power program
Prefeasibility Sudy
Oil Shale Fueled Power Generation
yOWl lVuJO
Environmental Impacts
N Environmental impacts of shale development will be minimal
Prefeasibility Study Oi Shale Fueled Power Generation
i
Development Advantages
Will create significant new jobopportunities in Jordan
Will avoidreduce foreign exchangelosses for expanding alternate fuel imports
Prefeasibility Study
Oil Shale Fueled Power Generation
VOOIIULL tO
Recommended Action Plan
N Basic recommendation
N Conceptual development schedule
U Project development plan
Key plan elements
N Funding requirements
Prefeasibility Study Oil Shale Fueled Power Generation
VOO4II )U OII
i
Basic Recommendation
N Expand efforts to develop an oil shaleshyfueled power generation program at the Sultani deposit
- Conduct required supporting studies
- Define facilities costs and business plans
- Obtain project funding
Prefeasibility Study
Oil Shale Fueled Power Generation
VON I II)ILL 12
C
Conceptual DevelopmentSchedule
1989-1990
- Conduct supporting studies - Define costsbusiness plans for 50
MW prototype and 400 MW commercial projects
- Develop project financing
N 1990-1993 - Build and operate the prototype project
N 1994-1996 - Expand the 50 MW prototype to 100 MW scale
U 1996-2000 - Expand the project to 400 MW scale
N 2000-2005 - Build a second 400 MW commercial project if needed
i 1 Prefeasiblity Study
dOil Shale Fueled Power Generation
VW IMLITO 13
Conceptual Development Plan
Months
1 Project development plan - Define project
costs1busness plans
-24 -12 0 12 24 36 48 60 72 84 96 108 120
2 Secure funding
3 Build and operate 50 MW prototype
Dergn and procurement
Mine development
Plant construction
Startup and testing
Operations
L- -
4 Expand prototype to 100 MW
Design and procurement
bullConstruction
Startup
5 Expand project to 400 MW
2nd 100 MW unit
3rd100 MW unit
i 44
4th 100 MW unit -
O Project dacision point
i Prefeasib~ity Study Oil Shale Fueled Power Generation
17958562aJocdanV 3-14-89 rsO
18
Phase I - ProjectDevelopment Plan
n Program development
Seminar workshop on prefeasibilitystudy Oate project development plan woek scope schedule arid budget
U Carry out project planning program
- Conduct continuing support studies - Test Sultani shale in existing FBC
- Firm up designs and specifications
- Update costs and economic analysis
- Develop business plans and requirements
Explore project funding alternatives
i Prefeasibility Study
Oil Shale Fueled Power Generation
VO MItUOR 14 -0
Key Plan Elements
N Project feasibility analysis
- Firm up designs and equipmentspecifications for all facilities
- Update cost estimates based on preliminary designs and specifications
Explore arrangements for contract mining and mine development
Update forecasts for demand growthand for retirements of older generating capacity
- Create updated economic analysis
Preleasibility StudyO1 Shae Fueled Power Generation
VOO1IOLWRI
Key Plan Elements (Contd)
Business entity requirement
- Explore optionsconditions for a new company to managebuildoperate the project
- Explore optionsconditions for obtaining a concession agreement for Sultani development
Explore optionsconditions for water rights commitment
Prefeasibility Study Oil Shale Fueled Power Generation
VMIOIA)lj 16S
i
Key Plan Elements (Contd)
U Continuing supporting studies
- Combustion tests (additional pilot tests for design and warranty purposes contract for large-scale burn operations in existing plants if appropriate)
- Additional core drilling and core analysis
- Oil shale crushing tests
- Spent ash leaching tests
- Geotechnical data base including soils analysis
- Environmental baseline data
Prefeasibility Study O Shae Fueled Power Generation
VMMMUldMOA
Steps Required to Develop an Oil Shale-to-Power Project
Create a development business plan - Schedule - Decision tree
Develop a work scope and budget for the development plan program including - Firming up designsspecificationscosts
- Developing business entity requirements - Continuing support studies
Carry out development plan program
Assemble all planning results in a report for discussion with financial institutions
Explore project finance opportunities
Finalize business arrangements
Implement prototype project
i Prefeasibility Study
Oil Shale Fueled Power Generation
VM1-11UJROLI
MARCH 15 JEA QUESTIONS (M S ARAFAH) ON PREFEASIBILITY
STUDY DRAFT REPORT
Rt
DIR EScBSULIVAN PHD OFJCEop~BUREAU FOR SCIENCE AND~TECHNOLOGYAGENCY - --FOR INTERNATIONAL DEVELOPMhINTSWASHINGON DC x20523---------4
4 -
-SUBJ E CT - -C O H~ E T 4N l
Dr Mr sullivan ------shy
c-rommnents We ~efr-preaereorPla -tobYou lete dted Jan 91989 regardn~i4po4t P ea e1 f i nd y ubel ow our -e ot r XcOrcerned Jordanian deipartments
- --A ar o~nnYu Y o turjlt~ lt K
4 C~mments
~1 N i gFIN I~fANDECONOMIC1COIMEN S -
It sidicaed that Beohtel and US AIDWash ingtonj~4- re ojy nen ing that E 2hould und ertake the n e tshyihaisAre ~our c leometprogram n order shye-t im~ ate d f n t v design and budget cost
4Al1so Lthe study ncal--ttsutnilndcaei~ A-1 A thas ~ l 1 be eeded idb~~~~~ rn o ei t n i la itheMWa~-~5s~ 4
hrPro hehgemetTh trOfT ses~fnr4 BOT)Vmanu- a n-mnf~cure 4 r~j or contra c4-or ivoIlveiintijn I 4 4investmnt ude smi ~w 2 Zha tev e r --~4~prce e ec r it v p4~ f JA gertiy geeated-at 4 JEA 3 a l b u y ~the same average~~ A
~jithia oncot in4 ordrtan ecpoemic asess thespePower generatjoon J ordan3 oi sha I eroic c inr~etJordan 4
2P ge i1- 1 Aj iit eu that OPin he atocontr~ct 4with owner4 ofext3ing (oconstriiction r(FB rml-t
qu i of S 11 t to test large tonnagen j es StaniUti n d ajIe -for se veralIQf 31 hi
evrEAPreferpilot qr the dP 1prt7n -that the4mPIt
andi to(7 he instalI 1e 2 310 A
_
JODN ELECTRICITYAUTHORIT LL
Dac
operated in Jordan i n or~der~~t ~n nuex~on mnining crushing and haidi igQhre~ and sash Maeia nd aSootoget enough olr ndaita needed for einolre
CEBbole~ -i s~
ccordance with Jordaian oil shale
large to~ bfig
1 3 le 1-2 Page 1-7 Cost Of Pwer~i It i S menti-oned that the conmecial oil hle~ lt~project (4 X1OOmw) 1is ninacompetative roqt~range-~while table 12 indicates thattcost of-pow Ais~mill
q kwiihcii r 1
average wih i ii -much higher ihantheshy-ost of ~Power gnrtofomJEA therimaPower s ta tions Please~ indicate on what basi o ~~ shave-~made your-statement
PK
14 Pae 2 Sction 4-0sIt 1nlkly that theChousing and off- -site infrastructur-ommnity fakilitieR) to be onsidered for both the demo and prototyp prjcs oeoverwe~4 hnk that their~c_6t is raterojects Mo
iwcv~- age -1 1 Mine O(perationIIt is indicate~d that mining cot eevdfoMine contractor~ are ficomiplee h
r and iyudi-t~con qidder contract mnn opio fr4 the min4 cmflt2ng are reIanddrepres~ent the real costs derived from Phspat miin contractors in
lestfor the eo rPooypuat in order tlt7
P I eadenote tha detthe new exchangerate ofthJraian~ Di~nner you may add 20j6 Kto the quoted
1 6 P Ias e consider the followin ecn hage_
171- The new exchange ra teof tUSD=54o0 fils1 72-W2 The new~ aerage tariff for selIn~electricityhas decrreased to 120 8 f ilIsicwh
17- Page 1-7 TbIe 1-2 W bev th tthe cap ita1 cot for the pwhokand forthe min n d ash hMnd1ing equipen
P B~2Anaor a -Tl 8156152 8176 1Q MYf -t -Now 520 t 1U
JDNEECRICIT AU-RA L14lLiL
2 ~are very high We suggest~ thta You rerconsie (- telowerus e~+d accuracy est a rangethan +30
Page4-22 Table 4-5weno0ti ced( that- PyroPowe ha ddeta(IiacCst fori the bo1ilerlocation and terha dutdetlease isxtr fo~ l C~ io~ s~ e~~ 1a~ a if and indicate theonldjusted ~percentagefor construction foin Jordan
19 Page-7 Table 11-2 -Yo aeue ihrinterest rate on Equity thatn on1DehI~laseinclude~ adetaied explanation of thisrr -tni kepin in miUndie JEA is1thaIt a non profit~ shyorgaiztion unik oher private UJSA utility~in ktation
~-~110- Regarding shy
the ra4ital Rt fthe project it is~requesed tobre k it intdo foreignMeanwhile cthe nd lorcal c-osfoeigptario i nt-re3t~shol becnierdo-h
rr n ontiondonnotopdbon the 9 cnieelocal portion~onth
1-1- 237~Pa
oningeny 9tooi s high~~ a lower 4value -should be~
4~ gt ~112- -Tbles t1-1 -8-8~ inclu~de t~he c~alculationscuultie nt enefits for of Th shyunttypes l i4s difeen geeatnmrer likely tocluae
-~ Q~ J7present vk1u for tenet tthe~benefits in feralterntives -t-oa s the
49
ehliyoi shale
Wea gree with you9 tha t th e percentage used ~ an for thenua~l 0 ~amp-M rahr CFBo ndsomewha~t highervrate be n ededma y for a C B l n Me n h l ~ a e r
indir e ta~ts the -estimatedma i variablec st i ddition t he fi-xed-9i 1 mislkih We --
thinktttiis too lowK -5
shy
1-14- e 4-29
opprza tion-o to The o i1s h1 costs-nc I deAbo 1h
Pa10 mman ormTSI62 a
IB I
JORD N EtECTICI1~ 4 E~)~Is-s
Date ib-_
~ ~riii~g~nd~o9~ru~hng h~tnlin cot~u~tv yo
i Dae Jnryit
1ts c 7 4-
i smiig iniand fh co I eY
susendi ca tI t icag th t1 ~an~approximate 15 ~pita L tYII I (-~a~ge or he owe bl ockj f aniitjes isof +the capthe)t~ial7cpi~lrharge Uoratelformny SI~Uj(uiity installa~tions~ whle page 6-1T9 talJshyit is mentioned that~ the Capital rate pe-r JEA isshyi5~PeaseJustify this~matter since~w o
i16- Pae 6-1 6
1 I4~t is mentioned that the costs of 4process Water are ~ 4 ~0 2$1 000 gallons
r~j~lt IHave~You considered additionalvalue ofbying waterfrom~ the Wa ters Aito i ~or ditoa cost~f o revrseoqoesplant if ground water is used
~~ I1 7- Table 6-1 Page 6-6 Please explain how did You come ou ihteoil~ shale miniing and proces~sing uit~Icost
ltII~I~ 8- Please note 1 t hatj the average JEA~productinr ot frmthermal I power stationsr (Istationbus-barCOSt)i sbewen 6 3-17 3 fils 4kwh You may use this~
l4~ 19-i For ~4 X 100~AMW Plat iti etindo pag e14-4 VolI 11 that4 at tota I of W42 14 epoye W II eemplo~yer] And on page 69yo1Iiti mentioned that a~ tot 1 f1 ~p yeI iNbe enp1oyed a
is~ high asrmetitexeds100personorthe ~41X100~MWh~~j nsatnpPrlae
I 1 The 4 following iftemns are a sumed to1 be excluded from theraPi ta 1 cot xoI
120-1 Perits I icen es 7
1_207~3 Imprt ~xe on s7pare par ts -and c(7orfmurab -ma~teria Is
04f4 4
~4 R j4 4
D4
~ ~ ~ AIf eS taxesq in acrac ihteJraand regulations should be considered aw
21- p1ea4s e indic ate Your Ju t f c io r us ga 6
44122- Table 977App 5Page4 9-1 4L IK Car1Yiniae that the hIRR of the 4 Otplantis rather unattractive (66)most
-( Cns1er4 ngthe logical base 4csek c pwhen cii 6OL
average sell~ing prc CkhampDEratio L801~2O~Aoreover4M the ne siellin prcwh o JEA ati theamptime~ Abeing os4ltp n~ot exceed 4 Ckwh~-However Ipage 1shy~ and 14 0 T indicate that ecnms for a commeri
S4A4scale joil 4 shale projc ~
appear Piomisig-nug o4Ywarrant continued dee fgfluht 4 feaibiit 4tudy wihil cost sevea~lili
do ar~sf Plas lear wether the ~x step jqs~$j~~lt 4
gtt 9o be considered arCcording4to jthe 4unattractiveresul to mentioned in IRR7 Table 97 gt4
a C4 44fET2 4 144-4444 P a g 1 T b6 l
htte~We ~ ~ ae~ rqieetfrteX ~ noie ~~ ~ 444 MW un t44 r te4l w w e o p r d i th e w t r n rre u f4m or4444~ the4444 54M4rto y e Pg~A~44EHiveL det ile an l A44
s o awa er c n um t a4r f rofsho in P6Io erT
e ch 2 50 M W aPln wa e d 41004 MW4 1 consumption_____________
ma4~2 k e u p houin~44 p A44 4444444 C O 4ltI4
a nd a sh et in etc 4 2 4 1 -24 P a g e4 2 - 1 A P P 5
4Yo 4_ j1 4 4~h444 N44 44
1gro nd tce t hir fthe w bern coqir mna t efora4e 4X10A M 444444 4 r i n to 4 4 4lo w w ehA 7 n 2 cinCie h rh4 n ttthh1eb -e 4 44t Of3 E4O
ea h n~ ffl 4 4Jl44 4 4444 4giv
6 ig re sofrat4 de in cl ar f w w at5 c hrw pe o
s h b 444 o t h e g nd L 44 h u i n C
r 4ne a4 t44 e L(704 2 4 p ae) 2 - o Au P dn 5ai 7~e r 44 I Y (1t 44a
ve7 rn e qu 1saharvthe y
and n~~~o speci~~~l4 p n l nh i n t x
r ~rA M e d r o t eu n 8 1 wTtl t t h
- c re e N I wo6
~ n n a i n a t d h l7 A PP6 gt
J
S2~3- Page 2-4 ~ ~ It ~is i
that oil eindicated the- sha le r our~ Cesin Jordan are 10 billion tons -The anulp e reere maiy exeed 50 4 billion tons ~
~ 24- 4Page~2 -l1 iujntr We beiv thtCBcmuto~ep i s high and~alSo
~~ ~ -2 ~~ Page 4-1~6 j - shy
Please~~ indicates your procedure to cool the omn ashand atwa icagd-eprtr
A Have you~ considered~ additional he~at exchanger topcool th ash and to imrve h cycleef ficiency
-~2~6 Page 4-16 It s~ indicated that ash from each silo i Amixed19 ~with~fabout 20 waterKb weight to minimize generation of dust~during trnprtto to mine and disposalHave you~ coniidered other 4lternativeto
~ ~eliminate dustiiig -and avoid use ofwat r uring it ransportationi such as~ using closed trucks or closed
of ~fans conUMnPo wihrlaintthe total plant auiir poe osupin 1~21- Table 5_-3 and I ~
Th~~ is- somneere c6ntradiction regardingplnneotpu~t in both am tables 21-~ Tabl~e 1-33
We noticed tha~t yourall9 cacacapac t fatro75 tion ae asdnWe thilt ~that 7capacityshyfacto is tobo high for- an oil shale fired plant duketo lack of existing simila~r ~plants handl~~~firing oil adshale ~K
216~ The study iniae thtawet~coigtower wi11~used Actually a b
dry cooling should be consideda5ini ~HTP S inZ atomnmz so water rnumption4the cycle~ efficiency willbe reducedHenre YO33~reconsider calculating the cyclefficiy
U~~~~~ codnt umconsidered ofhorizontal -aretypethe~ the vertical cian type can alsobeh considered
shy ~ ~ ~ I~~
2~2 Kconcrete shy
shjell stepl fltstack is onidereconcrete shell brick flue Rt c ~s beCaconsidered3V
2-19~- Deminiraized water~ tank3 capacity~ is -76 ui(meterThe recommnended tank cameter- ui tyi 00cbc
220Designconditions Pa~ge (4-74)te5 hat bow 3down percentage splusmn ~fomrpra til re i hou I be 3~)~
PoD Z 2 m a ad~ - e 5 1 2 iJS~ ~ p A f amp ~ ~ y1
4
JO R ECTICITY AUTHORTIT 4L
~ 4
Date~
t etats ttthe quantityof s i S ~1 000Tons ra Sthis tuntity 11- be transporited for severIy --to tu ofI pit a~te torg P KM ra~erm Spower plIatS about 12 midilidoni CUIA(- met ryea
h e ndd mp e he (d u p in i n L
area wil evric power plant6t Please zn1 a te~tiv s tudY for dumping th r~ a enoug
-from the power plantr~~h~
S 2- Please provide deald-ifrat ao etbaaiedrawing hwn TH11 R thaU and~pV ra~te takcing illto o 6it v- consumptionn _uig themrining equipment
alternate~ study 0o Jine operation for 1 shiftday Vand twoshifts day -lt
224- Conceptua~l pflR 1 for mi ing anusdtransportation of oil- shale a 0 dmj of hs f u r therV examinedh iV~sdpatI ho u1d be
orderj to poe~ehicalq and~eoomca1 fesblt of t his operation
SYour are requested te) study and consider all- above - iPoin s at your earliest in rder -to be peete y oiAnimain on March 29-301989 peetdb~o 4 n
S9incerly-You S
WDIRECTORGENERAL -
I~ CCMR WLINTON ~vs
5N
Pa D~t~IoAmmn -Jordtn -Tel 815615 20 Bl76 15 -19j A VINO- AFf TY
MARCH 21 RESPONSE TO JEA QUESTIONS
Bechtel Power Corporation Engineers - Constructors
Fifty Beale Street San Francisco California Mail Address P 0 Box 3965 San Franclco CA 94119
March 21 1989
Mr M S Arafah Director General Jordan Electricity Authority PO Box 2310 Amman Jordan
Subject Jordan Oil Shale Prefeasibility Study
Dear Mr Arafah
Your letter of 15 March 1989 with comments on the Oil Shale to Power Prefeasibility Study draft report has been referred to me for reply
The attached responses to each item in the reference letter follows the order submitted
Also attached are three revised pages for the draft report - Volume I
Page 6-1 Page 6-21 Page 6-23
Please copy these revised pages into the report previously sent to you
We plan to review this material with JEA during the March 2930 and April 1 meetings in Amman
rsuVertrul yours
W Linton Project Manager
WHLdc
Attachments Questionnaire Response Three revised pages
cc C J Aulisio R R Buta G D Gould T J Wilbanks
32389
Page 1
RESPONSE TO MARCH 15 1989 QUESTIONAIRE
OIL SHALE TO POWER PREFEASIBILITY STUDY
This study examines economic prospects in terms of a 1995-2000 timeframe
FIRANCIAL AND ECONOMIC COMMENTS
11 It is likely that a BOT deal can be structured at present JEA
generation costs for either 20 MW or 50 MW size units if GOJ is
willing to subsidize the incremental power generation cost
Furthermore these incremental costs can be recovered during the 25
year operation of a Commercial Scale Project
12 A 3rd Party Test was proposed as an alternate means to raising
$100+ for an independent JEA sponsored 20 MW Demonstration
program
13 71 millsKWH for Shale Power
VS
JEA 1987 costs
Purchased Power 17 filsKWH = 51 mills
Produced Power 1360 filsKWH = 41 mills
19952000 Costs - Expected to be 30 to 40 higher and in line
with the cost estimate presented in this study
It also is important to recognize that the busbar cost of power
generated by any new power source can not be compared directly
with the cost of existing older installed capacity because of the
lower capital cost component of the latter (See enclosed Figure
1-1 which demonstrates how total capital carrying costs decline as
the investment is paid off) Any new capacity whether coal oil
or oil shale will be an unreasonable disadvantage compared with
costs for existing older capacity
l
024
o2
0De return
E 016Total carrying charge
012 qu return
S -008
ety taxes and n rcw vshy000 X 0 5 10 15 20 25
Figure 1-1 Year-by-year Carrying Charge Components for 15-yearTax Recovery Period
1-7
30
32389
Page 2
14 Infrastructure Cost
Total People
OperatorFamilies Installed Cost
20 MW $10000000 185700 $54000Operator
50 MW 15000000 3241200 46000Operator
400 MW 45000000 10364000 43000Operator
Factored allowance for grass roots desert installation
including housing and community facilities was developed as
follows for the 50 MW case study
Infrastructure
50 MW
Family Housing 200 30K = $ 6 Million
Bachelor Housing 100 20K = 2 M
HospitalClinic (8 Beds) 11 M
SchoolMosque I1 M
Stores Services amp Recreation = 2 M
Facilities
Roads Electricity Water Sewage = 3 M
$15 Million
Infrastructure costs for the 20 MW and 400 MW cases was ratioed
from this breakdown
At this conceptual level costs are order-of-magnitude In a Phase
II program these infrastructure costs can be developed in detail
32389
Page 3
15 Contract Mining Alternatives
Page 4-11 Mine Operation
Based on Bechtels evaluation of the mine contractors price as found in Section 15 of the Mining Report it was concluded that
the mine contractors price does not include costs for such things
as developing the mine with a box-cut ramp haul roads
developing an area for the waste material maintaining the
haulroads constructing the mine services facilities diversion
ditches sedimentation ponds water well crushing the oil shale
pre-mixing the oil shale at the mine and other items associated
with operating a mine to support a power plant If it is proven
that the mine contractors price includes cost for the above
mentioned scope of work in additi-n to drill blast load and
haul then the contractors price can be used but in the meantime
the all inclusive cost developed by Bechtel should be used
Contract Mining appears to be attractive for the smaller size
plants but not for the larger commercial scale operation Some
third party must provide the necessary capital for trucks
loading mining machines etc under a contract arrangement
16 Reassessment due to Dinar value change needs further study and can
not be evaluated given present budget limitations If average
labor rate of $300hr still valid then little change involve with
study
If deemed necessary reexamination of project economics can be
done in Phase IIwhen funded
17 Costs in this study are based on recent similar Bechtel experience
on Mount Poso project and on Montana I project The Mount Poso
project is a 50 MW unit firing coal in a Pyropower boiler The
Montana I project is a 35 MW unit firing coal in a Keeler Dorr
Oliver FBC boiler utilizing dry cooling
32389
Page 4
18 The Pyropower quote of $186000000 to futnish and erect the steam
generator stack and baghouse has been adjusted to include
engineering construction indirect cost etc to be consistant
with the rest of the costs shown in Table 65 p 6-10 No
further adjustment for location was made
19 Equity funding has the lowest priority of payoff in case of a
liquidation and carries greater risk Hence a higher rate of
return is needed to attract these funds Debt funding is a first
mortgage and has first priority for payoff in case of liquidation
and carries less risk Hence it requires lower rate of return
than equity funding
The risk taking equity owner will ask for greater interest rate
to make funds available The only way to minimize this expense is
to find a loaning agency willing to provide 90 or perhaps 95 of
the investment cost It is likely that banks will require some
minimum equity participation
This Prefeasibility Study was not based on a non-profit utility
operation
Even though JEA is a non-profit organization its service
contributors are profit making groups It is visualized that the
Jordan Oil Shale Co (JOSCO) will be a stand alone business
enterprise servicing JEA under long term contract To secure
funding for the proposed project JOSCO will need attractive
enough contract terms to attract both equity and debt capital
110 Additional work is needed to develop the requested information
This work can be preformed as part of the Phase II program
111 Bechtel includes contingency in all of its estimates to cover
error emissions and unforeseen items within the defined scope of
the project The level of contingency is dependent upon the
amount of scope definition For a prefeasible study such as this
15 contingency is lower than normal
32389
Page 5
112 Tables 89 through 816 include a present value calculation to
establish the relative benefit for a shale project vs coal and
oil
113 The variable maintenance cost of 1 millsKWH has been adjusted for CFB plants with an additional $200000 per year or 06 millsKWH
This yields the following
Variable Maintenance - 10 millsKWH
CFB Adjustment - 06
Fixed Maintenance Cost - 40
Total Cost 56 MillsKWH
114 Page 4-29
The royalty costs are included in the weighted average oil shale
costs for the 50 megawatt plant
Page 4-8
Shale fuel costs include return on equity and royalty These are
two separate cost items Royalty is the last item mentioned in
the sentence and it therefore reads as royalty and not return on
royalty
Page 4-31 gives rates used by Bechtel based on our calculations
using the referenced procedures
DebtEquity Capital Charge Rate
5050 153
8020 139
Table 69 displays the calculation of the 153 capital charge
rate (Line 7 of Table 69 is not used in the calculation and
should be deleted)
32389
Page 6
116 No water purchase charge from the Water Authority was added to the
operating expense based on the statement that no resource costs
will be charged
$020 per 1000 gallons is rule of thumb for USA installations in
absence of client data
Boiler make up water (p4-17) is treated in a demineralizer
train If deemed necessary comparison with reverse osmosis
process can be performed in Phase II
Water requirements were estimated to be
Cubic Metres Per Year
20 MW 50 MW 400 MW
Mine amp Shale Processing 455000 761000 773000
Power Block 3000 6000 42000
Infrastructure 80000 140000 448000
Total 538000 907000 1263000
117 Annual average operating costs shown on Table 6-1 are in error
Financing Option 5050 8020
Cost Shown 56606 48945
Corrected Cost 60396 53236
Average mining and shale processing costs are developed year by
year in the Mining Report Appendix 5 Table 12-10
32389
Page 7
118 We would be interested in receiving the breakdown of these current
power cost figures (ie capital charges fuel cost number of
operators etc) Further economic analysis employing these
figures can be developed in Phase II
119 Manpower requirements for the three case studies were estimated as
fol lows
Mining amp Shale Processing
Power Block
Operations
Maintenance
Management
20 MW 50 MW 400 MW
75 163 396
54 78 175
46 73 455
10 10 10
185 324 1036
Page 14-4 of the Mine Report is for mine and shale processing
only It should be noted that most of these manpower requirements
involved new jobs for Jordanian people
120 At the April 1988 Amman Meeting it was agreed that the following
costs would be omitted
o Permits and Licenses
o Local Taxes
o Import Taxes
If necessary such costs can be developed and added into a revised
economic analysis as part of the Phase II program
121 6 average inflation rate is the figure recommended by Bechtel
based on USA conditions for use in long term economic analyses of
new power ventures
32389
Page 8
122 This matter is referred to ORNL who prepared a rate of return
analysis
Bechtels conclusion is based on computed busbar costscumulative
benefits compared to alternate fuels in the timeframe 1995 to 2000
Relative Busbar Power Cost Net 25 Year
Mills per KWH Benefits - Million US$
Sultani Oil Shale 71-83 Base Cost
Imported Coal
$50tonne 68-88 778
$70tonne 78-107 2531
Imported Oil
$17Bbl 56-76 (18) $24Bbl 61-96 1810
The above results are based on a capacity factor of 75 which is
considered to be a reasonable target for a new plant over its 25 year
life The average selling price of 6 cents per KWH cited in the
questionnaire is based on existing plant costs which may not include
all cost elements of new capacity evaluated in this study
32389
Page 9
TECHNICAL COMMENTS
21 See answer to Item 116
Total power plant raw wate consumption rates and annual
consumptions including the water requirements for wetting ash at the truck loading p int within the power plant are given in Tables 43 and 44 for 50 MW unit and Tables 53 and 54 for 20 MW unit
The raw water requirements for 4x0 MW plant were factored
excepting the mine where a revised mine pldn is employed to reduce water request The quantities shown on these tables exclude raw
water requirements for housing complex mine and ash wetting if
required at the ash disposal site
Total power plant requirements shown in the above referred tables
are
50 MW 20 MW
Rate gpm 207 102 (See Drawing M004)
Annual Use
Gallons 1400000 675000
Cooling tower blowndown supplemented with raw water is used for
wetting ash at the truck loading point within the power plant Raw water quantities attributable for ash wetting at the power
truck loading point are
50 MW 20 MW
Rate gpm 75 325
Annual Use
Gallons 500000 215000
These quantities are included in the quantities shown in
the above referred tables
32389
Page 10
22 We recognize the POTENTIAL for leaching toxic compounds from the
spent ash However this matter is not yet defined well enough to
recommend specific action steps The Prefeasibility Study page
7-12 recommends creation of a ground water dispersion model to
determine whether more specific contaminated water mitigation
plans are needed It is anticipated that the leachate rate will
be low and that aquifer dispersion will keep problem compounds
bel3w health standards thresholds
23 Noted
We have not received up to date resource study material which
defines 50 billion tons resource base Please furnish
The resource base at Sultani alone is adequate to support two 400
MW power projects capacity subject water availability The
2-million cubic metre per year water allowance for oilshale will
limit development to about 600 MW
24 Selection of a combustion temperature is a balance between carbon
combustion efficiency and heat loss due carbonate decomposition
For purposes of the Prefeasibility Study we have opted for high
combustion efficiency At lower efficiency larger shale
mineprocessing plants will be needed
25 Bottom ash is cooled by water exchange before discharge
Cooling water is supplied to the ash screw coolers as specified by
Pyropower See Drawing MOO5 2140 gpm flow for 50 MW and 860 gpm
flow for 20 MW Heat removed by the cooling water from the ash
screw coolers is dissipated to atmosphere via a wet cooling
tower Pyropower should indicate the temperature of the ash
discharged to be 5OOF
32389
Page 11
Initially we had considered using a heat exchanger to cool the ash
and improve the cycle efficiency Considering low cost of fuel
the additional capital costs and the system complexities it was
decided not to employ such heat recovery systems for this project
26 The suggested alternates were looked at briefly and the potential
for wind blown air pollution from the ash disposal areas are too
great to warrant dry disposal unless GO(] and World Bank are
willing to accept such a potential problem Wetting the ash is
tne only practical solution Hopefully some cementation will
occur helping to reduce future leaching potential
27 JEA requirements are noted This is a conceptual study not a
final design Optimal design analysis can be performed during
Phase II
2829
JEA requirements are noted and can be incorporated into the Phase
II design
210 The transformer size is adequate for base load operation A
higher capacity can be considered at the final design stage if the
Client prefers
211 From our experience it does not appear to be economical to
provide additional dry cooling towers to take care of maximum
ambient temperatures which may prevail only for a short period of
time in a year To study this an annual dry bulb temperature
duration curve is required Also adding additional dry cooling
towers will change the plant performance It should also be noted
that the dry cooling towers are very expensive and the size should
be selected carefly considering performance and cost and not on the basis of maximum ambient temperatures This can be studied
during Phase II
32389
Page 12
212 The plant gross output varies with condenser pressure
Condenser
Pressure Design 55 in HgA Annual Ave 35 in HgA
Unit Size MW 20 50 4xlO0 20 50 4xlO0
Gross Output MW 234 593 496 2415 607 TBD
Net Output MW 1975 501 400 205 515 TBD
To be developed in Phase II
Output for 4x100 MW is estimated by others
213 The fan power consumption of the CFB boiler is about 30 to 35 of
the total auxiliary power The fan power consumption of the dry
cooling tower is about 20 to 25 of the total auxiliary power
214 Table 1-1 does not include plant net output Therefore do not
understand the comment
215 Commercial operating experience with coal fueled CFBC units in LISA
and Europe has been uniformly good showing high on stream
availability in early years (See Table 2-6 which reports on
Pyropower experience)
We expect operations with high ash content fuel like oilshale will
have unique scale up problems such as
o Solid handling in and out
o Internal solids circulation
o Erosioncorrosion steam generator intervals
o Heat recovery from bottom ash
Consequently we are recommending these items be worked out in a
single 50 MW prototype
32389
Page 13
216 Maximum dry cooling is used in this study A small wet cooling
tower is used on circulating service water system
217 Horizontal condensate pump is adequate with dry cooling tower and it is cheaper Vertical condensate pumps with cans can be
considered in the final design if required
218 A concrete shell brick lined flue stack will be larger in diameter and costs more than a steel lined stack Brick lined stack can be
considered in the final design
219 Demineralized water tank capacity for 50 MW is 76 cu meters or 20000 gallons not 1000 cu meters For 20 MW plant it is 38 cu
meters or 10000 gallons
220 It is US practice to use an average continuous blowdown rate of
1 and maximum biowdown rate of 3 for this type of plants
221 This can be studied during Phase II
222 Same as 221
223 Same as 221
224 The recommended action plan calls for continuing support studies covering the referenced items Additional effort is needed to
further define these matters and confirm the conceptual plan
The next step is to develop an outline for a project plan including
o Work Scope
o Schedule
o Budget
accommodate the increase in the number of employees and
equipment Truck bays to accommodate the 136 tonne trucks
will be added The truck bays used for the 77 tonne
trucks will be used for the maintenance of other
equipment The warehouse change house training room
offices and cafeteria will be expanded accordingly
6025 Mining and Processing Economics
Details of the oil shale mining and processing plant
economics for the 400 MW plant are included in the Mining
Report (Appendix 5) These details are of the same
magnitude as prepared for the 20 MW and 50 MW plants
The summary of the cash flow analysis for the mine and
shale processing plant is presented in Table 6-1
Table 6-1
SUMMARY OF 400 MW PLANT OIL SHALE MINING AND PROCESSING COSTS
5050 Debt-Equity 8020 Debt-Equity
US $1000 US $1000
Capital Cost
Mine Development 30915 30915
Mine Equipment 66012 66012
Process Plant Facilities 50889 50889
Spare Parts 5000 5000
Working Capital 10000 10000
Capi tal ized Interest
During Construction 24423 39075
TOTAL 187239 201891
Operating Costs and Other Costs
Annual Cost 60386 53236
Product Mined and Processed
Annual Tonnes x 1000 7783 7783
Unit Cost
US $Tonne (weighted average)
US $l06Btu (weighted average) 776
156
684
138
Year 12 costs taken as 25 year average
6-6
-Au
Table 610 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
- FCC plant sizes equivalent to proposed power application
Prefeasibility Study Oil Shale Fueled Power Generation
VOO94GEampJRI26
i
PYROFLOW UNITS IN THE US
COLORADOUTE IOYA STATE UNIV UNIV OFNUCLA CO NORTHERNAMES IA BF GOODRICH110 1o0MW(a) 2x170000 Ibhr HENRYILCEDAR FALLS IA 120000 Ibhr GENERALGULF OILu EiN P MOTORSSbtUpStart-UIL 1987 O A 1I N000 TC
NORT10 PONTIACH B MIRANCHWV00000 lbhr
CORN PRODUCTSSM NORTH-CAROLINA STOCKTOD CA
400000 lbbhl t
RUMF RD ME
CEMENT CO CALIF PORTLAND-COLTON CA
190000 Iblhr Start-Up 1985 TRUMTFTWN NYU
3I75ERTOWN N
etar t-Up loss ACE COGENERATIONCABI
TRONA CA Oper t~on l -Start-UP 1990 ~ rt upz 091Start-up loss Start-up PNeLAI 1991
MTKESFICOENERATIO-N1
BASFIELDp Start-uStar-Up WESTCA9 199otgoUp 1 MAHONEV PA|00000 Ibhr A Oz 2X365000 Ibhr
SETtr-Ups 188B CHAT TANOOGA TN
G ULF OIL EXPLORATION 8ta-rt-u) 1085BAKERSFIELD NORTH BRANCHCA SPRING GROVE PANORTH BRANCH WV 400000 IbhtOperational 19835 5 0 0 I b h 9 0 0 0 Iblh r- tart-Upi 1991 S t r - U p s l e s s
SOUTHEAST PAPER MFG CO UNIVOF NORTH CAROLINArDUBLIN GA UHAPEL HILL NO400000 IbhrStart-Ups logo Start-Ups2X250O000 1loseIbhr B
- Withdrawing ash from combustor - Withdrawing fly ash
a Internal solids circulation of the steam generator
m Erosioncorrosion of steam generatorinternals
Heat recovery from bottom ash
U Operation with low calorific-value fuel
Prefeasblity Study O Shari Fueled Power Generation
VOO7AI 27
Impact of Scale-Up
Project Size
20 MW
50 MW
100 MW
50 MW boiler in 100 MW plant
Potential Risk
Design Scale-upOperation of to 100 MW Initial Plant Plant
Low Significant
Modest Modest
High Low for duplicate units
Modest Low for duplicate units
Prefeasibility Study Oil Shaje Fueled Power Generation
VOO71-4GEAL4n2
i
Conclusions
Defined risk of CFBC boiler is acceptable
U Operating experience with commercial CFBC boilers built and under construction will strengthen confidencelevel and minimize risk for a plant built in 1995
SPrefeasibility Study Oil Shale Fueled Power Generation
V007GHAAE29
ENVIRONMENTAL ASSESSMENT
a Mine and shale processing
- Fugitive dust emissions
- Noise levels
- Leachability of disposal piles
Power plant
- Fugitive dust emissions
- Gaseous emissions
- Noise levels
- Water effluents
U Conclusions
Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel
Prefeasibility Study Oil Shale Fueled Power Generalon
- Coaloil prices will be at least 15 greater after 1995
- Discovery of indigenous conventional fuel resources is inadequate for power plant purposes
Prefeasibility Study
Oil Shale Fueled Power Generation
VOO) IDWFO
Feasibility(Contd)
N Suitable financing will be available
- For $200 million 50 MW prototypeproject
- For $1000 million 400 MW commercial project
Government of Jordan will make basic commitments
- Long-term power purchase agreement
- Long-term access to Sultani shale deposit
Adequate water and manpower resources
- Attractive tax incentives
Prefeasibility Study
Oil Shale Fueled Power Generaion
VO bull1DUJJRO 6
Timeliness
U Timely development of Jordan oil shale needs prompt action to create - Additional definitive information
- Suitable business plan
Prefeasibility Study
Oil Shale Fueled Power Generation
VooI DUJo 7
i
Expansion Conditions
U Continued expansion of powergeneration from oil shale in Jordan depends on water availability
Prospects for power export or importand domestic load growth will affect size of the needed shale-to-power program
Prefeasibility Sudy
Oil Shale Fueled Power Generation
yOWl lVuJO
Environmental Impacts
N Environmental impacts of shale development will be minimal
Prefeasibility Study Oi Shale Fueled Power Generation
i
Development Advantages
Will create significant new jobopportunities in Jordan
Will avoidreduce foreign exchangelosses for expanding alternate fuel imports
Prefeasibility Study
Oil Shale Fueled Power Generation
VOOIIULL tO
Recommended Action Plan
N Basic recommendation
N Conceptual development schedule
U Project development plan
Key plan elements
N Funding requirements
Prefeasibility Study Oil Shale Fueled Power Generation
VOO4II )U OII
i
Basic Recommendation
N Expand efforts to develop an oil shaleshyfueled power generation program at the Sultani deposit
- Conduct required supporting studies
- Define facilities costs and business plans
- Obtain project funding
Prefeasibility Study
Oil Shale Fueled Power Generation
VON I II)ILL 12
C
Conceptual DevelopmentSchedule
1989-1990
- Conduct supporting studies - Define costsbusiness plans for 50
MW prototype and 400 MW commercial projects
- Develop project financing
N 1990-1993 - Build and operate the prototype project
N 1994-1996 - Expand the 50 MW prototype to 100 MW scale
U 1996-2000 - Expand the project to 400 MW scale
N 2000-2005 - Build a second 400 MW commercial project if needed
i 1 Prefeasiblity Study
dOil Shale Fueled Power Generation
VW IMLITO 13
Conceptual Development Plan
Months
1 Project development plan - Define project
costs1busness plans
-24 -12 0 12 24 36 48 60 72 84 96 108 120
2 Secure funding
3 Build and operate 50 MW prototype
Dergn and procurement
Mine development
Plant construction
Startup and testing
Operations
L- -
4 Expand prototype to 100 MW
Design and procurement
bullConstruction
Startup
5 Expand project to 400 MW
2nd 100 MW unit
3rd100 MW unit
i 44
4th 100 MW unit -
O Project dacision point
i Prefeasib~ity Study Oil Shale Fueled Power Generation
17958562aJocdanV 3-14-89 rsO
18
Phase I - ProjectDevelopment Plan
n Program development
Seminar workshop on prefeasibilitystudy Oate project development plan woek scope schedule arid budget
U Carry out project planning program
- Conduct continuing support studies - Test Sultani shale in existing FBC
- Firm up designs and specifications
- Update costs and economic analysis
- Develop business plans and requirements
Explore project funding alternatives
i Prefeasibility Study
Oil Shale Fueled Power Generation
VO MItUOR 14 -0
Key Plan Elements
N Project feasibility analysis
- Firm up designs and equipmentspecifications for all facilities
- Update cost estimates based on preliminary designs and specifications
Explore arrangements for contract mining and mine development
Update forecasts for demand growthand for retirements of older generating capacity
- Create updated economic analysis
Preleasibility StudyO1 Shae Fueled Power Generation
VOO1IOLWRI
Key Plan Elements (Contd)
Business entity requirement
- Explore optionsconditions for a new company to managebuildoperate the project
- Explore optionsconditions for obtaining a concession agreement for Sultani development
Explore optionsconditions for water rights commitment
Prefeasibility Study Oil Shale Fueled Power Generation
VMIOIA)lj 16S
i
Key Plan Elements (Contd)
U Continuing supporting studies
- Combustion tests (additional pilot tests for design and warranty purposes contract for large-scale burn operations in existing plants if appropriate)
- Additional core drilling and core analysis
- Oil shale crushing tests
- Spent ash leaching tests
- Geotechnical data base including soils analysis
- Environmental baseline data
Prefeasibility Study O Shae Fueled Power Generation
VMMMUldMOA
Steps Required to Develop an Oil Shale-to-Power Project
Create a development business plan - Schedule - Decision tree
Develop a work scope and budget for the development plan program including - Firming up designsspecificationscosts
- Developing business entity requirements - Continuing support studies
Carry out development plan program
Assemble all planning results in a report for discussion with financial institutions
Explore project finance opportunities
Finalize business arrangements
Implement prototype project
i Prefeasibility Study
Oil Shale Fueled Power Generation
VM1-11UJROLI
MARCH 15 JEA QUESTIONS (M S ARAFAH) ON PREFEASIBILITY
STUDY DRAFT REPORT
Rt
DIR EScBSULIVAN PHD OFJCEop~BUREAU FOR SCIENCE AND~TECHNOLOGYAGENCY - --FOR INTERNATIONAL DEVELOPMhINTSWASHINGON DC x20523---------4
4 -
-SUBJ E CT - -C O H~ E T 4N l
Dr Mr sullivan ------shy
c-rommnents We ~efr-preaereorPla -tobYou lete dted Jan 91989 regardn~i4po4t P ea e1 f i nd y ubel ow our -e ot r XcOrcerned Jordanian deipartments
- --A ar o~nnYu Y o turjlt~ lt K
4 C~mments
~1 N i gFIN I~fANDECONOMIC1COIMEN S -
It sidicaed that Beohtel and US AIDWash ingtonj~4- re ojy nen ing that E 2hould und ertake the n e tshyihaisAre ~our c leometprogram n order shye-t im~ ate d f n t v design and budget cost
4Al1so Lthe study ncal--ttsutnilndcaei~ A-1 A thas ~ l 1 be eeded idb~~~~~ rn o ei t n i la itheMWa~-~5s~ 4
hrPro hehgemetTh trOfT ses~fnr4 BOT)Vmanu- a n-mnf~cure 4 r~j or contra c4-or ivoIlveiintijn I 4 4investmnt ude smi ~w 2 Zha tev e r --~4~prce e ec r it v p4~ f JA gertiy geeated-at 4 JEA 3 a l b u y ~the same average~~ A
~jithia oncot in4 ordrtan ecpoemic asess thespePower generatjoon J ordan3 oi sha I eroic c inr~etJordan 4
2P ge i1- 1 Aj iit eu that OPin he atocontr~ct 4with owner4 ofext3ing (oconstriiction r(FB rml-t
qu i of S 11 t to test large tonnagen j es StaniUti n d ajIe -for se veralIQf 31 hi
evrEAPreferpilot qr the dP 1prt7n -that the4mPIt
andi to(7 he instalI 1e 2 310 A
_
JODN ELECTRICITYAUTHORIT LL
Dac
operated in Jordan i n or~der~~t ~n nuex~on mnining crushing and haidi igQhre~ and sash Maeia nd aSootoget enough olr ndaita needed for einolre
CEBbole~ -i s~
ccordance with Jordaian oil shale
large to~ bfig
1 3 le 1-2 Page 1-7 Cost Of Pwer~i It i S menti-oned that the conmecial oil hle~ lt~project (4 X1OOmw) 1is ninacompetative roqt~range-~while table 12 indicates thattcost of-pow Ais~mill
q kwiihcii r 1
average wih i ii -much higher ihantheshy-ost of ~Power gnrtofomJEA therimaPower s ta tions Please~ indicate on what basi o ~~ shave-~made your-statement
PK
14 Pae 2 Sction 4-0sIt 1nlkly that theChousing and off- -site infrastructur-ommnity fakilitieR) to be onsidered for both the demo and prototyp prjcs oeoverwe~4 hnk that their~c_6t is raterojects Mo
iwcv~- age -1 1 Mine O(perationIIt is indicate~d that mining cot eevdfoMine contractor~ are ficomiplee h
r and iyudi-t~con qidder contract mnn opio fr4 the min4 cmflt2ng are reIanddrepres~ent the real costs derived from Phspat miin contractors in
lestfor the eo rPooypuat in order tlt7
P I eadenote tha detthe new exchangerate ofthJraian~ Di~nner you may add 20j6 Kto the quoted
1 6 P Ias e consider the followin ecn hage_
171- The new exchange ra teof tUSD=54o0 fils1 72-W2 The new~ aerage tariff for selIn~electricityhas decrreased to 120 8 f ilIsicwh
17- Page 1-7 TbIe 1-2 W bev th tthe cap ita1 cot for the pwhokand forthe min n d ash hMnd1ing equipen
P B~2Anaor a -Tl 8156152 8176 1Q MYf -t -Now 520 t 1U
JDNEECRICIT AU-RA L14lLiL
2 ~are very high We suggest~ thta You rerconsie (- telowerus e~+d accuracy est a rangethan +30
Page4-22 Table 4-5weno0ti ced( that- PyroPowe ha ddeta(IiacCst fori the bo1ilerlocation and terha dutdetlease isxtr fo~ l C~ io~ s~ e~~ 1a~ a if and indicate theonldjusted ~percentagefor construction foin Jordan
19 Page-7 Table 11-2 -Yo aeue ihrinterest rate on Equity thatn on1DehI~laseinclude~ adetaied explanation of thisrr -tni kepin in miUndie JEA is1thaIt a non profit~ shyorgaiztion unik oher private UJSA utility~in ktation
~-~110- Regarding shy
the ra4ital Rt fthe project it is~requesed tobre k it intdo foreignMeanwhile cthe nd lorcal c-osfoeigptario i nt-re3t~shol becnierdo-h
rr n ontiondonnotopdbon the 9 cnieelocal portion~onth
1-1- 237~Pa
oningeny 9tooi s high~~ a lower 4value -should be~
4~ gt ~112- -Tbles t1-1 -8-8~ inclu~de t~he c~alculationscuultie nt enefits for of Th shyunttypes l i4s difeen geeatnmrer likely tocluae
-~ Q~ J7present vk1u for tenet tthe~benefits in feralterntives -t-oa s the
49
ehliyoi shale
Wea gree with you9 tha t th e percentage used ~ an for thenua~l 0 ~amp-M rahr CFBo ndsomewha~t highervrate be n ededma y for a C B l n Me n h l ~ a e r
indir e ta~ts the -estimatedma i variablec st i ddition t he fi-xed-9i 1 mislkih We --
thinktttiis too lowK -5
shy
1-14- e 4-29
opprza tion-o to The o i1s h1 costs-nc I deAbo 1h
Pa10 mman ormTSI62 a
IB I
JORD N EtECTICI1~ 4 E~)~Is-s
Date ib-_
~ ~riii~g~nd~o9~ru~hng h~tnlin cot~u~tv yo
i Dae Jnryit
1ts c 7 4-
i smiig iniand fh co I eY
susendi ca tI t icag th t1 ~an~approximate 15 ~pita L tYII I (-~a~ge or he owe bl ockj f aniitjes isof +the capthe)t~ial7cpi~lrharge Uoratelformny SI~Uj(uiity installa~tions~ whle page 6-1T9 talJshyit is mentioned that~ the Capital rate pe-r JEA isshyi5~PeaseJustify this~matter since~w o
i16- Pae 6-1 6
1 I4~t is mentioned that the costs of 4process Water are ~ 4 ~0 2$1 000 gallons
r~j~lt IHave~You considered additionalvalue ofbying waterfrom~ the Wa ters Aito i ~or ditoa cost~f o revrseoqoesplant if ground water is used
~~ I1 7- Table 6-1 Page 6-6 Please explain how did You come ou ihteoil~ shale miniing and proces~sing uit~Icost
ltII~I~ 8- Please note 1 t hatj the average JEA~productinr ot frmthermal I power stationsr (Istationbus-barCOSt)i sbewen 6 3-17 3 fils 4kwh You may use this~
l4~ 19-i For ~4 X 100~AMW Plat iti etindo pag e14-4 VolI 11 that4 at tota I of W42 14 epoye W II eemplo~yer] And on page 69yo1Iiti mentioned that a~ tot 1 f1 ~p yeI iNbe enp1oyed a
is~ high asrmetitexeds100personorthe ~41X100~MWh~~j nsatnpPrlae
I 1 The 4 following iftemns are a sumed to1 be excluded from theraPi ta 1 cot xoI
120-1 Perits I icen es 7
1_207~3 Imprt ~xe on s7pare par ts -and c(7orfmurab -ma~teria Is
04f4 4
~4 R j4 4
D4
~ ~ ~ AIf eS taxesq in acrac ihteJraand regulations should be considered aw
21- p1ea4s e indic ate Your Ju t f c io r us ga 6
44122- Table 977App 5Page4 9-1 4L IK Car1Yiniae that the hIRR of the 4 Otplantis rather unattractive (66)most
-( Cns1er4 ngthe logical base 4csek c pwhen cii 6OL
average sell~ing prc CkhampDEratio L801~2O~Aoreover4M the ne siellin prcwh o JEA ati theamptime~ Abeing os4ltp n~ot exceed 4 Ckwh~-However Ipage 1shy~ and 14 0 T indicate that ecnms for a commeri
S4A4scale joil 4 shale projc ~
appear Piomisig-nug o4Ywarrant continued dee fgfluht 4 feaibiit 4tudy wihil cost sevea~lili
do ar~sf Plas lear wether the ~x step jqs~$j~~lt 4
gtt 9o be considered arCcording4to jthe 4unattractiveresul to mentioned in IRR7 Table 97 gt4
a C4 44fET2 4 144-4444 P a g 1 T b6 l
htte~We ~ ~ ae~ rqieetfrteX ~ noie ~~ ~ 444 MW un t44 r te4l w w e o p r d i th e w t r n rre u f4m or4444~ the4444 54M4rto y e Pg~A~44EHiveL det ile an l A44
s o awa er c n um t a4r f rofsho in P6Io erT
e ch 2 50 M W aPln wa e d 41004 MW4 1 consumption_____________
ma4~2 k e u p houin~44 p A44 4444444 C O 4ltI4
a nd a sh et in etc 4 2 4 1 -24 P a g e4 2 - 1 A P P 5
4Yo 4_ j1 4 4~h444 N44 44
1gro nd tce t hir fthe w bern coqir mna t efora4e 4X10A M 444444 4 r i n to 4 4 4lo w w ehA 7 n 2 cinCie h rh4 n ttthh1eb -e 4 44t Of3 E4O
ea h n~ ffl 4 4Jl44 4 4444 4giv
6 ig re sofrat4 de in cl ar f w w at5 c hrw pe o
s h b 444 o t h e g nd L 44 h u i n C
r 4ne a4 t44 e L(704 2 4 p ae) 2 - o Au P dn 5ai 7~e r 44 I Y (1t 44a
ve7 rn e qu 1saharvthe y
and n~~~o speci~~~l4 p n l nh i n t x
r ~rA M e d r o t eu n 8 1 wTtl t t h
- c re e N I wo6
~ n n a i n a t d h l7 A PP6 gt
J
S2~3- Page 2-4 ~ ~ It ~is i
that oil eindicated the- sha le r our~ Cesin Jordan are 10 billion tons -The anulp e reere maiy exeed 50 4 billion tons ~
~ 24- 4Page~2 -l1 iujntr We beiv thtCBcmuto~ep i s high and~alSo
~~ ~ -2 ~~ Page 4-1~6 j - shy
Please~~ indicates your procedure to cool the omn ashand atwa icagd-eprtr
A Have you~ considered~ additional he~at exchanger topcool th ash and to imrve h cycleef ficiency
-~2~6 Page 4-16 It s~ indicated that ash from each silo i Amixed19 ~with~fabout 20 waterKb weight to minimize generation of dust~during trnprtto to mine and disposalHave you~ coniidered other 4lternativeto
~ ~eliminate dustiiig -and avoid use ofwat r uring it ransportationi such as~ using closed trucks or closed
of ~fans conUMnPo wihrlaintthe total plant auiir poe osupin 1~21- Table 5_-3 and I ~
Th~~ is- somneere c6ntradiction regardingplnneotpu~t in both am tables 21-~ Tabl~e 1-33
We noticed tha~t yourall9 cacacapac t fatro75 tion ae asdnWe thilt ~that 7capacityshyfacto is tobo high for- an oil shale fired plant duketo lack of existing simila~r ~plants handl~~~firing oil adshale ~K
216~ The study iniae thtawet~coigtower wi11~used Actually a b
dry cooling should be consideda5ini ~HTP S inZ atomnmz so water rnumption4the cycle~ efficiency willbe reducedHenre YO33~reconsider calculating the cyclefficiy
U~~~~~ codnt umconsidered ofhorizontal -aretypethe~ the vertical cian type can alsobeh considered
shy ~ ~ ~ I~~
2~2 Kconcrete shy
shjell stepl fltstack is onidereconcrete shell brick flue Rt c ~s beCaconsidered3V
2-19~- Deminiraized water~ tank3 capacity~ is -76 ui(meterThe recommnended tank cameter- ui tyi 00cbc
220Designconditions Pa~ge (4-74)te5 hat bow 3down percentage splusmn ~fomrpra til re i hou I be 3~)~
PoD Z 2 m a ad~ - e 5 1 2 iJS~ ~ p A f amp ~ ~ y1
4
JO R ECTICITY AUTHORTIT 4L
~ 4
Date~
t etats ttthe quantityof s i S ~1 000Tons ra Sthis tuntity 11- be transporited for severIy --to tu ofI pit a~te torg P KM ra~erm Spower plIatS about 12 midilidoni CUIA(- met ryea
h e ndd mp e he (d u p in i n L
area wil evric power plant6t Please zn1 a te~tiv s tudY for dumping th r~ a enoug
-from the power plantr~~h~
S 2- Please provide deald-ifrat ao etbaaiedrawing hwn TH11 R thaU and~pV ra~te takcing illto o 6it v- consumptionn _uig themrining equipment
alternate~ study 0o Jine operation for 1 shiftday Vand twoshifts day -lt
224- Conceptua~l pflR 1 for mi ing anusdtransportation of oil- shale a 0 dmj of hs f u r therV examinedh iV~sdpatI ho u1d be
orderj to poe~ehicalq and~eoomca1 fesblt of t his operation
SYour are requested te) study and consider all- above - iPoin s at your earliest in rder -to be peete y oiAnimain on March 29-301989 peetdb~o 4 n
S9incerly-You S
WDIRECTORGENERAL -
I~ CCMR WLINTON ~vs
5N
Pa D~t~IoAmmn -Jordtn -Tel 815615 20 Bl76 15 -19j A VINO- AFf TY
MARCH 21 RESPONSE TO JEA QUESTIONS
Bechtel Power Corporation Engineers - Constructors
Fifty Beale Street San Francisco California Mail Address P 0 Box 3965 San Franclco CA 94119
March 21 1989
Mr M S Arafah Director General Jordan Electricity Authority PO Box 2310 Amman Jordan
Subject Jordan Oil Shale Prefeasibility Study
Dear Mr Arafah
Your letter of 15 March 1989 with comments on the Oil Shale to Power Prefeasibility Study draft report has been referred to me for reply
The attached responses to each item in the reference letter follows the order submitted
Also attached are three revised pages for the draft report - Volume I
Page 6-1 Page 6-21 Page 6-23
Please copy these revised pages into the report previously sent to you
We plan to review this material with JEA during the March 2930 and April 1 meetings in Amman
rsuVertrul yours
W Linton Project Manager
WHLdc
Attachments Questionnaire Response Three revised pages
cc C J Aulisio R R Buta G D Gould T J Wilbanks
32389
Page 1
RESPONSE TO MARCH 15 1989 QUESTIONAIRE
OIL SHALE TO POWER PREFEASIBILITY STUDY
This study examines economic prospects in terms of a 1995-2000 timeframe
FIRANCIAL AND ECONOMIC COMMENTS
11 It is likely that a BOT deal can be structured at present JEA
generation costs for either 20 MW or 50 MW size units if GOJ is
willing to subsidize the incremental power generation cost
Furthermore these incremental costs can be recovered during the 25
year operation of a Commercial Scale Project
12 A 3rd Party Test was proposed as an alternate means to raising
$100+ for an independent JEA sponsored 20 MW Demonstration
program
13 71 millsKWH for Shale Power
VS
JEA 1987 costs
Purchased Power 17 filsKWH = 51 mills
Produced Power 1360 filsKWH = 41 mills
19952000 Costs - Expected to be 30 to 40 higher and in line
with the cost estimate presented in this study
It also is important to recognize that the busbar cost of power
generated by any new power source can not be compared directly
with the cost of existing older installed capacity because of the
lower capital cost component of the latter (See enclosed Figure
1-1 which demonstrates how total capital carrying costs decline as
the investment is paid off) Any new capacity whether coal oil
or oil shale will be an unreasonable disadvantage compared with
costs for existing older capacity
l
024
o2
0De return
E 016Total carrying charge
012 qu return
S -008
ety taxes and n rcw vshy000 X 0 5 10 15 20 25
Figure 1-1 Year-by-year Carrying Charge Components for 15-yearTax Recovery Period
1-7
30
32389
Page 2
14 Infrastructure Cost
Total People
OperatorFamilies Installed Cost
20 MW $10000000 185700 $54000Operator
50 MW 15000000 3241200 46000Operator
400 MW 45000000 10364000 43000Operator
Factored allowance for grass roots desert installation
including housing and community facilities was developed as
follows for the 50 MW case study
Infrastructure
50 MW
Family Housing 200 30K = $ 6 Million
Bachelor Housing 100 20K = 2 M
HospitalClinic (8 Beds) 11 M
SchoolMosque I1 M
Stores Services amp Recreation = 2 M
Facilities
Roads Electricity Water Sewage = 3 M
$15 Million
Infrastructure costs for the 20 MW and 400 MW cases was ratioed
from this breakdown
At this conceptual level costs are order-of-magnitude In a Phase
II program these infrastructure costs can be developed in detail
32389
Page 3
15 Contract Mining Alternatives
Page 4-11 Mine Operation
Based on Bechtels evaluation of the mine contractors price as found in Section 15 of the Mining Report it was concluded that
the mine contractors price does not include costs for such things
as developing the mine with a box-cut ramp haul roads
developing an area for the waste material maintaining the
haulroads constructing the mine services facilities diversion
ditches sedimentation ponds water well crushing the oil shale
pre-mixing the oil shale at the mine and other items associated
with operating a mine to support a power plant If it is proven
that the mine contractors price includes cost for the above
mentioned scope of work in additi-n to drill blast load and
haul then the contractors price can be used but in the meantime
the all inclusive cost developed by Bechtel should be used
Contract Mining appears to be attractive for the smaller size
plants but not for the larger commercial scale operation Some
third party must provide the necessary capital for trucks
loading mining machines etc under a contract arrangement
16 Reassessment due to Dinar value change needs further study and can
not be evaluated given present budget limitations If average
labor rate of $300hr still valid then little change involve with
study
If deemed necessary reexamination of project economics can be
done in Phase IIwhen funded
17 Costs in this study are based on recent similar Bechtel experience
on Mount Poso project and on Montana I project The Mount Poso
project is a 50 MW unit firing coal in a Pyropower boiler The
Montana I project is a 35 MW unit firing coal in a Keeler Dorr
Oliver FBC boiler utilizing dry cooling
32389
Page 4
18 The Pyropower quote of $186000000 to futnish and erect the steam
generator stack and baghouse has been adjusted to include
engineering construction indirect cost etc to be consistant
with the rest of the costs shown in Table 65 p 6-10 No
further adjustment for location was made
19 Equity funding has the lowest priority of payoff in case of a
liquidation and carries greater risk Hence a higher rate of
return is needed to attract these funds Debt funding is a first
mortgage and has first priority for payoff in case of liquidation
and carries less risk Hence it requires lower rate of return
than equity funding
The risk taking equity owner will ask for greater interest rate
to make funds available The only way to minimize this expense is
to find a loaning agency willing to provide 90 or perhaps 95 of
the investment cost It is likely that banks will require some
minimum equity participation
This Prefeasibility Study was not based on a non-profit utility
operation
Even though JEA is a non-profit organization its service
contributors are profit making groups It is visualized that the
Jordan Oil Shale Co (JOSCO) will be a stand alone business
enterprise servicing JEA under long term contract To secure
funding for the proposed project JOSCO will need attractive
enough contract terms to attract both equity and debt capital
110 Additional work is needed to develop the requested information
This work can be preformed as part of the Phase II program
111 Bechtel includes contingency in all of its estimates to cover
error emissions and unforeseen items within the defined scope of
the project The level of contingency is dependent upon the
amount of scope definition For a prefeasible study such as this
15 contingency is lower than normal
32389
Page 5
112 Tables 89 through 816 include a present value calculation to
establish the relative benefit for a shale project vs coal and
oil
113 The variable maintenance cost of 1 millsKWH has been adjusted for CFB plants with an additional $200000 per year or 06 millsKWH
This yields the following
Variable Maintenance - 10 millsKWH
CFB Adjustment - 06
Fixed Maintenance Cost - 40
Total Cost 56 MillsKWH
114 Page 4-29
The royalty costs are included in the weighted average oil shale
costs for the 50 megawatt plant
Page 4-8
Shale fuel costs include return on equity and royalty These are
two separate cost items Royalty is the last item mentioned in
the sentence and it therefore reads as royalty and not return on
royalty
Page 4-31 gives rates used by Bechtel based on our calculations
using the referenced procedures
DebtEquity Capital Charge Rate
5050 153
8020 139
Table 69 displays the calculation of the 153 capital charge
rate (Line 7 of Table 69 is not used in the calculation and
should be deleted)
32389
Page 6
116 No water purchase charge from the Water Authority was added to the
operating expense based on the statement that no resource costs
will be charged
$020 per 1000 gallons is rule of thumb for USA installations in
absence of client data
Boiler make up water (p4-17) is treated in a demineralizer
train If deemed necessary comparison with reverse osmosis
process can be performed in Phase II
Water requirements were estimated to be
Cubic Metres Per Year
20 MW 50 MW 400 MW
Mine amp Shale Processing 455000 761000 773000
Power Block 3000 6000 42000
Infrastructure 80000 140000 448000
Total 538000 907000 1263000
117 Annual average operating costs shown on Table 6-1 are in error
Financing Option 5050 8020
Cost Shown 56606 48945
Corrected Cost 60396 53236
Average mining and shale processing costs are developed year by
year in the Mining Report Appendix 5 Table 12-10
32389
Page 7
118 We would be interested in receiving the breakdown of these current
power cost figures (ie capital charges fuel cost number of
operators etc) Further economic analysis employing these
figures can be developed in Phase II
119 Manpower requirements for the three case studies were estimated as
fol lows
Mining amp Shale Processing
Power Block
Operations
Maintenance
Management
20 MW 50 MW 400 MW
75 163 396
54 78 175
46 73 455
10 10 10
185 324 1036
Page 14-4 of the Mine Report is for mine and shale processing
only It should be noted that most of these manpower requirements
involved new jobs for Jordanian people
120 At the April 1988 Amman Meeting it was agreed that the following
costs would be omitted
o Permits and Licenses
o Local Taxes
o Import Taxes
If necessary such costs can be developed and added into a revised
economic analysis as part of the Phase II program
121 6 average inflation rate is the figure recommended by Bechtel
based on USA conditions for use in long term economic analyses of
new power ventures
32389
Page 8
122 This matter is referred to ORNL who prepared a rate of return
analysis
Bechtels conclusion is based on computed busbar costscumulative
benefits compared to alternate fuels in the timeframe 1995 to 2000
Relative Busbar Power Cost Net 25 Year
Mills per KWH Benefits - Million US$
Sultani Oil Shale 71-83 Base Cost
Imported Coal
$50tonne 68-88 778
$70tonne 78-107 2531
Imported Oil
$17Bbl 56-76 (18) $24Bbl 61-96 1810
The above results are based on a capacity factor of 75 which is
considered to be a reasonable target for a new plant over its 25 year
life The average selling price of 6 cents per KWH cited in the
questionnaire is based on existing plant costs which may not include
all cost elements of new capacity evaluated in this study
32389
Page 9
TECHNICAL COMMENTS
21 See answer to Item 116
Total power plant raw wate consumption rates and annual
consumptions including the water requirements for wetting ash at the truck loading p int within the power plant are given in Tables 43 and 44 for 50 MW unit and Tables 53 and 54 for 20 MW unit
The raw water requirements for 4x0 MW plant were factored
excepting the mine where a revised mine pldn is employed to reduce water request The quantities shown on these tables exclude raw
water requirements for housing complex mine and ash wetting if
required at the ash disposal site
Total power plant requirements shown in the above referred tables
are
50 MW 20 MW
Rate gpm 207 102 (See Drawing M004)
Annual Use
Gallons 1400000 675000
Cooling tower blowndown supplemented with raw water is used for
wetting ash at the truck loading point within the power plant Raw water quantities attributable for ash wetting at the power
truck loading point are
50 MW 20 MW
Rate gpm 75 325
Annual Use
Gallons 500000 215000
These quantities are included in the quantities shown in
the above referred tables
32389
Page 10
22 We recognize the POTENTIAL for leaching toxic compounds from the
spent ash However this matter is not yet defined well enough to
recommend specific action steps The Prefeasibility Study page
7-12 recommends creation of a ground water dispersion model to
determine whether more specific contaminated water mitigation
plans are needed It is anticipated that the leachate rate will
be low and that aquifer dispersion will keep problem compounds
bel3w health standards thresholds
23 Noted
We have not received up to date resource study material which
defines 50 billion tons resource base Please furnish
The resource base at Sultani alone is adequate to support two 400
MW power projects capacity subject water availability The
2-million cubic metre per year water allowance for oilshale will
limit development to about 600 MW
24 Selection of a combustion temperature is a balance between carbon
combustion efficiency and heat loss due carbonate decomposition
For purposes of the Prefeasibility Study we have opted for high
combustion efficiency At lower efficiency larger shale
mineprocessing plants will be needed
25 Bottom ash is cooled by water exchange before discharge
Cooling water is supplied to the ash screw coolers as specified by
Pyropower See Drawing MOO5 2140 gpm flow for 50 MW and 860 gpm
flow for 20 MW Heat removed by the cooling water from the ash
screw coolers is dissipated to atmosphere via a wet cooling
tower Pyropower should indicate the temperature of the ash
discharged to be 5OOF
32389
Page 11
Initially we had considered using a heat exchanger to cool the ash
and improve the cycle efficiency Considering low cost of fuel
the additional capital costs and the system complexities it was
decided not to employ such heat recovery systems for this project
26 The suggested alternates were looked at briefly and the potential
for wind blown air pollution from the ash disposal areas are too
great to warrant dry disposal unless GO(] and World Bank are
willing to accept such a potential problem Wetting the ash is
tne only practical solution Hopefully some cementation will
occur helping to reduce future leaching potential
27 JEA requirements are noted This is a conceptual study not a
final design Optimal design analysis can be performed during
Phase II
2829
JEA requirements are noted and can be incorporated into the Phase
II design
210 The transformer size is adequate for base load operation A
higher capacity can be considered at the final design stage if the
Client prefers
211 From our experience it does not appear to be economical to
provide additional dry cooling towers to take care of maximum
ambient temperatures which may prevail only for a short period of
time in a year To study this an annual dry bulb temperature
duration curve is required Also adding additional dry cooling
towers will change the plant performance It should also be noted
that the dry cooling towers are very expensive and the size should
be selected carefly considering performance and cost and not on the basis of maximum ambient temperatures This can be studied
during Phase II
32389
Page 12
212 The plant gross output varies with condenser pressure
Condenser
Pressure Design 55 in HgA Annual Ave 35 in HgA
Unit Size MW 20 50 4xlO0 20 50 4xlO0
Gross Output MW 234 593 496 2415 607 TBD
Net Output MW 1975 501 400 205 515 TBD
To be developed in Phase II
Output for 4x100 MW is estimated by others
213 The fan power consumption of the CFB boiler is about 30 to 35 of
the total auxiliary power The fan power consumption of the dry
cooling tower is about 20 to 25 of the total auxiliary power
214 Table 1-1 does not include plant net output Therefore do not
understand the comment
215 Commercial operating experience with coal fueled CFBC units in LISA
and Europe has been uniformly good showing high on stream
availability in early years (See Table 2-6 which reports on
Pyropower experience)
We expect operations with high ash content fuel like oilshale will
have unique scale up problems such as
o Solid handling in and out
o Internal solids circulation
o Erosioncorrosion steam generator intervals
o Heat recovery from bottom ash
Consequently we are recommending these items be worked out in a
single 50 MW prototype
32389
Page 13
216 Maximum dry cooling is used in this study A small wet cooling
tower is used on circulating service water system
217 Horizontal condensate pump is adequate with dry cooling tower and it is cheaper Vertical condensate pumps with cans can be
considered in the final design if required
218 A concrete shell brick lined flue stack will be larger in diameter and costs more than a steel lined stack Brick lined stack can be
considered in the final design
219 Demineralized water tank capacity for 50 MW is 76 cu meters or 20000 gallons not 1000 cu meters For 20 MW plant it is 38 cu
meters or 10000 gallons
220 It is US practice to use an average continuous blowdown rate of
1 and maximum biowdown rate of 3 for this type of plants
221 This can be studied during Phase II
222 Same as 221
223 Same as 221
224 The recommended action plan calls for continuing support studies covering the referenced items Additional effort is needed to
further define these matters and confirm the conceptual plan
The next step is to develop an outline for a project plan including
o Work Scope
o Schedule
o Budget
accommodate the increase in the number of employees and
equipment Truck bays to accommodate the 136 tonne trucks
will be added The truck bays used for the 77 tonne
trucks will be used for the maintenance of other
equipment The warehouse change house training room
offices and cafeteria will be expanded accordingly
6025 Mining and Processing Economics
Details of the oil shale mining and processing plant
economics for the 400 MW plant are included in the Mining
Report (Appendix 5) These details are of the same
magnitude as prepared for the 20 MW and 50 MW plants
The summary of the cash flow analysis for the mine and
shale processing plant is presented in Table 6-1
Table 6-1
SUMMARY OF 400 MW PLANT OIL SHALE MINING AND PROCESSING COSTS
5050 Debt-Equity 8020 Debt-Equity
US $1000 US $1000
Capital Cost
Mine Development 30915 30915
Mine Equipment 66012 66012
Process Plant Facilities 50889 50889
Spare Parts 5000 5000
Working Capital 10000 10000
Capi tal ized Interest
During Construction 24423 39075
TOTAL 187239 201891
Operating Costs and Other Costs
Annual Cost 60386 53236
Product Mined and Processed
Annual Tonnes x 1000 7783 7783
Unit Cost
US $Tonne (weighted average)
US $l06Btu (weighted average) 776
156
684
138
Year 12 costs taken as 25 year average
6-6
-Au
Table 610 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
- FCC plant sizes equivalent to proposed power application
Prefeasibility Study Oil Shale Fueled Power Generation
VOO94GEampJRI26
i
PYROFLOW UNITS IN THE US
COLORADOUTE IOYA STATE UNIV UNIV OFNUCLA CO NORTHERNAMES IA BF GOODRICH110 1o0MW(a) 2x170000 Ibhr HENRYILCEDAR FALLS IA 120000 Ibhr GENERALGULF OILu EiN P MOTORSSbtUpStart-UIL 1987 O A 1I N000 TC
NORT10 PONTIACH B MIRANCHWV00000 lbhr
CORN PRODUCTSSM NORTH-CAROLINA STOCKTOD CA
400000 lbbhl t
RUMF RD ME
CEMENT CO CALIF PORTLAND-COLTON CA
190000 Iblhr Start-Up 1985 TRUMTFTWN NYU
3I75ERTOWN N
etar t-Up loss ACE COGENERATIONCABI
TRONA CA Oper t~on l -Start-UP 1990 ~ rt upz 091Start-up loss Start-up PNeLAI 1991
MTKESFICOENERATIO-N1
BASFIELDp Start-uStar-Up WESTCA9 199otgoUp 1 MAHONEV PA|00000 Ibhr A Oz 2X365000 Ibhr
SETtr-Ups 188B CHAT TANOOGA TN
G ULF OIL EXPLORATION 8ta-rt-u) 1085BAKERSFIELD NORTH BRANCHCA SPRING GROVE PANORTH BRANCH WV 400000 IbhtOperational 19835 5 0 0 I b h 9 0 0 0 Iblh r- tart-Upi 1991 S t r - U p s l e s s
SOUTHEAST PAPER MFG CO UNIVOF NORTH CAROLINArDUBLIN GA UHAPEL HILL NO400000 IbhrStart-Ups logo Start-Ups2X250O000 1loseIbhr B
- Withdrawing ash from combustor - Withdrawing fly ash
a Internal solids circulation of the steam generator
m Erosioncorrosion of steam generatorinternals
Heat recovery from bottom ash
U Operation with low calorific-value fuel
Prefeasblity Study O Shari Fueled Power Generation
VOO7AI 27
Impact of Scale-Up
Project Size
20 MW
50 MW
100 MW
50 MW boiler in 100 MW plant
Potential Risk
Design Scale-upOperation of to 100 MW Initial Plant Plant
Low Significant
Modest Modest
High Low for duplicate units
Modest Low for duplicate units
Prefeasibility Study Oil Shaje Fueled Power Generation
VOO71-4GEAL4n2
i
Conclusions
Defined risk of CFBC boiler is acceptable
U Operating experience with commercial CFBC boilers built and under construction will strengthen confidencelevel and minimize risk for a plant built in 1995
SPrefeasibility Study Oil Shale Fueled Power Generation
V007GHAAE29
ENVIRONMENTAL ASSESSMENT
a Mine and shale processing
- Fugitive dust emissions
- Noise levels
- Leachability of disposal piles
Power plant
- Fugitive dust emissions
- Gaseous emissions
- Noise levels
- Water effluents
U Conclusions
Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel
Prefeasibility Study Oil Shale Fueled Power Generalon
- Coaloil prices will be at least 15 greater after 1995
- Discovery of indigenous conventional fuel resources is inadequate for power plant purposes
Prefeasibility Study
Oil Shale Fueled Power Generation
VOO) IDWFO
Feasibility(Contd)
N Suitable financing will be available
- For $200 million 50 MW prototypeproject
- For $1000 million 400 MW commercial project
Government of Jordan will make basic commitments
- Long-term power purchase agreement
- Long-term access to Sultani shale deposit
Adequate water and manpower resources
- Attractive tax incentives
Prefeasibility Study
Oil Shale Fueled Power Generaion
VO bull1DUJJRO 6
Timeliness
U Timely development of Jordan oil shale needs prompt action to create - Additional definitive information
- Suitable business plan
Prefeasibility Study
Oil Shale Fueled Power Generation
VooI DUJo 7
i
Expansion Conditions
U Continued expansion of powergeneration from oil shale in Jordan depends on water availability
Prospects for power export or importand domestic load growth will affect size of the needed shale-to-power program
Prefeasibility Sudy
Oil Shale Fueled Power Generation
yOWl lVuJO
Environmental Impacts
N Environmental impacts of shale development will be minimal
Prefeasibility Study Oi Shale Fueled Power Generation
i
Development Advantages
Will create significant new jobopportunities in Jordan
Will avoidreduce foreign exchangelosses for expanding alternate fuel imports
Prefeasibility Study
Oil Shale Fueled Power Generation
VOOIIULL tO
Recommended Action Plan
N Basic recommendation
N Conceptual development schedule
U Project development plan
Key plan elements
N Funding requirements
Prefeasibility Study Oil Shale Fueled Power Generation
VOO4II )U OII
i
Basic Recommendation
N Expand efforts to develop an oil shaleshyfueled power generation program at the Sultani deposit
- Conduct required supporting studies
- Define facilities costs and business plans
- Obtain project funding
Prefeasibility Study
Oil Shale Fueled Power Generation
VON I II)ILL 12
C
Conceptual DevelopmentSchedule
1989-1990
- Conduct supporting studies - Define costsbusiness plans for 50
MW prototype and 400 MW commercial projects
- Develop project financing
N 1990-1993 - Build and operate the prototype project
N 1994-1996 - Expand the 50 MW prototype to 100 MW scale
U 1996-2000 - Expand the project to 400 MW scale
N 2000-2005 - Build a second 400 MW commercial project if needed
i 1 Prefeasiblity Study
dOil Shale Fueled Power Generation
VW IMLITO 13
Conceptual Development Plan
Months
1 Project development plan - Define project
costs1busness plans
-24 -12 0 12 24 36 48 60 72 84 96 108 120
2 Secure funding
3 Build and operate 50 MW prototype
Dergn and procurement
Mine development
Plant construction
Startup and testing
Operations
L- -
4 Expand prototype to 100 MW
Design and procurement
bullConstruction
Startup
5 Expand project to 400 MW
2nd 100 MW unit
3rd100 MW unit
i 44
4th 100 MW unit -
O Project dacision point
i Prefeasib~ity Study Oil Shale Fueled Power Generation
17958562aJocdanV 3-14-89 rsO
18
Phase I - ProjectDevelopment Plan
n Program development
Seminar workshop on prefeasibilitystudy Oate project development plan woek scope schedule arid budget
U Carry out project planning program
- Conduct continuing support studies - Test Sultani shale in existing FBC
- Firm up designs and specifications
- Update costs and economic analysis
- Develop business plans and requirements
Explore project funding alternatives
i Prefeasibility Study
Oil Shale Fueled Power Generation
VO MItUOR 14 -0
Key Plan Elements
N Project feasibility analysis
- Firm up designs and equipmentspecifications for all facilities
- Update cost estimates based on preliminary designs and specifications
Explore arrangements for contract mining and mine development
Update forecasts for demand growthand for retirements of older generating capacity
- Create updated economic analysis
Preleasibility StudyO1 Shae Fueled Power Generation
VOO1IOLWRI
Key Plan Elements (Contd)
Business entity requirement
- Explore optionsconditions for a new company to managebuildoperate the project
- Explore optionsconditions for obtaining a concession agreement for Sultani development
Explore optionsconditions for water rights commitment
Prefeasibility Study Oil Shale Fueled Power Generation
VMIOIA)lj 16S
i
Key Plan Elements (Contd)
U Continuing supporting studies
- Combustion tests (additional pilot tests for design and warranty purposes contract for large-scale burn operations in existing plants if appropriate)
- Additional core drilling and core analysis
- Oil shale crushing tests
- Spent ash leaching tests
- Geotechnical data base including soils analysis
- Environmental baseline data
Prefeasibility Study O Shae Fueled Power Generation
VMMMUldMOA
Steps Required to Develop an Oil Shale-to-Power Project
Create a development business plan - Schedule - Decision tree
Develop a work scope and budget for the development plan program including - Firming up designsspecificationscosts
- Developing business entity requirements - Continuing support studies
Carry out development plan program
Assemble all planning results in a report for discussion with financial institutions
Explore project finance opportunities
Finalize business arrangements
Implement prototype project
i Prefeasibility Study
Oil Shale Fueled Power Generation
VM1-11UJROLI
MARCH 15 JEA QUESTIONS (M S ARAFAH) ON PREFEASIBILITY
STUDY DRAFT REPORT
Rt
DIR EScBSULIVAN PHD OFJCEop~BUREAU FOR SCIENCE AND~TECHNOLOGYAGENCY - --FOR INTERNATIONAL DEVELOPMhINTSWASHINGON DC x20523---------4
4 -
-SUBJ E CT - -C O H~ E T 4N l
Dr Mr sullivan ------shy
c-rommnents We ~efr-preaereorPla -tobYou lete dted Jan 91989 regardn~i4po4t P ea e1 f i nd y ubel ow our -e ot r XcOrcerned Jordanian deipartments
- --A ar o~nnYu Y o turjlt~ lt K
4 C~mments
~1 N i gFIN I~fANDECONOMIC1COIMEN S -
It sidicaed that Beohtel and US AIDWash ingtonj~4- re ojy nen ing that E 2hould und ertake the n e tshyihaisAre ~our c leometprogram n order shye-t im~ ate d f n t v design and budget cost
4Al1so Lthe study ncal--ttsutnilndcaei~ A-1 A thas ~ l 1 be eeded idb~~~~~ rn o ei t n i la itheMWa~-~5s~ 4
hrPro hehgemetTh trOfT ses~fnr4 BOT)Vmanu- a n-mnf~cure 4 r~j or contra c4-or ivoIlveiintijn I 4 4investmnt ude smi ~w 2 Zha tev e r --~4~prce e ec r it v p4~ f JA gertiy geeated-at 4 JEA 3 a l b u y ~the same average~~ A
~jithia oncot in4 ordrtan ecpoemic asess thespePower generatjoon J ordan3 oi sha I eroic c inr~etJordan 4
2P ge i1- 1 Aj iit eu that OPin he atocontr~ct 4with owner4 ofext3ing (oconstriiction r(FB rml-t
qu i of S 11 t to test large tonnagen j es StaniUti n d ajIe -for se veralIQf 31 hi
evrEAPreferpilot qr the dP 1prt7n -that the4mPIt
andi to(7 he instalI 1e 2 310 A
_
JODN ELECTRICITYAUTHORIT LL
Dac
operated in Jordan i n or~der~~t ~n nuex~on mnining crushing and haidi igQhre~ and sash Maeia nd aSootoget enough olr ndaita needed for einolre
CEBbole~ -i s~
ccordance with Jordaian oil shale
large to~ bfig
1 3 le 1-2 Page 1-7 Cost Of Pwer~i It i S menti-oned that the conmecial oil hle~ lt~project (4 X1OOmw) 1is ninacompetative roqt~range-~while table 12 indicates thattcost of-pow Ais~mill
q kwiihcii r 1
average wih i ii -much higher ihantheshy-ost of ~Power gnrtofomJEA therimaPower s ta tions Please~ indicate on what basi o ~~ shave-~made your-statement
PK
14 Pae 2 Sction 4-0sIt 1nlkly that theChousing and off- -site infrastructur-ommnity fakilitieR) to be onsidered for both the demo and prototyp prjcs oeoverwe~4 hnk that their~c_6t is raterojects Mo
iwcv~- age -1 1 Mine O(perationIIt is indicate~d that mining cot eevdfoMine contractor~ are ficomiplee h
r and iyudi-t~con qidder contract mnn opio fr4 the min4 cmflt2ng are reIanddrepres~ent the real costs derived from Phspat miin contractors in
lestfor the eo rPooypuat in order tlt7
P I eadenote tha detthe new exchangerate ofthJraian~ Di~nner you may add 20j6 Kto the quoted
1 6 P Ias e consider the followin ecn hage_
171- The new exchange ra teof tUSD=54o0 fils1 72-W2 The new~ aerage tariff for selIn~electricityhas decrreased to 120 8 f ilIsicwh
17- Page 1-7 TbIe 1-2 W bev th tthe cap ita1 cot for the pwhokand forthe min n d ash hMnd1ing equipen
P B~2Anaor a -Tl 8156152 8176 1Q MYf -t -Now 520 t 1U
JDNEECRICIT AU-RA L14lLiL
2 ~are very high We suggest~ thta You rerconsie (- telowerus e~+d accuracy est a rangethan +30
Page4-22 Table 4-5weno0ti ced( that- PyroPowe ha ddeta(IiacCst fori the bo1ilerlocation and terha dutdetlease isxtr fo~ l C~ io~ s~ e~~ 1a~ a if and indicate theonldjusted ~percentagefor construction foin Jordan
19 Page-7 Table 11-2 -Yo aeue ihrinterest rate on Equity thatn on1DehI~laseinclude~ adetaied explanation of thisrr -tni kepin in miUndie JEA is1thaIt a non profit~ shyorgaiztion unik oher private UJSA utility~in ktation
~-~110- Regarding shy
the ra4ital Rt fthe project it is~requesed tobre k it intdo foreignMeanwhile cthe nd lorcal c-osfoeigptario i nt-re3t~shol becnierdo-h
rr n ontiondonnotopdbon the 9 cnieelocal portion~onth
1-1- 237~Pa
oningeny 9tooi s high~~ a lower 4value -should be~
4~ gt ~112- -Tbles t1-1 -8-8~ inclu~de t~he c~alculationscuultie nt enefits for of Th shyunttypes l i4s difeen geeatnmrer likely tocluae
-~ Q~ J7present vk1u for tenet tthe~benefits in feralterntives -t-oa s the
49
ehliyoi shale
Wea gree with you9 tha t th e percentage used ~ an for thenua~l 0 ~amp-M rahr CFBo ndsomewha~t highervrate be n ededma y for a C B l n Me n h l ~ a e r
indir e ta~ts the -estimatedma i variablec st i ddition t he fi-xed-9i 1 mislkih We --
thinktttiis too lowK -5
shy
1-14- e 4-29
opprza tion-o to The o i1s h1 costs-nc I deAbo 1h
Pa10 mman ormTSI62 a
IB I
JORD N EtECTICI1~ 4 E~)~Is-s
Date ib-_
~ ~riii~g~nd~o9~ru~hng h~tnlin cot~u~tv yo
i Dae Jnryit
1ts c 7 4-
i smiig iniand fh co I eY
susendi ca tI t icag th t1 ~an~approximate 15 ~pita L tYII I (-~a~ge or he owe bl ockj f aniitjes isof +the capthe)t~ial7cpi~lrharge Uoratelformny SI~Uj(uiity installa~tions~ whle page 6-1T9 talJshyit is mentioned that~ the Capital rate pe-r JEA isshyi5~PeaseJustify this~matter since~w o
i16- Pae 6-1 6
1 I4~t is mentioned that the costs of 4process Water are ~ 4 ~0 2$1 000 gallons
r~j~lt IHave~You considered additionalvalue ofbying waterfrom~ the Wa ters Aito i ~or ditoa cost~f o revrseoqoesplant if ground water is used
~~ I1 7- Table 6-1 Page 6-6 Please explain how did You come ou ihteoil~ shale miniing and proces~sing uit~Icost
ltII~I~ 8- Please note 1 t hatj the average JEA~productinr ot frmthermal I power stationsr (Istationbus-barCOSt)i sbewen 6 3-17 3 fils 4kwh You may use this~
l4~ 19-i For ~4 X 100~AMW Plat iti etindo pag e14-4 VolI 11 that4 at tota I of W42 14 epoye W II eemplo~yer] And on page 69yo1Iiti mentioned that a~ tot 1 f1 ~p yeI iNbe enp1oyed a
is~ high asrmetitexeds100personorthe ~41X100~MWh~~j nsatnpPrlae
I 1 The 4 following iftemns are a sumed to1 be excluded from theraPi ta 1 cot xoI
120-1 Perits I icen es 7
1_207~3 Imprt ~xe on s7pare par ts -and c(7orfmurab -ma~teria Is
04f4 4
~4 R j4 4
D4
~ ~ ~ AIf eS taxesq in acrac ihteJraand regulations should be considered aw
21- p1ea4s e indic ate Your Ju t f c io r us ga 6
44122- Table 977App 5Page4 9-1 4L IK Car1Yiniae that the hIRR of the 4 Otplantis rather unattractive (66)most
-( Cns1er4 ngthe logical base 4csek c pwhen cii 6OL
average sell~ing prc CkhampDEratio L801~2O~Aoreover4M the ne siellin prcwh o JEA ati theamptime~ Abeing os4ltp n~ot exceed 4 Ckwh~-However Ipage 1shy~ and 14 0 T indicate that ecnms for a commeri
S4A4scale joil 4 shale projc ~
appear Piomisig-nug o4Ywarrant continued dee fgfluht 4 feaibiit 4tudy wihil cost sevea~lili
do ar~sf Plas lear wether the ~x step jqs~$j~~lt 4
gtt 9o be considered arCcording4to jthe 4unattractiveresul to mentioned in IRR7 Table 97 gt4
a C4 44fET2 4 144-4444 P a g 1 T b6 l
htte~We ~ ~ ae~ rqieetfrteX ~ noie ~~ ~ 444 MW un t44 r te4l w w e o p r d i th e w t r n rre u f4m or4444~ the4444 54M4rto y e Pg~A~44EHiveL det ile an l A44
s o awa er c n um t a4r f rofsho in P6Io erT
e ch 2 50 M W aPln wa e d 41004 MW4 1 consumption_____________
ma4~2 k e u p houin~44 p A44 4444444 C O 4ltI4
a nd a sh et in etc 4 2 4 1 -24 P a g e4 2 - 1 A P P 5
4Yo 4_ j1 4 4~h444 N44 44
1gro nd tce t hir fthe w bern coqir mna t efora4e 4X10A M 444444 4 r i n to 4 4 4lo w w ehA 7 n 2 cinCie h rh4 n ttthh1eb -e 4 44t Of3 E4O
ea h n~ ffl 4 4Jl44 4 4444 4giv
6 ig re sofrat4 de in cl ar f w w at5 c hrw pe o
s h b 444 o t h e g nd L 44 h u i n C
r 4ne a4 t44 e L(704 2 4 p ae) 2 - o Au P dn 5ai 7~e r 44 I Y (1t 44a
ve7 rn e qu 1saharvthe y
and n~~~o speci~~~l4 p n l nh i n t x
r ~rA M e d r o t eu n 8 1 wTtl t t h
- c re e N I wo6
~ n n a i n a t d h l7 A PP6 gt
J
S2~3- Page 2-4 ~ ~ It ~is i
that oil eindicated the- sha le r our~ Cesin Jordan are 10 billion tons -The anulp e reere maiy exeed 50 4 billion tons ~
~ 24- 4Page~2 -l1 iujntr We beiv thtCBcmuto~ep i s high and~alSo
~~ ~ -2 ~~ Page 4-1~6 j - shy
Please~~ indicates your procedure to cool the omn ashand atwa icagd-eprtr
A Have you~ considered~ additional he~at exchanger topcool th ash and to imrve h cycleef ficiency
-~2~6 Page 4-16 It s~ indicated that ash from each silo i Amixed19 ~with~fabout 20 waterKb weight to minimize generation of dust~during trnprtto to mine and disposalHave you~ coniidered other 4lternativeto
~ ~eliminate dustiiig -and avoid use ofwat r uring it ransportationi such as~ using closed trucks or closed
of ~fans conUMnPo wihrlaintthe total plant auiir poe osupin 1~21- Table 5_-3 and I ~
Th~~ is- somneere c6ntradiction regardingplnneotpu~t in both am tables 21-~ Tabl~e 1-33
We noticed tha~t yourall9 cacacapac t fatro75 tion ae asdnWe thilt ~that 7capacityshyfacto is tobo high for- an oil shale fired plant duketo lack of existing simila~r ~plants handl~~~firing oil adshale ~K
216~ The study iniae thtawet~coigtower wi11~used Actually a b
dry cooling should be consideda5ini ~HTP S inZ atomnmz so water rnumption4the cycle~ efficiency willbe reducedHenre YO33~reconsider calculating the cyclefficiy
U~~~~~ codnt umconsidered ofhorizontal -aretypethe~ the vertical cian type can alsobeh considered
shy ~ ~ ~ I~~
2~2 Kconcrete shy
shjell stepl fltstack is onidereconcrete shell brick flue Rt c ~s beCaconsidered3V
2-19~- Deminiraized water~ tank3 capacity~ is -76 ui(meterThe recommnended tank cameter- ui tyi 00cbc
220Designconditions Pa~ge (4-74)te5 hat bow 3down percentage splusmn ~fomrpra til re i hou I be 3~)~
PoD Z 2 m a ad~ - e 5 1 2 iJS~ ~ p A f amp ~ ~ y1
4
JO R ECTICITY AUTHORTIT 4L
~ 4
Date~
t etats ttthe quantityof s i S ~1 000Tons ra Sthis tuntity 11- be transporited for severIy --to tu ofI pit a~te torg P KM ra~erm Spower plIatS about 12 midilidoni CUIA(- met ryea
h e ndd mp e he (d u p in i n L
area wil evric power plant6t Please zn1 a te~tiv s tudY for dumping th r~ a enoug
-from the power plantr~~h~
S 2- Please provide deald-ifrat ao etbaaiedrawing hwn TH11 R thaU and~pV ra~te takcing illto o 6it v- consumptionn _uig themrining equipment
alternate~ study 0o Jine operation for 1 shiftday Vand twoshifts day -lt
224- Conceptua~l pflR 1 for mi ing anusdtransportation of oil- shale a 0 dmj of hs f u r therV examinedh iV~sdpatI ho u1d be
orderj to poe~ehicalq and~eoomca1 fesblt of t his operation
SYour are requested te) study and consider all- above - iPoin s at your earliest in rder -to be peete y oiAnimain on March 29-301989 peetdb~o 4 n
S9incerly-You S
WDIRECTORGENERAL -
I~ CCMR WLINTON ~vs
5N
Pa D~t~IoAmmn -Jordtn -Tel 815615 20 Bl76 15 -19j A VINO- AFf TY
MARCH 21 RESPONSE TO JEA QUESTIONS
Bechtel Power Corporation Engineers - Constructors
Fifty Beale Street San Francisco California Mail Address P 0 Box 3965 San Franclco CA 94119
March 21 1989
Mr M S Arafah Director General Jordan Electricity Authority PO Box 2310 Amman Jordan
Subject Jordan Oil Shale Prefeasibility Study
Dear Mr Arafah
Your letter of 15 March 1989 with comments on the Oil Shale to Power Prefeasibility Study draft report has been referred to me for reply
The attached responses to each item in the reference letter follows the order submitted
Also attached are three revised pages for the draft report - Volume I
Page 6-1 Page 6-21 Page 6-23
Please copy these revised pages into the report previously sent to you
We plan to review this material with JEA during the March 2930 and April 1 meetings in Amman
rsuVertrul yours
W Linton Project Manager
WHLdc
Attachments Questionnaire Response Three revised pages
cc C J Aulisio R R Buta G D Gould T J Wilbanks
32389
Page 1
RESPONSE TO MARCH 15 1989 QUESTIONAIRE
OIL SHALE TO POWER PREFEASIBILITY STUDY
This study examines economic prospects in terms of a 1995-2000 timeframe
FIRANCIAL AND ECONOMIC COMMENTS
11 It is likely that a BOT deal can be structured at present JEA
generation costs for either 20 MW or 50 MW size units if GOJ is
willing to subsidize the incremental power generation cost
Furthermore these incremental costs can be recovered during the 25
year operation of a Commercial Scale Project
12 A 3rd Party Test was proposed as an alternate means to raising
$100+ for an independent JEA sponsored 20 MW Demonstration
program
13 71 millsKWH for Shale Power
VS
JEA 1987 costs
Purchased Power 17 filsKWH = 51 mills
Produced Power 1360 filsKWH = 41 mills
19952000 Costs - Expected to be 30 to 40 higher and in line
with the cost estimate presented in this study
It also is important to recognize that the busbar cost of power
generated by any new power source can not be compared directly
with the cost of existing older installed capacity because of the
lower capital cost component of the latter (See enclosed Figure
1-1 which demonstrates how total capital carrying costs decline as
the investment is paid off) Any new capacity whether coal oil
or oil shale will be an unreasonable disadvantage compared with
costs for existing older capacity
l
024
o2
0De return
E 016Total carrying charge
012 qu return
S -008
ety taxes and n rcw vshy000 X 0 5 10 15 20 25
Figure 1-1 Year-by-year Carrying Charge Components for 15-yearTax Recovery Period
1-7
30
32389
Page 2
14 Infrastructure Cost
Total People
OperatorFamilies Installed Cost
20 MW $10000000 185700 $54000Operator
50 MW 15000000 3241200 46000Operator
400 MW 45000000 10364000 43000Operator
Factored allowance for grass roots desert installation
including housing and community facilities was developed as
follows for the 50 MW case study
Infrastructure
50 MW
Family Housing 200 30K = $ 6 Million
Bachelor Housing 100 20K = 2 M
HospitalClinic (8 Beds) 11 M
SchoolMosque I1 M
Stores Services amp Recreation = 2 M
Facilities
Roads Electricity Water Sewage = 3 M
$15 Million
Infrastructure costs for the 20 MW and 400 MW cases was ratioed
from this breakdown
At this conceptual level costs are order-of-magnitude In a Phase
II program these infrastructure costs can be developed in detail
32389
Page 3
15 Contract Mining Alternatives
Page 4-11 Mine Operation
Based on Bechtels evaluation of the mine contractors price as found in Section 15 of the Mining Report it was concluded that
the mine contractors price does not include costs for such things
as developing the mine with a box-cut ramp haul roads
developing an area for the waste material maintaining the
haulroads constructing the mine services facilities diversion
ditches sedimentation ponds water well crushing the oil shale
pre-mixing the oil shale at the mine and other items associated
with operating a mine to support a power plant If it is proven
that the mine contractors price includes cost for the above
mentioned scope of work in additi-n to drill blast load and
haul then the contractors price can be used but in the meantime
the all inclusive cost developed by Bechtel should be used
Contract Mining appears to be attractive for the smaller size
plants but not for the larger commercial scale operation Some
third party must provide the necessary capital for trucks
loading mining machines etc under a contract arrangement
16 Reassessment due to Dinar value change needs further study and can
not be evaluated given present budget limitations If average
labor rate of $300hr still valid then little change involve with
study
If deemed necessary reexamination of project economics can be
done in Phase IIwhen funded
17 Costs in this study are based on recent similar Bechtel experience
on Mount Poso project and on Montana I project The Mount Poso
project is a 50 MW unit firing coal in a Pyropower boiler The
Montana I project is a 35 MW unit firing coal in a Keeler Dorr
Oliver FBC boiler utilizing dry cooling
32389
Page 4
18 The Pyropower quote of $186000000 to futnish and erect the steam
generator stack and baghouse has been adjusted to include
engineering construction indirect cost etc to be consistant
with the rest of the costs shown in Table 65 p 6-10 No
further adjustment for location was made
19 Equity funding has the lowest priority of payoff in case of a
liquidation and carries greater risk Hence a higher rate of
return is needed to attract these funds Debt funding is a first
mortgage and has first priority for payoff in case of liquidation
and carries less risk Hence it requires lower rate of return
than equity funding
The risk taking equity owner will ask for greater interest rate
to make funds available The only way to minimize this expense is
to find a loaning agency willing to provide 90 or perhaps 95 of
the investment cost It is likely that banks will require some
minimum equity participation
This Prefeasibility Study was not based on a non-profit utility
operation
Even though JEA is a non-profit organization its service
contributors are profit making groups It is visualized that the
Jordan Oil Shale Co (JOSCO) will be a stand alone business
enterprise servicing JEA under long term contract To secure
funding for the proposed project JOSCO will need attractive
enough contract terms to attract both equity and debt capital
110 Additional work is needed to develop the requested information
This work can be preformed as part of the Phase II program
111 Bechtel includes contingency in all of its estimates to cover
error emissions and unforeseen items within the defined scope of
the project The level of contingency is dependent upon the
amount of scope definition For a prefeasible study such as this
15 contingency is lower than normal
32389
Page 5
112 Tables 89 through 816 include a present value calculation to
establish the relative benefit for a shale project vs coal and
oil
113 The variable maintenance cost of 1 millsKWH has been adjusted for CFB plants with an additional $200000 per year or 06 millsKWH
This yields the following
Variable Maintenance - 10 millsKWH
CFB Adjustment - 06
Fixed Maintenance Cost - 40
Total Cost 56 MillsKWH
114 Page 4-29
The royalty costs are included in the weighted average oil shale
costs for the 50 megawatt plant
Page 4-8
Shale fuel costs include return on equity and royalty These are
two separate cost items Royalty is the last item mentioned in
the sentence and it therefore reads as royalty and not return on
royalty
Page 4-31 gives rates used by Bechtel based on our calculations
using the referenced procedures
DebtEquity Capital Charge Rate
5050 153
8020 139
Table 69 displays the calculation of the 153 capital charge
rate (Line 7 of Table 69 is not used in the calculation and
should be deleted)
32389
Page 6
116 No water purchase charge from the Water Authority was added to the
operating expense based on the statement that no resource costs
will be charged
$020 per 1000 gallons is rule of thumb for USA installations in
absence of client data
Boiler make up water (p4-17) is treated in a demineralizer
train If deemed necessary comparison with reverse osmosis
process can be performed in Phase II
Water requirements were estimated to be
Cubic Metres Per Year
20 MW 50 MW 400 MW
Mine amp Shale Processing 455000 761000 773000
Power Block 3000 6000 42000
Infrastructure 80000 140000 448000
Total 538000 907000 1263000
117 Annual average operating costs shown on Table 6-1 are in error
Financing Option 5050 8020
Cost Shown 56606 48945
Corrected Cost 60396 53236
Average mining and shale processing costs are developed year by
year in the Mining Report Appendix 5 Table 12-10
32389
Page 7
118 We would be interested in receiving the breakdown of these current
power cost figures (ie capital charges fuel cost number of
operators etc) Further economic analysis employing these
figures can be developed in Phase II
119 Manpower requirements for the three case studies were estimated as
fol lows
Mining amp Shale Processing
Power Block
Operations
Maintenance
Management
20 MW 50 MW 400 MW
75 163 396
54 78 175
46 73 455
10 10 10
185 324 1036
Page 14-4 of the Mine Report is for mine and shale processing
only It should be noted that most of these manpower requirements
involved new jobs for Jordanian people
120 At the April 1988 Amman Meeting it was agreed that the following
costs would be omitted
o Permits and Licenses
o Local Taxes
o Import Taxes
If necessary such costs can be developed and added into a revised
economic analysis as part of the Phase II program
121 6 average inflation rate is the figure recommended by Bechtel
based on USA conditions for use in long term economic analyses of
new power ventures
32389
Page 8
122 This matter is referred to ORNL who prepared a rate of return
analysis
Bechtels conclusion is based on computed busbar costscumulative
benefits compared to alternate fuels in the timeframe 1995 to 2000
Relative Busbar Power Cost Net 25 Year
Mills per KWH Benefits - Million US$
Sultani Oil Shale 71-83 Base Cost
Imported Coal
$50tonne 68-88 778
$70tonne 78-107 2531
Imported Oil
$17Bbl 56-76 (18) $24Bbl 61-96 1810
The above results are based on a capacity factor of 75 which is
considered to be a reasonable target for a new plant over its 25 year
life The average selling price of 6 cents per KWH cited in the
questionnaire is based on existing plant costs which may not include
all cost elements of new capacity evaluated in this study
32389
Page 9
TECHNICAL COMMENTS
21 See answer to Item 116
Total power plant raw wate consumption rates and annual
consumptions including the water requirements for wetting ash at the truck loading p int within the power plant are given in Tables 43 and 44 for 50 MW unit and Tables 53 and 54 for 20 MW unit
The raw water requirements for 4x0 MW plant were factored
excepting the mine where a revised mine pldn is employed to reduce water request The quantities shown on these tables exclude raw
water requirements for housing complex mine and ash wetting if
required at the ash disposal site
Total power plant requirements shown in the above referred tables
are
50 MW 20 MW
Rate gpm 207 102 (See Drawing M004)
Annual Use
Gallons 1400000 675000
Cooling tower blowndown supplemented with raw water is used for
wetting ash at the truck loading point within the power plant Raw water quantities attributable for ash wetting at the power
truck loading point are
50 MW 20 MW
Rate gpm 75 325
Annual Use
Gallons 500000 215000
These quantities are included in the quantities shown in
the above referred tables
32389
Page 10
22 We recognize the POTENTIAL for leaching toxic compounds from the
spent ash However this matter is not yet defined well enough to
recommend specific action steps The Prefeasibility Study page
7-12 recommends creation of a ground water dispersion model to
determine whether more specific contaminated water mitigation
plans are needed It is anticipated that the leachate rate will
be low and that aquifer dispersion will keep problem compounds
bel3w health standards thresholds
23 Noted
We have not received up to date resource study material which
defines 50 billion tons resource base Please furnish
The resource base at Sultani alone is adequate to support two 400
MW power projects capacity subject water availability The
2-million cubic metre per year water allowance for oilshale will
limit development to about 600 MW
24 Selection of a combustion temperature is a balance between carbon
combustion efficiency and heat loss due carbonate decomposition
For purposes of the Prefeasibility Study we have opted for high
combustion efficiency At lower efficiency larger shale
mineprocessing plants will be needed
25 Bottom ash is cooled by water exchange before discharge
Cooling water is supplied to the ash screw coolers as specified by
Pyropower See Drawing MOO5 2140 gpm flow for 50 MW and 860 gpm
flow for 20 MW Heat removed by the cooling water from the ash
screw coolers is dissipated to atmosphere via a wet cooling
tower Pyropower should indicate the temperature of the ash
discharged to be 5OOF
32389
Page 11
Initially we had considered using a heat exchanger to cool the ash
and improve the cycle efficiency Considering low cost of fuel
the additional capital costs and the system complexities it was
decided not to employ such heat recovery systems for this project
26 The suggested alternates were looked at briefly and the potential
for wind blown air pollution from the ash disposal areas are too
great to warrant dry disposal unless GO(] and World Bank are
willing to accept such a potential problem Wetting the ash is
tne only practical solution Hopefully some cementation will
occur helping to reduce future leaching potential
27 JEA requirements are noted This is a conceptual study not a
final design Optimal design analysis can be performed during
Phase II
2829
JEA requirements are noted and can be incorporated into the Phase
II design
210 The transformer size is adequate for base load operation A
higher capacity can be considered at the final design stage if the
Client prefers
211 From our experience it does not appear to be economical to
provide additional dry cooling towers to take care of maximum
ambient temperatures which may prevail only for a short period of
time in a year To study this an annual dry bulb temperature
duration curve is required Also adding additional dry cooling
towers will change the plant performance It should also be noted
that the dry cooling towers are very expensive and the size should
be selected carefly considering performance and cost and not on the basis of maximum ambient temperatures This can be studied
during Phase II
32389
Page 12
212 The plant gross output varies with condenser pressure
Condenser
Pressure Design 55 in HgA Annual Ave 35 in HgA
Unit Size MW 20 50 4xlO0 20 50 4xlO0
Gross Output MW 234 593 496 2415 607 TBD
Net Output MW 1975 501 400 205 515 TBD
To be developed in Phase II
Output for 4x100 MW is estimated by others
213 The fan power consumption of the CFB boiler is about 30 to 35 of
the total auxiliary power The fan power consumption of the dry
cooling tower is about 20 to 25 of the total auxiliary power
214 Table 1-1 does not include plant net output Therefore do not
understand the comment
215 Commercial operating experience with coal fueled CFBC units in LISA
and Europe has been uniformly good showing high on stream
availability in early years (See Table 2-6 which reports on
Pyropower experience)
We expect operations with high ash content fuel like oilshale will
have unique scale up problems such as
o Solid handling in and out
o Internal solids circulation
o Erosioncorrosion steam generator intervals
o Heat recovery from bottom ash
Consequently we are recommending these items be worked out in a
single 50 MW prototype
32389
Page 13
216 Maximum dry cooling is used in this study A small wet cooling
tower is used on circulating service water system
217 Horizontal condensate pump is adequate with dry cooling tower and it is cheaper Vertical condensate pumps with cans can be
considered in the final design if required
218 A concrete shell brick lined flue stack will be larger in diameter and costs more than a steel lined stack Brick lined stack can be
considered in the final design
219 Demineralized water tank capacity for 50 MW is 76 cu meters or 20000 gallons not 1000 cu meters For 20 MW plant it is 38 cu
meters or 10000 gallons
220 It is US practice to use an average continuous blowdown rate of
1 and maximum biowdown rate of 3 for this type of plants
221 This can be studied during Phase II
222 Same as 221
223 Same as 221
224 The recommended action plan calls for continuing support studies covering the referenced items Additional effort is needed to
further define these matters and confirm the conceptual plan
The next step is to develop an outline for a project plan including
o Work Scope
o Schedule
o Budget
accommodate the increase in the number of employees and
equipment Truck bays to accommodate the 136 tonne trucks
will be added The truck bays used for the 77 tonne
trucks will be used for the maintenance of other
equipment The warehouse change house training room
offices and cafeteria will be expanded accordingly
6025 Mining and Processing Economics
Details of the oil shale mining and processing plant
economics for the 400 MW plant are included in the Mining
Report (Appendix 5) These details are of the same
magnitude as prepared for the 20 MW and 50 MW plants
The summary of the cash flow analysis for the mine and
shale processing plant is presented in Table 6-1
Table 6-1
SUMMARY OF 400 MW PLANT OIL SHALE MINING AND PROCESSING COSTS
5050 Debt-Equity 8020 Debt-Equity
US $1000 US $1000
Capital Cost
Mine Development 30915 30915
Mine Equipment 66012 66012
Process Plant Facilities 50889 50889
Spare Parts 5000 5000
Working Capital 10000 10000
Capi tal ized Interest
During Construction 24423 39075
TOTAL 187239 201891
Operating Costs and Other Costs
Annual Cost 60386 53236
Product Mined and Processed
Annual Tonnes x 1000 7783 7783
Unit Cost
US $Tonne (weighted average)
US $l06Btu (weighted average) 776
156
684
138
Year 12 costs taken as 25 year average
6-6
-Au
Table 610 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
- FCC plant sizes equivalent to proposed power application
Prefeasibility Study Oil Shale Fueled Power Generation
VOO94GEampJRI26
i
PYROFLOW UNITS IN THE US
COLORADOUTE IOYA STATE UNIV UNIV OFNUCLA CO NORTHERNAMES IA BF GOODRICH110 1o0MW(a) 2x170000 Ibhr HENRYILCEDAR FALLS IA 120000 Ibhr GENERALGULF OILu EiN P MOTORSSbtUpStart-UIL 1987 O A 1I N000 TC
NORT10 PONTIACH B MIRANCHWV00000 lbhr
CORN PRODUCTSSM NORTH-CAROLINA STOCKTOD CA
400000 lbbhl t
RUMF RD ME
CEMENT CO CALIF PORTLAND-COLTON CA
190000 Iblhr Start-Up 1985 TRUMTFTWN NYU
3I75ERTOWN N
etar t-Up loss ACE COGENERATIONCABI
TRONA CA Oper t~on l -Start-UP 1990 ~ rt upz 091Start-up loss Start-up PNeLAI 1991
MTKESFICOENERATIO-N1
BASFIELDp Start-uStar-Up WESTCA9 199otgoUp 1 MAHONEV PA|00000 Ibhr A Oz 2X365000 Ibhr
SETtr-Ups 188B CHAT TANOOGA TN
G ULF OIL EXPLORATION 8ta-rt-u) 1085BAKERSFIELD NORTH BRANCHCA SPRING GROVE PANORTH BRANCH WV 400000 IbhtOperational 19835 5 0 0 I b h 9 0 0 0 Iblh r- tart-Upi 1991 S t r - U p s l e s s
SOUTHEAST PAPER MFG CO UNIVOF NORTH CAROLINArDUBLIN GA UHAPEL HILL NO400000 IbhrStart-Ups logo Start-Ups2X250O000 1loseIbhr B
- Withdrawing ash from combustor - Withdrawing fly ash
a Internal solids circulation of the steam generator
m Erosioncorrosion of steam generatorinternals
Heat recovery from bottom ash
U Operation with low calorific-value fuel
Prefeasblity Study O Shari Fueled Power Generation
VOO7AI 27
Impact of Scale-Up
Project Size
20 MW
50 MW
100 MW
50 MW boiler in 100 MW plant
Potential Risk
Design Scale-upOperation of to 100 MW Initial Plant Plant
Low Significant
Modest Modest
High Low for duplicate units
Modest Low for duplicate units
Prefeasibility Study Oil Shaje Fueled Power Generation
VOO71-4GEAL4n2
i
Conclusions
Defined risk of CFBC boiler is acceptable
U Operating experience with commercial CFBC boilers built and under construction will strengthen confidencelevel and minimize risk for a plant built in 1995
SPrefeasibility Study Oil Shale Fueled Power Generation
V007GHAAE29
ENVIRONMENTAL ASSESSMENT
a Mine and shale processing
- Fugitive dust emissions
- Noise levels
- Leachability of disposal piles
Power plant
- Fugitive dust emissions
- Gaseous emissions
- Noise levels
- Water effluents
U Conclusions
Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel
Prefeasibility Study Oil Shale Fueled Power Generalon
- Coaloil prices will be at least 15 greater after 1995
- Discovery of indigenous conventional fuel resources is inadequate for power plant purposes
Prefeasibility Study
Oil Shale Fueled Power Generation
VOO) IDWFO
Feasibility(Contd)
N Suitable financing will be available
- For $200 million 50 MW prototypeproject
- For $1000 million 400 MW commercial project
Government of Jordan will make basic commitments
- Long-term power purchase agreement
- Long-term access to Sultani shale deposit
Adequate water and manpower resources
- Attractive tax incentives
Prefeasibility Study
Oil Shale Fueled Power Generaion
VO bull1DUJJRO 6
Timeliness
U Timely development of Jordan oil shale needs prompt action to create - Additional definitive information
- Suitable business plan
Prefeasibility Study
Oil Shale Fueled Power Generation
VooI DUJo 7
i
Expansion Conditions
U Continued expansion of powergeneration from oil shale in Jordan depends on water availability
Prospects for power export or importand domestic load growth will affect size of the needed shale-to-power program
Prefeasibility Sudy
Oil Shale Fueled Power Generation
yOWl lVuJO
Environmental Impacts
N Environmental impacts of shale development will be minimal
Prefeasibility Study Oi Shale Fueled Power Generation
i
Development Advantages
Will create significant new jobopportunities in Jordan
Will avoidreduce foreign exchangelosses for expanding alternate fuel imports
Prefeasibility Study
Oil Shale Fueled Power Generation
VOOIIULL tO
Recommended Action Plan
N Basic recommendation
N Conceptual development schedule
U Project development plan
Key plan elements
N Funding requirements
Prefeasibility Study Oil Shale Fueled Power Generation
VOO4II )U OII
i
Basic Recommendation
N Expand efforts to develop an oil shaleshyfueled power generation program at the Sultani deposit
- Conduct required supporting studies
- Define facilities costs and business plans
- Obtain project funding
Prefeasibility Study
Oil Shale Fueled Power Generation
VON I II)ILL 12
C
Conceptual DevelopmentSchedule
1989-1990
- Conduct supporting studies - Define costsbusiness plans for 50
MW prototype and 400 MW commercial projects
- Develop project financing
N 1990-1993 - Build and operate the prototype project
N 1994-1996 - Expand the 50 MW prototype to 100 MW scale
U 1996-2000 - Expand the project to 400 MW scale
N 2000-2005 - Build a second 400 MW commercial project if needed
i 1 Prefeasiblity Study
dOil Shale Fueled Power Generation
VW IMLITO 13
Conceptual Development Plan
Months
1 Project development plan - Define project
costs1busness plans
-24 -12 0 12 24 36 48 60 72 84 96 108 120
2 Secure funding
3 Build and operate 50 MW prototype
Dergn and procurement
Mine development
Plant construction
Startup and testing
Operations
L- -
4 Expand prototype to 100 MW
Design and procurement
bullConstruction
Startup
5 Expand project to 400 MW
2nd 100 MW unit
3rd100 MW unit
i 44
4th 100 MW unit -
O Project dacision point
i Prefeasib~ity Study Oil Shale Fueled Power Generation
17958562aJocdanV 3-14-89 rsO
18
Phase I - ProjectDevelopment Plan
n Program development
Seminar workshop on prefeasibilitystudy Oate project development plan woek scope schedule arid budget
U Carry out project planning program
- Conduct continuing support studies - Test Sultani shale in existing FBC
- Firm up designs and specifications
- Update costs and economic analysis
- Develop business plans and requirements
Explore project funding alternatives
i Prefeasibility Study
Oil Shale Fueled Power Generation
VO MItUOR 14 -0
Key Plan Elements
N Project feasibility analysis
- Firm up designs and equipmentspecifications for all facilities
- Update cost estimates based on preliminary designs and specifications
Explore arrangements for contract mining and mine development
Update forecasts for demand growthand for retirements of older generating capacity
- Create updated economic analysis
Preleasibility StudyO1 Shae Fueled Power Generation
VOO1IOLWRI
Key Plan Elements (Contd)
Business entity requirement
- Explore optionsconditions for a new company to managebuildoperate the project
- Explore optionsconditions for obtaining a concession agreement for Sultani development
Explore optionsconditions for water rights commitment
Prefeasibility Study Oil Shale Fueled Power Generation
VMIOIA)lj 16S
i
Key Plan Elements (Contd)
U Continuing supporting studies
- Combustion tests (additional pilot tests for design and warranty purposes contract for large-scale burn operations in existing plants if appropriate)
- Additional core drilling and core analysis
- Oil shale crushing tests
- Spent ash leaching tests
- Geotechnical data base including soils analysis
- Environmental baseline data
Prefeasibility Study O Shae Fueled Power Generation
VMMMUldMOA
Steps Required to Develop an Oil Shale-to-Power Project
Create a development business plan - Schedule - Decision tree
Develop a work scope and budget for the development plan program including - Firming up designsspecificationscosts
- Developing business entity requirements - Continuing support studies
Carry out development plan program
Assemble all planning results in a report for discussion with financial institutions
Explore project finance opportunities
Finalize business arrangements
Implement prototype project
i Prefeasibility Study
Oil Shale Fueled Power Generation
VM1-11UJROLI
MARCH 15 JEA QUESTIONS (M S ARAFAH) ON PREFEASIBILITY
STUDY DRAFT REPORT
Rt
DIR EScBSULIVAN PHD OFJCEop~BUREAU FOR SCIENCE AND~TECHNOLOGYAGENCY - --FOR INTERNATIONAL DEVELOPMhINTSWASHINGON DC x20523---------4
4 -
-SUBJ E CT - -C O H~ E T 4N l
Dr Mr sullivan ------shy
c-rommnents We ~efr-preaereorPla -tobYou lete dted Jan 91989 regardn~i4po4t P ea e1 f i nd y ubel ow our -e ot r XcOrcerned Jordanian deipartments
- --A ar o~nnYu Y o turjlt~ lt K
4 C~mments
~1 N i gFIN I~fANDECONOMIC1COIMEN S -
It sidicaed that Beohtel and US AIDWash ingtonj~4- re ojy nen ing that E 2hould und ertake the n e tshyihaisAre ~our c leometprogram n order shye-t im~ ate d f n t v design and budget cost
4Al1so Lthe study ncal--ttsutnilndcaei~ A-1 A thas ~ l 1 be eeded idb~~~~~ rn o ei t n i la itheMWa~-~5s~ 4
hrPro hehgemetTh trOfT ses~fnr4 BOT)Vmanu- a n-mnf~cure 4 r~j or contra c4-or ivoIlveiintijn I 4 4investmnt ude smi ~w 2 Zha tev e r --~4~prce e ec r it v p4~ f JA gertiy geeated-at 4 JEA 3 a l b u y ~the same average~~ A
~jithia oncot in4 ordrtan ecpoemic asess thespePower generatjoon J ordan3 oi sha I eroic c inr~etJordan 4
2P ge i1- 1 Aj iit eu that OPin he atocontr~ct 4with owner4 ofext3ing (oconstriiction r(FB rml-t
qu i of S 11 t to test large tonnagen j es StaniUti n d ajIe -for se veralIQf 31 hi
evrEAPreferpilot qr the dP 1prt7n -that the4mPIt
andi to(7 he instalI 1e 2 310 A
_
JODN ELECTRICITYAUTHORIT LL
Dac
operated in Jordan i n or~der~~t ~n nuex~on mnining crushing and haidi igQhre~ and sash Maeia nd aSootoget enough olr ndaita needed for einolre
CEBbole~ -i s~
ccordance with Jordaian oil shale
large to~ bfig
1 3 le 1-2 Page 1-7 Cost Of Pwer~i It i S menti-oned that the conmecial oil hle~ lt~project (4 X1OOmw) 1is ninacompetative roqt~range-~while table 12 indicates thattcost of-pow Ais~mill
q kwiihcii r 1
average wih i ii -much higher ihantheshy-ost of ~Power gnrtofomJEA therimaPower s ta tions Please~ indicate on what basi o ~~ shave-~made your-statement
PK
14 Pae 2 Sction 4-0sIt 1nlkly that theChousing and off- -site infrastructur-ommnity fakilitieR) to be onsidered for both the demo and prototyp prjcs oeoverwe~4 hnk that their~c_6t is raterojects Mo
iwcv~- age -1 1 Mine O(perationIIt is indicate~d that mining cot eevdfoMine contractor~ are ficomiplee h
r and iyudi-t~con qidder contract mnn opio fr4 the min4 cmflt2ng are reIanddrepres~ent the real costs derived from Phspat miin contractors in
lestfor the eo rPooypuat in order tlt7
P I eadenote tha detthe new exchangerate ofthJraian~ Di~nner you may add 20j6 Kto the quoted
1 6 P Ias e consider the followin ecn hage_
171- The new exchange ra teof tUSD=54o0 fils1 72-W2 The new~ aerage tariff for selIn~electricityhas decrreased to 120 8 f ilIsicwh
17- Page 1-7 TbIe 1-2 W bev th tthe cap ita1 cot for the pwhokand forthe min n d ash hMnd1ing equipen
P B~2Anaor a -Tl 8156152 8176 1Q MYf -t -Now 520 t 1U
JDNEECRICIT AU-RA L14lLiL
2 ~are very high We suggest~ thta You rerconsie (- telowerus e~+d accuracy est a rangethan +30
Page4-22 Table 4-5weno0ti ced( that- PyroPowe ha ddeta(IiacCst fori the bo1ilerlocation and terha dutdetlease isxtr fo~ l C~ io~ s~ e~~ 1a~ a if and indicate theonldjusted ~percentagefor construction foin Jordan
19 Page-7 Table 11-2 -Yo aeue ihrinterest rate on Equity thatn on1DehI~laseinclude~ adetaied explanation of thisrr -tni kepin in miUndie JEA is1thaIt a non profit~ shyorgaiztion unik oher private UJSA utility~in ktation
~-~110- Regarding shy
the ra4ital Rt fthe project it is~requesed tobre k it intdo foreignMeanwhile cthe nd lorcal c-osfoeigptario i nt-re3t~shol becnierdo-h
rr n ontiondonnotopdbon the 9 cnieelocal portion~onth
1-1- 237~Pa
oningeny 9tooi s high~~ a lower 4value -should be~
4~ gt ~112- -Tbles t1-1 -8-8~ inclu~de t~he c~alculationscuultie nt enefits for of Th shyunttypes l i4s difeen geeatnmrer likely tocluae
-~ Q~ J7present vk1u for tenet tthe~benefits in feralterntives -t-oa s the
49
ehliyoi shale
Wea gree with you9 tha t th e percentage used ~ an for thenua~l 0 ~amp-M rahr CFBo ndsomewha~t highervrate be n ededma y for a C B l n Me n h l ~ a e r
indir e ta~ts the -estimatedma i variablec st i ddition t he fi-xed-9i 1 mislkih We --
thinktttiis too lowK -5
shy
1-14- e 4-29
opprza tion-o to The o i1s h1 costs-nc I deAbo 1h
Pa10 mman ormTSI62 a
IB I
JORD N EtECTICI1~ 4 E~)~Is-s
Date ib-_
~ ~riii~g~nd~o9~ru~hng h~tnlin cot~u~tv yo
i Dae Jnryit
1ts c 7 4-
i smiig iniand fh co I eY
susendi ca tI t icag th t1 ~an~approximate 15 ~pita L tYII I (-~a~ge or he owe bl ockj f aniitjes isof +the capthe)t~ial7cpi~lrharge Uoratelformny SI~Uj(uiity installa~tions~ whle page 6-1T9 talJshyit is mentioned that~ the Capital rate pe-r JEA isshyi5~PeaseJustify this~matter since~w o
i16- Pae 6-1 6
1 I4~t is mentioned that the costs of 4process Water are ~ 4 ~0 2$1 000 gallons
r~j~lt IHave~You considered additionalvalue ofbying waterfrom~ the Wa ters Aito i ~or ditoa cost~f o revrseoqoesplant if ground water is used
~~ I1 7- Table 6-1 Page 6-6 Please explain how did You come ou ihteoil~ shale miniing and proces~sing uit~Icost
ltII~I~ 8- Please note 1 t hatj the average JEA~productinr ot frmthermal I power stationsr (Istationbus-barCOSt)i sbewen 6 3-17 3 fils 4kwh You may use this~
l4~ 19-i For ~4 X 100~AMW Plat iti etindo pag e14-4 VolI 11 that4 at tota I of W42 14 epoye W II eemplo~yer] And on page 69yo1Iiti mentioned that a~ tot 1 f1 ~p yeI iNbe enp1oyed a
is~ high asrmetitexeds100personorthe ~41X100~MWh~~j nsatnpPrlae
I 1 The 4 following iftemns are a sumed to1 be excluded from theraPi ta 1 cot xoI
120-1 Perits I icen es 7
1_207~3 Imprt ~xe on s7pare par ts -and c(7orfmurab -ma~teria Is
04f4 4
~4 R j4 4
D4
~ ~ ~ AIf eS taxesq in acrac ihteJraand regulations should be considered aw
21- p1ea4s e indic ate Your Ju t f c io r us ga 6
44122- Table 977App 5Page4 9-1 4L IK Car1Yiniae that the hIRR of the 4 Otplantis rather unattractive (66)most
-( Cns1er4 ngthe logical base 4csek c pwhen cii 6OL
average sell~ing prc CkhampDEratio L801~2O~Aoreover4M the ne siellin prcwh o JEA ati theamptime~ Abeing os4ltp n~ot exceed 4 Ckwh~-However Ipage 1shy~ and 14 0 T indicate that ecnms for a commeri
S4A4scale joil 4 shale projc ~
appear Piomisig-nug o4Ywarrant continued dee fgfluht 4 feaibiit 4tudy wihil cost sevea~lili
do ar~sf Plas lear wether the ~x step jqs~$j~~lt 4
gtt 9o be considered arCcording4to jthe 4unattractiveresul to mentioned in IRR7 Table 97 gt4
a C4 44fET2 4 144-4444 P a g 1 T b6 l
htte~We ~ ~ ae~ rqieetfrteX ~ noie ~~ ~ 444 MW un t44 r te4l w w e o p r d i th e w t r n rre u f4m or4444~ the4444 54M4rto y e Pg~A~44EHiveL det ile an l A44
s o awa er c n um t a4r f rofsho in P6Io erT
e ch 2 50 M W aPln wa e d 41004 MW4 1 consumption_____________
ma4~2 k e u p houin~44 p A44 4444444 C O 4ltI4
a nd a sh et in etc 4 2 4 1 -24 P a g e4 2 - 1 A P P 5
4Yo 4_ j1 4 4~h444 N44 44
1gro nd tce t hir fthe w bern coqir mna t efora4e 4X10A M 444444 4 r i n to 4 4 4lo w w ehA 7 n 2 cinCie h rh4 n ttthh1eb -e 4 44t Of3 E4O
ea h n~ ffl 4 4Jl44 4 4444 4giv
6 ig re sofrat4 de in cl ar f w w at5 c hrw pe o
s h b 444 o t h e g nd L 44 h u i n C
r 4ne a4 t44 e L(704 2 4 p ae) 2 - o Au P dn 5ai 7~e r 44 I Y (1t 44a
ve7 rn e qu 1saharvthe y
and n~~~o speci~~~l4 p n l nh i n t x
r ~rA M e d r o t eu n 8 1 wTtl t t h
- c re e N I wo6
~ n n a i n a t d h l7 A PP6 gt
J
S2~3- Page 2-4 ~ ~ It ~is i
that oil eindicated the- sha le r our~ Cesin Jordan are 10 billion tons -The anulp e reere maiy exeed 50 4 billion tons ~
~ 24- 4Page~2 -l1 iujntr We beiv thtCBcmuto~ep i s high and~alSo
~~ ~ -2 ~~ Page 4-1~6 j - shy
Please~~ indicates your procedure to cool the omn ashand atwa icagd-eprtr
A Have you~ considered~ additional he~at exchanger topcool th ash and to imrve h cycleef ficiency
-~2~6 Page 4-16 It s~ indicated that ash from each silo i Amixed19 ~with~fabout 20 waterKb weight to minimize generation of dust~during trnprtto to mine and disposalHave you~ coniidered other 4lternativeto
~ ~eliminate dustiiig -and avoid use ofwat r uring it ransportationi such as~ using closed trucks or closed
of ~fans conUMnPo wihrlaintthe total plant auiir poe osupin 1~21- Table 5_-3 and I ~
Th~~ is- somneere c6ntradiction regardingplnneotpu~t in both am tables 21-~ Tabl~e 1-33
We noticed tha~t yourall9 cacacapac t fatro75 tion ae asdnWe thilt ~that 7capacityshyfacto is tobo high for- an oil shale fired plant duketo lack of existing simila~r ~plants handl~~~firing oil adshale ~K
216~ The study iniae thtawet~coigtower wi11~used Actually a b
dry cooling should be consideda5ini ~HTP S inZ atomnmz so water rnumption4the cycle~ efficiency willbe reducedHenre YO33~reconsider calculating the cyclefficiy
U~~~~~ codnt umconsidered ofhorizontal -aretypethe~ the vertical cian type can alsobeh considered
shy ~ ~ ~ I~~
2~2 Kconcrete shy
shjell stepl fltstack is onidereconcrete shell brick flue Rt c ~s beCaconsidered3V
2-19~- Deminiraized water~ tank3 capacity~ is -76 ui(meterThe recommnended tank cameter- ui tyi 00cbc
220Designconditions Pa~ge (4-74)te5 hat bow 3down percentage splusmn ~fomrpra til re i hou I be 3~)~
PoD Z 2 m a ad~ - e 5 1 2 iJS~ ~ p A f amp ~ ~ y1
4
JO R ECTICITY AUTHORTIT 4L
~ 4
Date~
t etats ttthe quantityof s i S ~1 000Tons ra Sthis tuntity 11- be transporited for severIy --to tu ofI pit a~te torg P KM ra~erm Spower plIatS about 12 midilidoni CUIA(- met ryea
h e ndd mp e he (d u p in i n L
area wil evric power plant6t Please zn1 a te~tiv s tudY for dumping th r~ a enoug
-from the power plantr~~h~
S 2- Please provide deald-ifrat ao etbaaiedrawing hwn TH11 R thaU and~pV ra~te takcing illto o 6it v- consumptionn _uig themrining equipment
alternate~ study 0o Jine operation for 1 shiftday Vand twoshifts day -lt
224- Conceptua~l pflR 1 for mi ing anusdtransportation of oil- shale a 0 dmj of hs f u r therV examinedh iV~sdpatI ho u1d be
orderj to poe~ehicalq and~eoomca1 fesblt of t his operation
SYour are requested te) study and consider all- above - iPoin s at your earliest in rder -to be peete y oiAnimain on March 29-301989 peetdb~o 4 n
S9incerly-You S
WDIRECTORGENERAL -
I~ CCMR WLINTON ~vs
5N
Pa D~t~IoAmmn -Jordtn -Tel 815615 20 Bl76 15 -19j A VINO- AFf TY
MARCH 21 RESPONSE TO JEA QUESTIONS
Bechtel Power Corporation Engineers - Constructors
Fifty Beale Street San Francisco California Mail Address P 0 Box 3965 San Franclco CA 94119
March 21 1989
Mr M S Arafah Director General Jordan Electricity Authority PO Box 2310 Amman Jordan
Subject Jordan Oil Shale Prefeasibility Study
Dear Mr Arafah
Your letter of 15 March 1989 with comments on the Oil Shale to Power Prefeasibility Study draft report has been referred to me for reply
The attached responses to each item in the reference letter follows the order submitted
Also attached are three revised pages for the draft report - Volume I
Page 6-1 Page 6-21 Page 6-23
Please copy these revised pages into the report previously sent to you
We plan to review this material with JEA during the March 2930 and April 1 meetings in Amman
rsuVertrul yours
W Linton Project Manager
WHLdc
Attachments Questionnaire Response Three revised pages
cc C J Aulisio R R Buta G D Gould T J Wilbanks
32389
Page 1
RESPONSE TO MARCH 15 1989 QUESTIONAIRE
OIL SHALE TO POWER PREFEASIBILITY STUDY
This study examines economic prospects in terms of a 1995-2000 timeframe
FIRANCIAL AND ECONOMIC COMMENTS
11 It is likely that a BOT deal can be structured at present JEA
generation costs for either 20 MW or 50 MW size units if GOJ is
willing to subsidize the incremental power generation cost
Furthermore these incremental costs can be recovered during the 25
year operation of a Commercial Scale Project
12 A 3rd Party Test was proposed as an alternate means to raising
$100+ for an independent JEA sponsored 20 MW Demonstration
program
13 71 millsKWH for Shale Power
VS
JEA 1987 costs
Purchased Power 17 filsKWH = 51 mills
Produced Power 1360 filsKWH = 41 mills
19952000 Costs - Expected to be 30 to 40 higher and in line
with the cost estimate presented in this study
It also is important to recognize that the busbar cost of power
generated by any new power source can not be compared directly
with the cost of existing older installed capacity because of the
lower capital cost component of the latter (See enclosed Figure
1-1 which demonstrates how total capital carrying costs decline as
the investment is paid off) Any new capacity whether coal oil
or oil shale will be an unreasonable disadvantage compared with
costs for existing older capacity
l
024
o2
0De return
E 016Total carrying charge
012 qu return
S -008
ety taxes and n rcw vshy000 X 0 5 10 15 20 25
Figure 1-1 Year-by-year Carrying Charge Components for 15-yearTax Recovery Period
1-7
30
32389
Page 2
14 Infrastructure Cost
Total People
OperatorFamilies Installed Cost
20 MW $10000000 185700 $54000Operator
50 MW 15000000 3241200 46000Operator
400 MW 45000000 10364000 43000Operator
Factored allowance for grass roots desert installation
including housing and community facilities was developed as
follows for the 50 MW case study
Infrastructure
50 MW
Family Housing 200 30K = $ 6 Million
Bachelor Housing 100 20K = 2 M
HospitalClinic (8 Beds) 11 M
SchoolMosque I1 M
Stores Services amp Recreation = 2 M
Facilities
Roads Electricity Water Sewage = 3 M
$15 Million
Infrastructure costs for the 20 MW and 400 MW cases was ratioed
from this breakdown
At this conceptual level costs are order-of-magnitude In a Phase
II program these infrastructure costs can be developed in detail
32389
Page 3
15 Contract Mining Alternatives
Page 4-11 Mine Operation
Based on Bechtels evaluation of the mine contractors price as found in Section 15 of the Mining Report it was concluded that
the mine contractors price does not include costs for such things
as developing the mine with a box-cut ramp haul roads
developing an area for the waste material maintaining the
haulroads constructing the mine services facilities diversion
ditches sedimentation ponds water well crushing the oil shale
pre-mixing the oil shale at the mine and other items associated
with operating a mine to support a power plant If it is proven
that the mine contractors price includes cost for the above
mentioned scope of work in additi-n to drill blast load and
haul then the contractors price can be used but in the meantime
the all inclusive cost developed by Bechtel should be used
Contract Mining appears to be attractive for the smaller size
plants but not for the larger commercial scale operation Some
third party must provide the necessary capital for trucks
loading mining machines etc under a contract arrangement
16 Reassessment due to Dinar value change needs further study and can
not be evaluated given present budget limitations If average
labor rate of $300hr still valid then little change involve with
study
If deemed necessary reexamination of project economics can be
done in Phase IIwhen funded
17 Costs in this study are based on recent similar Bechtel experience
on Mount Poso project and on Montana I project The Mount Poso
project is a 50 MW unit firing coal in a Pyropower boiler The
Montana I project is a 35 MW unit firing coal in a Keeler Dorr
Oliver FBC boiler utilizing dry cooling
32389
Page 4
18 The Pyropower quote of $186000000 to futnish and erect the steam
generator stack and baghouse has been adjusted to include
engineering construction indirect cost etc to be consistant
with the rest of the costs shown in Table 65 p 6-10 No
further adjustment for location was made
19 Equity funding has the lowest priority of payoff in case of a
liquidation and carries greater risk Hence a higher rate of
return is needed to attract these funds Debt funding is a first
mortgage and has first priority for payoff in case of liquidation
and carries less risk Hence it requires lower rate of return
than equity funding
The risk taking equity owner will ask for greater interest rate
to make funds available The only way to minimize this expense is
to find a loaning agency willing to provide 90 or perhaps 95 of
the investment cost It is likely that banks will require some
minimum equity participation
This Prefeasibility Study was not based on a non-profit utility
operation
Even though JEA is a non-profit organization its service
contributors are profit making groups It is visualized that the
Jordan Oil Shale Co (JOSCO) will be a stand alone business
enterprise servicing JEA under long term contract To secure
funding for the proposed project JOSCO will need attractive
enough contract terms to attract both equity and debt capital
110 Additional work is needed to develop the requested information
This work can be preformed as part of the Phase II program
111 Bechtel includes contingency in all of its estimates to cover
error emissions and unforeseen items within the defined scope of
the project The level of contingency is dependent upon the
amount of scope definition For a prefeasible study such as this
15 contingency is lower than normal
32389
Page 5
112 Tables 89 through 816 include a present value calculation to
establish the relative benefit for a shale project vs coal and
oil
113 The variable maintenance cost of 1 millsKWH has been adjusted for CFB plants with an additional $200000 per year or 06 millsKWH
This yields the following
Variable Maintenance - 10 millsKWH
CFB Adjustment - 06
Fixed Maintenance Cost - 40
Total Cost 56 MillsKWH
114 Page 4-29
The royalty costs are included in the weighted average oil shale
costs for the 50 megawatt plant
Page 4-8
Shale fuel costs include return on equity and royalty These are
two separate cost items Royalty is the last item mentioned in
the sentence and it therefore reads as royalty and not return on
royalty
Page 4-31 gives rates used by Bechtel based on our calculations
using the referenced procedures
DebtEquity Capital Charge Rate
5050 153
8020 139
Table 69 displays the calculation of the 153 capital charge
rate (Line 7 of Table 69 is not used in the calculation and
should be deleted)
32389
Page 6
116 No water purchase charge from the Water Authority was added to the
operating expense based on the statement that no resource costs
will be charged
$020 per 1000 gallons is rule of thumb for USA installations in
absence of client data
Boiler make up water (p4-17) is treated in a demineralizer
train If deemed necessary comparison with reverse osmosis
process can be performed in Phase II
Water requirements were estimated to be
Cubic Metres Per Year
20 MW 50 MW 400 MW
Mine amp Shale Processing 455000 761000 773000
Power Block 3000 6000 42000
Infrastructure 80000 140000 448000
Total 538000 907000 1263000
117 Annual average operating costs shown on Table 6-1 are in error
Financing Option 5050 8020
Cost Shown 56606 48945
Corrected Cost 60396 53236
Average mining and shale processing costs are developed year by
year in the Mining Report Appendix 5 Table 12-10
32389
Page 7
118 We would be interested in receiving the breakdown of these current
power cost figures (ie capital charges fuel cost number of
operators etc) Further economic analysis employing these
figures can be developed in Phase II
119 Manpower requirements for the three case studies were estimated as
fol lows
Mining amp Shale Processing
Power Block
Operations
Maintenance
Management
20 MW 50 MW 400 MW
75 163 396
54 78 175
46 73 455
10 10 10
185 324 1036
Page 14-4 of the Mine Report is for mine and shale processing
only It should be noted that most of these manpower requirements
involved new jobs for Jordanian people
120 At the April 1988 Amman Meeting it was agreed that the following
costs would be omitted
o Permits and Licenses
o Local Taxes
o Import Taxes
If necessary such costs can be developed and added into a revised
economic analysis as part of the Phase II program
121 6 average inflation rate is the figure recommended by Bechtel
based on USA conditions for use in long term economic analyses of
new power ventures
32389
Page 8
122 This matter is referred to ORNL who prepared a rate of return
analysis
Bechtels conclusion is based on computed busbar costscumulative
benefits compared to alternate fuels in the timeframe 1995 to 2000
Relative Busbar Power Cost Net 25 Year
Mills per KWH Benefits - Million US$
Sultani Oil Shale 71-83 Base Cost
Imported Coal
$50tonne 68-88 778
$70tonne 78-107 2531
Imported Oil
$17Bbl 56-76 (18) $24Bbl 61-96 1810
The above results are based on a capacity factor of 75 which is
considered to be a reasonable target for a new plant over its 25 year
life The average selling price of 6 cents per KWH cited in the
questionnaire is based on existing plant costs which may not include
all cost elements of new capacity evaluated in this study
32389
Page 9
TECHNICAL COMMENTS
21 See answer to Item 116
Total power plant raw wate consumption rates and annual
consumptions including the water requirements for wetting ash at the truck loading p int within the power plant are given in Tables 43 and 44 for 50 MW unit and Tables 53 and 54 for 20 MW unit
The raw water requirements for 4x0 MW plant were factored
excepting the mine where a revised mine pldn is employed to reduce water request The quantities shown on these tables exclude raw
water requirements for housing complex mine and ash wetting if
required at the ash disposal site
Total power plant requirements shown in the above referred tables
are
50 MW 20 MW
Rate gpm 207 102 (See Drawing M004)
Annual Use
Gallons 1400000 675000
Cooling tower blowndown supplemented with raw water is used for
wetting ash at the truck loading point within the power plant Raw water quantities attributable for ash wetting at the power
truck loading point are
50 MW 20 MW
Rate gpm 75 325
Annual Use
Gallons 500000 215000
These quantities are included in the quantities shown in
the above referred tables
32389
Page 10
22 We recognize the POTENTIAL for leaching toxic compounds from the
spent ash However this matter is not yet defined well enough to
recommend specific action steps The Prefeasibility Study page
7-12 recommends creation of a ground water dispersion model to
determine whether more specific contaminated water mitigation
plans are needed It is anticipated that the leachate rate will
be low and that aquifer dispersion will keep problem compounds
bel3w health standards thresholds
23 Noted
We have not received up to date resource study material which
defines 50 billion tons resource base Please furnish
The resource base at Sultani alone is adequate to support two 400
MW power projects capacity subject water availability The
2-million cubic metre per year water allowance for oilshale will
limit development to about 600 MW
24 Selection of a combustion temperature is a balance between carbon
combustion efficiency and heat loss due carbonate decomposition
For purposes of the Prefeasibility Study we have opted for high
combustion efficiency At lower efficiency larger shale
mineprocessing plants will be needed
25 Bottom ash is cooled by water exchange before discharge
Cooling water is supplied to the ash screw coolers as specified by
Pyropower See Drawing MOO5 2140 gpm flow for 50 MW and 860 gpm
flow for 20 MW Heat removed by the cooling water from the ash
screw coolers is dissipated to atmosphere via a wet cooling
tower Pyropower should indicate the temperature of the ash
discharged to be 5OOF
32389
Page 11
Initially we had considered using a heat exchanger to cool the ash
and improve the cycle efficiency Considering low cost of fuel
the additional capital costs and the system complexities it was
decided not to employ such heat recovery systems for this project
26 The suggested alternates were looked at briefly and the potential
for wind blown air pollution from the ash disposal areas are too
great to warrant dry disposal unless GO(] and World Bank are
willing to accept such a potential problem Wetting the ash is
tne only practical solution Hopefully some cementation will
occur helping to reduce future leaching potential
27 JEA requirements are noted This is a conceptual study not a
final design Optimal design analysis can be performed during
Phase II
2829
JEA requirements are noted and can be incorporated into the Phase
II design
210 The transformer size is adequate for base load operation A
higher capacity can be considered at the final design stage if the
Client prefers
211 From our experience it does not appear to be economical to
provide additional dry cooling towers to take care of maximum
ambient temperatures which may prevail only for a short period of
time in a year To study this an annual dry bulb temperature
duration curve is required Also adding additional dry cooling
towers will change the plant performance It should also be noted
that the dry cooling towers are very expensive and the size should
be selected carefly considering performance and cost and not on the basis of maximum ambient temperatures This can be studied
during Phase II
32389
Page 12
212 The plant gross output varies with condenser pressure
Condenser
Pressure Design 55 in HgA Annual Ave 35 in HgA
Unit Size MW 20 50 4xlO0 20 50 4xlO0
Gross Output MW 234 593 496 2415 607 TBD
Net Output MW 1975 501 400 205 515 TBD
To be developed in Phase II
Output for 4x100 MW is estimated by others
213 The fan power consumption of the CFB boiler is about 30 to 35 of
the total auxiliary power The fan power consumption of the dry
cooling tower is about 20 to 25 of the total auxiliary power
214 Table 1-1 does not include plant net output Therefore do not
understand the comment
215 Commercial operating experience with coal fueled CFBC units in LISA
and Europe has been uniformly good showing high on stream
availability in early years (See Table 2-6 which reports on
Pyropower experience)
We expect operations with high ash content fuel like oilshale will
have unique scale up problems such as
o Solid handling in and out
o Internal solids circulation
o Erosioncorrosion steam generator intervals
o Heat recovery from bottom ash
Consequently we are recommending these items be worked out in a
single 50 MW prototype
32389
Page 13
216 Maximum dry cooling is used in this study A small wet cooling
tower is used on circulating service water system
217 Horizontal condensate pump is adequate with dry cooling tower and it is cheaper Vertical condensate pumps with cans can be
considered in the final design if required
218 A concrete shell brick lined flue stack will be larger in diameter and costs more than a steel lined stack Brick lined stack can be
considered in the final design
219 Demineralized water tank capacity for 50 MW is 76 cu meters or 20000 gallons not 1000 cu meters For 20 MW plant it is 38 cu
meters or 10000 gallons
220 It is US practice to use an average continuous blowdown rate of
1 and maximum biowdown rate of 3 for this type of plants
221 This can be studied during Phase II
222 Same as 221
223 Same as 221
224 The recommended action plan calls for continuing support studies covering the referenced items Additional effort is needed to
further define these matters and confirm the conceptual plan
The next step is to develop an outline for a project plan including
o Work Scope
o Schedule
o Budget
accommodate the increase in the number of employees and
equipment Truck bays to accommodate the 136 tonne trucks
will be added The truck bays used for the 77 tonne
trucks will be used for the maintenance of other
equipment The warehouse change house training room
offices and cafeteria will be expanded accordingly
6025 Mining and Processing Economics
Details of the oil shale mining and processing plant
economics for the 400 MW plant are included in the Mining
Report (Appendix 5) These details are of the same
magnitude as prepared for the 20 MW and 50 MW plants
The summary of the cash flow analysis for the mine and
shale processing plant is presented in Table 6-1
Table 6-1
SUMMARY OF 400 MW PLANT OIL SHALE MINING AND PROCESSING COSTS
5050 Debt-Equity 8020 Debt-Equity
US $1000 US $1000
Capital Cost
Mine Development 30915 30915
Mine Equipment 66012 66012
Process Plant Facilities 50889 50889
Spare Parts 5000 5000
Working Capital 10000 10000
Capi tal ized Interest
During Construction 24423 39075
TOTAL 187239 201891
Operating Costs and Other Costs
Annual Cost 60386 53236
Product Mined and Processed
Annual Tonnes x 1000 7783 7783
Unit Cost
US $Tonne (weighted average)
US $l06Btu (weighted average) 776
156
684
138
Year 12 costs taken as 25 year average
6-6
-Au
Table 610 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
- FCC plant sizes equivalent to proposed power application
Prefeasibility Study Oil Shale Fueled Power Generation
VOO94GEampJRI26
i
PYROFLOW UNITS IN THE US
COLORADOUTE IOYA STATE UNIV UNIV OFNUCLA CO NORTHERNAMES IA BF GOODRICH110 1o0MW(a) 2x170000 Ibhr HENRYILCEDAR FALLS IA 120000 Ibhr GENERALGULF OILu EiN P MOTORSSbtUpStart-UIL 1987 O A 1I N000 TC
NORT10 PONTIACH B MIRANCHWV00000 lbhr
CORN PRODUCTSSM NORTH-CAROLINA STOCKTOD CA
400000 lbbhl t
RUMF RD ME
CEMENT CO CALIF PORTLAND-COLTON CA
190000 Iblhr Start-Up 1985 TRUMTFTWN NYU
3I75ERTOWN N
etar t-Up loss ACE COGENERATIONCABI
TRONA CA Oper t~on l -Start-UP 1990 ~ rt upz 091Start-up loss Start-up PNeLAI 1991
MTKESFICOENERATIO-N1
BASFIELDp Start-uStar-Up WESTCA9 199otgoUp 1 MAHONEV PA|00000 Ibhr A Oz 2X365000 Ibhr
SETtr-Ups 188B CHAT TANOOGA TN
G ULF OIL EXPLORATION 8ta-rt-u) 1085BAKERSFIELD NORTH BRANCHCA SPRING GROVE PANORTH BRANCH WV 400000 IbhtOperational 19835 5 0 0 I b h 9 0 0 0 Iblh r- tart-Upi 1991 S t r - U p s l e s s
SOUTHEAST PAPER MFG CO UNIVOF NORTH CAROLINArDUBLIN GA UHAPEL HILL NO400000 IbhrStart-Ups logo Start-Ups2X250O000 1loseIbhr B
- Withdrawing ash from combustor - Withdrawing fly ash
a Internal solids circulation of the steam generator
m Erosioncorrosion of steam generatorinternals
Heat recovery from bottom ash
U Operation with low calorific-value fuel
Prefeasblity Study O Shari Fueled Power Generation
VOO7AI 27
Impact of Scale-Up
Project Size
20 MW
50 MW
100 MW
50 MW boiler in 100 MW plant
Potential Risk
Design Scale-upOperation of to 100 MW Initial Plant Plant
Low Significant
Modest Modest
High Low for duplicate units
Modest Low for duplicate units
Prefeasibility Study Oil Shaje Fueled Power Generation
VOO71-4GEAL4n2
i
Conclusions
Defined risk of CFBC boiler is acceptable
U Operating experience with commercial CFBC boilers built and under construction will strengthen confidencelevel and minimize risk for a plant built in 1995
SPrefeasibility Study Oil Shale Fueled Power Generation
V007GHAAE29
ENVIRONMENTAL ASSESSMENT
a Mine and shale processing
- Fugitive dust emissions
- Noise levels
- Leachability of disposal piles
Power plant
- Fugitive dust emissions
- Gaseous emissions
- Noise levels
- Water effluents
U Conclusions
Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel
Prefeasibility Study Oil Shale Fueled Power Generalon
- Coaloil prices will be at least 15 greater after 1995
- Discovery of indigenous conventional fuel resources is inadequate for power plant purposes
Prefeasibility Study
Oil Shale Fueled Power Generation
VOO) IDWFO
Feasibility(Contd)
N Suitable financing will be available
- For $200 million 50 MW prototypeproject
- For $1000 million 400 MW commercial project
Government of Jordan will make basic commitments
- Long-term power purchase agreement
- Long-term access to Sultani shale deposit
Adequate water and manpower resources
- Attractive tax incentives
Prefeasibility Study
Oil Shale Fueled Power Generaion
VO bull1DUJJRO 6
Timeliness
U Timely development of Jordan oil shale needs prompt action to create - Additional definitive information
- Suitable business plan
Prefeasibility Study
Oil Shale Fueled Power Generation
VooI DUJo 7
i
Expansion Conditions
U Continued expansion of powergeneration from oil shale in Jordan depends on water availability
Prospects for power export or importand domestic load growth will affect size of the needed shale-to-power program
Prefeasibility Sudy
Oil Shale Fueled Power Generation
yOWl lVuJO
Environmental Impacts
N Environmental impacts of shale development will be minimal
Prefeasibility Study Oi Shale Fueled Power Generation
i
Development Advantages
Will create significant new jobopportunities in Jordan
Will avoidreduce foreign exchangelosses for expanding alternate fuel imports
Prefeasibility Study
Oil Shale Fueled Power Generation
VOOIIULL tO
Recommended Action Plan
N Basic recommendation
N Conceptual development schedule
U Project development plan
Key plan elements
N Funding requirements
Prefeasibility Study Oil Shale Fueled Power Generation
VOO4II )U OII
i
Basic Recommendation
N Expand efforts to develop an oil shaleshyfueled power generation program at the Sultani deposit
- Conduct required supporting studies
- Define facilities costs and business plans
- Obtain project funding
Prefeasibility Study
Oil Shale Fueled Power Generation
VON I II)ILL 12
C
Conceptual DevelopmentSchedule
1989-1990
- Conduct supporting studies - Define costsbusiness plans for 50
MW prototype and 400 MW commercial projects
- Develop project financing
N 1990-1993 - Build and operate the prototype project
N 1994-1996 - Expand the 50 MW prototype to 100 MW scale
U 1996-2000 - Expand the project to 400 MW scale
N 2000-2005 - Build a second 400 MW commercial project if needed
i 1 Prefeasiblity Study
dOil Shale Fueled Power Generation
VW IMLITO 13
Conceptual Development Plan
Months
1 Project development plan - Define project
costs1busness plans
-24 -12 0 12 24 36 48 60 72 84 96 108 120
2 Secure funding
3 Build and operate 50 MW prototype
Dergn and procurement
Mine development
Plant construction
Startup and testing
Operations
L- -
4 Expand prototype to 100 MW
Design and procurement
bullConstruction
Startup
5 Expand project to 400 MW
2nd 100 MW unit
3rd100 MW unit
i 44
4th 100 MW unit -
O Project dacision point
i Prefeasib~ity Study Oil Shale Fueled Power Generation
17958562aJocdanV 3-14-89 rsO
18
Phase I - ProjectDevelopment Plan
n Program development
Seminar workshop on prefeasibilitystudy Oate project development plan woek scope schedule arid budget
U Carry out project planning program
- Conduct continuing support studies - Test Sultani shale in existing FBC
- Firm up designs and specifications
- Update costs and economic analysis
- Develop business plans and requirements
Explore project funding alternatives
i Prefeasibility Study
Oil Shale Fueled Power Generation
VO MItUOR 14 -0
Key Plan Elements
N Project feasibility analysis
- Firm up designs and equipmentspecifications for all facilities
- Update cost estimates based on preliminary designs and specifications
Explore arrangements for contract mining and mine development
Update forecasts for demand growthand for retirements of older generating capacity
- Create updated economic analysis
Preleasibility StudyO1 Shae Fueled Power Generation
VOO1IOLWRI
Key Plan Elements (Contd)
Business entity requirement
- Explore optionsconditions for a new company to managebuildoperate the project
- Explore optionsconditions for obtaining a concession agreement for Sultani development
Explore optionsconditions for water rights commitment
Prefeasibility Study Oil Shale Fueled Power Generation
VMIOIA)lj 16S
i
Key Plan Elements (Contd)
U Continuing supporting studies
- Combustion tests (additional pilot tests for design and warranty purposes contract for large-scale burn operations in existing plants if appropriate)
- Additional core drilling and core analysis
- Oil shale crushing tests
- Spent ash leaching tests
- Geotechnical data base including soils analysis
- Environmental baseline data
Prefeasibility Study O Shae Fueled Power Generation
VMMMUldMOA
Steps Required to Develop an Oil Shale-to-Power Project
Create a development business plan - Schedule - Decision tree
Develop a work scope and budget for the development plan program including - Firming up designsspecificationscosts
- Developing business entity requirements - Continuing support studies
Carry out development plan program
Assemble all planning results in a report for discussion with financial institutions
Explore project finance opportunities
Finalize business arrangements
Implement prototype project
i Prefeasibility Study
Oil Shale Fueled Power Generation
VM1-11UJROLI
MARCH 15 JEA QUESTIONS (M S ARAFAH) ON PREFEASIBILITY
STUDY DRAFT REPORT
Rt
DIR EScBSULIVAN PHD OFJCEop~BUREAU FOR SCIENCE AND~TECHNOLOGYAGENCY - --FOR INTERNATIONAL DEVELOPMhINTSWASHINGON DC x20523---------4
4 -
-SUBJ E CT - -C O H~ E T 4N l
Dr Mr sullivan ------shy
c-rommnents We ~efr-preaereorPla -tobYou lete dted Jan 91989 regardn~i4po4t P ea e1 f i nd y ubel ow our -e ot r XcOrcerned Jordanian deipartments
- --A ar o~nnYu Y o turjlt~ lt K
4 C~mments
~1 N i gFIN I~fANDECONOMIC1COIMEN S -
It sidicaed that Beohtel and US AIDWash ingtonj~4- re ojy nen ing that E 2hould und ertake the n e tshyihaisAre ~our c leometprogram n order shye-t im~ ate d f n t v design and budget cost
4Al1so Lthe study ncal--ttsutnilndcaei~ A-1 A thas ~ l 1 be eeded idb~~~~~ rn o ei t n i la itheMWa~-~5s~ 4
hrPro hehgemetTh trOfT ses~fnr4 BOT)Vmanu- a n-mnf~cure 4 r~j or contra c4-or ivoIlveiintijn I 4 4investmnt ude smi ~w 2 Zha tev e r --~4~prce e ec r it v p4~ f JA gertiy geeated-at 4 JEA 3 a l b u y ~the same average~~ A
~jithia oncot in4 ordrtan ecpoemic asess thespePower generatjoon J ordan3 oi sha I eroic c inr~etJordan 4
2P ge i1- 1 Aj iit eu that OPin he atocontr~ct 4with owner4 ofext3ing (oconstriiction r(FB rml-t
qu i of S 11 t to test large tonnagen j es StaniUti n d ajIe -for se veralIQf 31 hi
evrEAPreferpilot qr the dP 1prt7n -that the4mPIt
andi to(7 he instalI 1e 2 310 A
_
JODN ELECTRICITYAUTHORIT LL
Dac
operated in Jordan i n or~der~~t ~n nuex~on mnining crushing and haidi igQhre~ and sash Maeia nd aSootoget enough olr ndaita needed for einolre
CEBbole~ -i s~
ccordance with Jordaian oil shale
large to~ bfig
1 3 le 1-2 Page 1-7 Cost Of Pwer~i It i S menti-oned that the conmecial oil hle~ lt~project (4 X1OOmw) 1is ninacompetative roqt~range-~while table 12 indicates thattcost of-pow Ais~mill
q kwiihcii r 1
average wih i ii -much higher ihantheshy-ost of ~Power gnrtofomJEA therimaPower s ta tions Please~ indicate on what basi o ~~ shave-~made your-statement
PK
14 Pae 2 Sction 4-0sIt 1nlkly that theChousing and off- -site infrastructur-ommnity fakilitieR) to be onsidered for both the demo and prototyp prjcs oeoverwe~4 hnk that their~c_6t is raterojects Mo
iwcv~- age -1 1 Mine O(perationIIt is indicate~d that mining cot eevdfoMine contractor~ are ficomiplee h
r and iyudi-t~con qidder contract mnn opio fr4 the min4 cmflt2ng are reIanddrepres~ent the real costs derived from Phspat miin contractors in
lestfor the eo rPooypuat in order tlt7
P I eadenote tha detthe new exchangerate ofthJraian~ Di~nner you may add 20j6 Kto the quoted
1 6 P Ias e consider the followin ecn hage_
171- The new exchange ra teof tUSD=54o0 fils1 72-W2 The new~ aerage tariff for selIn~electricityhas decrreased to 120 8 f ilIsicwh
17- Page 1-7 TbIe 1-2 W bev th tthe cap ita1 cot for the pwhokand forthe min n d ash hMnd1ing equipen
P B~2Anaor a -Tl 8156152 8176 1Q MYf -t -Now 520 t 1U
JDNEECRICIT AU-RA L14lLiL
2 ~are very high We suggest~ thta You rerconsie (- telowerus e~+d accuracy est a rangethan +30
Page4-22 Table 4-5weno0ti ced( that- PyroPowe ha ddeta(IiacCst fori the bo1ilerlocation and terha dutdetlease isxtr fo~ l C~ io~ s~ e~~ 1a~ a if and indicate theonldjusted ~percentagefor construction foin Jordan
19 Page-7 Table 11-2 -Yo aeue ihrinterest rate on Equity thatn on1DehI~laseinclude~ adetaied explanation of thisrr -tni kepin in miUndie JEA is1thaIt a non profit~ shyorgaiztion unik oher private UJSA utility~in ktation
~-~110- Regarding shy
the ra4ital Rt fthe project it is~requesed tobre k it intdo foreignMeanwhile cthe nd lorcal c-osfoeigptario i nt-re3t~shol becnierdo-h
rr n ontiondonnotopdbon the 9 cnieelocal portion~onth
1-1- 237~Pa
oningeny 9tooi s high~~ a lower 4value -should be~
4~ gt ~112- -Tbles t1-1 -8-8~ inclu~de t~he c~alculationscuultie nt enefits for of Th shyunttypes l i4s difeen geeatnmrer likely tocluae
-~ Q~ J7present vk1u for tenet tthe~benefits in feralterntives -t-oa s the
49
ehliyoi shale
Wea gree with you9 tha t th e percentage used ~ an for thenua~l 0 ~amp-M rahr CFBo ndsomewha~t highervrate be n ededma y for a C B l n Me n h l ~ a e r
indir e ta~ts the -estimatedma i variablec st i ddition t he fi-xed-9i 1 mislkih We --
thinktttiis too lowK -5
shy
1-14- e 4-29
opprza tion-o to The o i1s h1 costs-nc I deAbo 1h
Pa10 mman ormTSI62 a
IB I
JORD N EtECTICI1~ 4 E~)~Is-s
Date ib-_
~ ~riii~g~nd~o9~ru~hng h~tnlin cot~u~tv yo
i Dae Jnryit
1ts c 7 4-
i smiig iniand fh co I eY
susendi ca tI t icag th t1 ~an~approximate 15 ~pita L tYII I (-~a~ge or he owe bl ockj f aniitjes isof +the capthe)t~ial7cpi~lrharge Uoratelformny SI~Uj(uiity installa~tions~ whle page 6-1T9 talJshyit is mentioned that~ the Capital rate pe-r JEA isshyi5~PeaseJustify this~matter since~w o
i16- Pae 6-1 6
1 I4~t is mentioned that the costs of 4process Water are ~ 4 ~0 2$1 000 gallons
r~j~lt IHave~You considered additionalvalue ofbying waterfrom~ the Wa ters Aito i ~or ditoa cost~f o revrseoqoesplant if ground water is used
~~ I1 7- Table 6-1 Page 6-6 Please explain how did You come ou ihteoil~ shale miniing and proces~sing uit~Icost
ltII~I~ 8- Please note 1 t hatj the average JEA~productinr ot frmthermal I power stationsr (Istationbus-barCOSt)i sbewen 6 3-17 3 fils 4kwh You may use this~
l4~ 19-i For ~4 X 100~AMW Plat iti etindo pag e14-4 VolI 11 that4 at tota I of W42 14 epoye W II eemplo~yer] And on page 69yo1Iiti mentioned that a~ tot 1 f1 ~p yeI iNbe enp1oyed a
is~ high asrmetitexeds100personorthe ~41X100~MWh~~j nsatnpPrlae
I 1 The 4 following iftemns are a sumed to1 be excluded from theraPi ta 1 cot xoI
120-1 Perits I icen es 7
1_207~3 Imprt ~xe on s7pare par ts -and c(7orfmurab -ma~teria Is
04f4 4
~4 R j4 4
D4
~ ~ ~ AIf eS taxesq in acrac ihteJraand regulations should be considered aw
21- p1ea4s e indic ate Your Ju t f c io r us ga 6
44122- Table 977App 5Page4 9-1 4L IK Car1Yiniae that the hIRR of the 4 Otplantis rather unattractive (66)most
-( Cns1er4 ngthe logical base 4csek c pwhen cii 6OL
average sell~ing prc CkhampDEratio L801~2O~Aoreover4M the ne siellin prcwh o JEA ati theamptime~ Abeing os4ltp n~ot exceed 4 Ckwh~-However Ipage 1shy~ and 14 0 T indicate that ecnms for a commeri
S4A4scale joil 4 shale projc ~
appear Piomisig-nug o4Ywarrant continued dee fgfluht 4 feaibiit 4tudy wihil cost sevea~lili
do ar~sf Plas lear wether the ~x step jqs~$j~~lt 4
gtt 9o be considered arCcording4to jthe 4unattractiveresul to mentioned in IRR7 Table 97 gt4
a C4 44fET2 4 144-4444 P a g 1 T b6 l
htte~We ~ ~ ae~ rqieetfrteX ~ noie ~~ ~ 444 MW un t44 r te4l w w e o p r d i th e w t r n rre u f4m or4444~ the4444 54M4rto y e Pg~A~44EHiveL det ile an l A44
s o awa er c n um t a4r f rofsho in P6Io erT
e ch 2 50 M W aPln wa e d 41004 MW4 1 consumption_____________
ma4~2 k e u p houin~44 p A44 4444444 C O 4ltI4
a nd a sh et in etc 4 2 4 1 -24 P a g e4 2 - 1 A P P 5
4Yo 4_ j1 4 4~h444 N44 44
1gro nd tce t hir fthe w bern coqir mna t efora4e 4X10A M 444444 4 r i n to 4 4 4lo w w ehA 7 n 2 cinCie h rh4 n ttthh1eb -e 4 44t Of3 E4O
ea h n~ ffl 4 4Jl44 4 4444 4giv
6 ig re sofrat4 de in cl ar f w w at5 c hrw pe o
s h b 444 o t h e g nd L 44 h u i n C
r 4ne a4 t44 e L(704 2 4 p ae) 2 - o Au P dn 5ai 7~e r 44 I Y (1t 44a
ve7 rn e qu 1saharvthe y
and n~~~o speci~~~l4 p n l nh i n t x
r ~rA M e d r o t eu n 8 1 wTtl t t h
- c re e N I wo6
~ n n a i n a t d h l7 A PP6 gt
J
S2~3- Page 2-4 ~ ~ It ~is i
that oil eindicated the- sha le r our~ Cesin Jordan are 10 billion tons -The anulp e reere maiy exeed 50 4 billion tons ~
~ 24- 4Page~2 -l1 iujntr We beiv thtCBcmuto~ep i s high and~alSo
~~ ~ -2 ~~ Page 4-1~6 j - shy
Please~~ indicates your procedure to cool the omn ashand atwa icagd-eprtr
A Have you~ considered~ additional he~at exchanger topcool th ash and to imrve h cycleef ficiency
-~2~6 Page 4-16 It s~ indicated that ash from each silo i Amixed19 ~with~fabout 20 waterKb weight to minimize generation of dust~during trnprtto to mine and disposalHave you~ coniidered other 4lternativeto
~ ~eliminate dustiiig -and avoid use ofwat r uring it ransportationi such as~ using closed trucks or closed
of ~fans conUMnPo wihrlaintthe total plant auiir poe osupin 1~21- Table 5_-3 and I ~
Th~~ is- somneere c6ntradiction regardingplnneotpu~t in both am tables 21-~ Tabl~e 1-33
We noticed tha~t yourall9 cacacapac t fatro75 tion ae asdnWe thilt ~that 7capacityshyfacto is tobo high for- an oil shale fired plant duketo lack of existing simila~r ~plants handl~~~firing oil adshale ~K
216~ The study iniae thtawet~coigtower wi11~used Actually a b
dry cooling should be consideda5ini ~HTP S inZ atomnmz so water rnumption4the cycle~ efficiency willbe reducedHenre YO33~reconsider calculating the cyclefficiy
U~~~~~ codnt umconsidered ofhorizontal -aretypethe~ the vertical cian type can alsobeh considered
shy ~ ~ ~ I~~
2~2 Kconcrete shy
shjell stepl fltstack is onidereconcrete shell brick flue Rt c ~s beCaconsidered3V
2-19~- Deminiraized water~ tank3 capacity~ is -76 ui(meterThe recommnended tank cameter- ui tyi 00cbc
220Designconditions Pa~ge (4-74)te5 hat bow 3down percentage splusmn ~fomrpra til re i hou I be 3~)~
PoD Z 2 m a ad~ - e 5 1 2 iJS~ ~ p A f amp ~ ~ y1
4
JO R ECTICITY AUTHORTIT 4L
~ 4
Date~
t etats ttthe quantityof s i S ~1 000Tons ra Sthis tuntity 11- be transporited for severIy --to tu ofI pit a~te torg P KM ra~erm Spower plIatS about 12 midilidoni CUIA(- met ryea
h e ndd mp e he (d u p in i n L
area wil evric power plant6t Please zn1 a te~tiv s tudY for dumping th r~ a enoug
-from the power plantr~~h~
S 2- Please provide deald-ifrat ao etbaaiedrawing hwn TH11 R thaU and~pV ra~te takcing illto o 6it v- consumptionn _uig themrining equipment
alternate~ study 0o Jine operation for 1 shiftday Vand twoshifts day -lt
224- Conceptua~l pflR 1 for mi ing anusdtransportation of oil- shale a 0 dmj of hs f u r therV examinedh iV~sdpatI ho u1d be
orderj to poe~ehicalq and~eoomca1 fesblt of t his operation
SYour are requested te) study and consider all- above - iPoin s at your earliest in rder -to be peete y oiAnimain on March 29-301989 peetdb~o 4 n
S9incerly-You S
WDIRECTORGENERAL -
I~ CCMR WLINTON ~vs
5N
Pa D~t~IoAmmn -Jordtn -Tel 815615 20 Bl76 15 -19j A VINO- AFf TY
MARCH 21 RESPONSE TO JEA QUESTIONS
Bechtel Power Corporation Engineers - Constructors
Fifty Beale Street San Francisco California Mail Address P 0 Box 3965 San Franclco CA 94119
March 21 1989
Mr M S Arafah Director General Jordan Electricity Authority PO Box 2310 Amman Jordan
Subject Jordan Oil Shale Prefeasibility Study
Dear Mr Arafah
Your letter of 15 March 1989 with comments on the Oil Shale to Power Prefeasibility Study draft report has been referred to me for reply
The attached responses to each item in the reference letter follows the order submitted
Also attached are three revised pages for the draft report - Volume I
Page 6-1 Page 6-21 Page 6-23
Please copy these revised pages into the report previously sent to you
We plan to review this material with JEA during the March 2930 and April 1 meetings in Amman
rsuVertrul yours
W Linton Project Manager
WHLdc
Attachments Questionnaire Response Three revised pages
cc C J Aulisio R R Buta G D Gould T J Wilbanks
32389
Page 1
RESPONSE TO MARCH 15 1989 QUESTIONAIRE
OIL SHALE TO POWER PREFEASIBILITY STUDY
This study examines economic prospects in terms of a 1995-2000 timeframe
FIRANCIAL AND ECONOMIC COMMENTS
11 It is likely that a BOT deal can be structured at present JEA
generation costs for either 20 MW or 50 MW size units if GOJ is
willing to subsidize the incremental power generation cost
Furthermore these incremental costs can be recovered during the 25
year operation of a Commercial Scale Project
12 A 3rd Party Test was proposed as an alternate means to raising
$100+ for an independent JEA sponsored 20 MW Demonstration
program
13 71 millsKWH for Shale Power
VS
JEA 1987 costs
Purchased Power 17 filsKWH = 51 mills
Produced Power 1360 filsKWH = 41 mills
19952000 Costs - Expected to be 30 to 40 higher and in line
with the cost estimate presented in this study
It also is important to recognize that the busbar cost of power
generated by any new power source can not be compared directly
with the cost of existing older installed capacity because of the
lower capital cost component of the latter (See enclosed Figure
1-1 which demonstrates how total capital carrying costs decline as
the investment is paid off) Any new capacity whether coal oil
or oil shale will be an unreasonable disadvantage compared with
costs for existing older capacity
l
024
o2
0De return
E 016Total carrying charge
012 qu return
S -008
ety taxes and n rcw vshy000 X 0 5 10 15 20 25
Figure 1-1 Year-by-year Carrying Charge Components for 15-yearTax Recovery Period
1-7
30
32389
Page 2
14 Infrastructure Cost
Total People
OperatorFamilies Installed Cost
20 MW $10000000 185700 $54000Operator
50 MW 15000000 3241200 46000Operator
400 MW 45000000 10364000 43000Operator
Factored allowance for grass roots desert installation
including housing and community facilities was developed as
follows for the 50 MW case study
Infrastructure
50 MW
Family Housing 200 30K = $ 6 Million
Bachelor Housing 100 20K = 2 M
HospitalClinic (8 Beds) 11 M
SchoolMosque I1 M
Stores Services amp Recreation = 2 M
Facilities
Roads Electricity Water Sewage = 3 M
$15 Million
Infrastructure costs for the 20 MW and 400 MW cases was ratioed
from this breakdown
At this conceptual level costs are order-of-magnitude In a Phase
II program these infrastructure costs can be developed in detail
32389
Page 3
15 Contract Mining Alternatives
Page 4-11 Mine Operation
Based on Bechtels evaluation of the mine contractors price as found in Section 15 of the Mining Report it was concluded that
the mine contractors price does not include costs for such things
as developing the mine with a box-cut ramp haul roads
developing an area for the waste material maintaining the
haulroads constructing the mine services facilities diversion
ditches sedimentation ponds water well crushing the oil shale
pre-mixing the oil shale at the mine and other items associated
with operating a mine to support a power plant If it is proven
that the mine contractors price includes cost for the above
mentioned scope of work in additi-n to drill blast load and
haul then the contractors price can be used but in the meantime
the all inclusive cost developed by Bechtel should be used
Contract Mining appears to be attractive for the smaller size
plants but not for the larger commercial scale operation Some
third party must provide the necessary capital for trucks
loading mining machines etc under a contract arrangement
16 Reassessment due to Dinar value change needs further study and can
not be evaluated given present budget limitations If average
labor rate of $300hr still valid then little change involve with
study
If deemed necessary reexamination of project economics can be
done in Phase IIwhen funded
17 Costs in this study are based on recent similar Bechtel experience
on Mount Poso project and on Montana I project The Mount Poso
project is a 50 MW unit firing coal in a Pyropower boiler The
Montana I project is a 35 MW unit firing coal in a Keeler Dorr
Oliver FBC boiler utilizing dry cooling
32389
Page 4
18 The Pyropower quote of $186000000 to futnish and erect the steam
generator stack and baghouse has been adjusted to include
engineering construction indirect cost etc to be consistant
with the rest of the costs shown in Table 65 p 6-10 No
further adjustment for location was made
19 Equity funding has the lowest priority of payoff in case of a
liquidation and carries greater risk Hence a higher rate of
return is needed to attract these funds Debt funding is a first
mortgage and has first priority for payoff in case of liquidation
and carries less risk Hence it requires lower rate of return
than equity funding
The risk taking equity owner will ask for greater interest rate
to make funds available The only way to minimize this expense is
to find a loaning agency willing to provide 90 or perhaps 95 of
the investment cost It is likely that banks will require some
minimum equity participation
This Prefeasibility Study was not based on a non-profit utility
operation
Even though JEA is a non-profit organization its service
contributors are profit making groups It is visualized that the
Jordan Oil Shale Co (JOSCO) will be a stand alone business
enterprise servicing JEA under long term contract To secure
funding for the proposed project JOSCO will need attractive
enough contract terms to attract both equity and debt capital
110 Additional work is needed to develop the requested information
This work can be preformed as part of the Phase II program
111 Bechtel includes contingency in all of its estimates to cover
error emissions and unforeseen items within the defined scope of
the project The level of contingency is dependent upon the
amount of scope definition For a prefeasible study such as this
15 contingency is lower than normal
32389
Page 5
112 Tables 89 through 816 include a present value calculation to
establish the relative benefit for a shale project vs coal and
oil
113 The variable maintenance cost of 1 millsKWH has been adjusted for CFB plants with an additional $200000 per year or 06 millsKWH
This yields the following
Variable Maintenance - 10 millsKWH
CFB Adjustment - 06
Fixed Maintenance Cost - 40
Total Cost 56 MillsKWH
114 Page 4-29
The royalty costs are included in the weighted average oil shale
costs for the 50 megawatt plant
Page 4-8
Shale fuel costs include return on equity and royalty These are
two separate cost items Royalty is the last item mentioned in
the sentence and it therefore reads as royalty and not return on
royalty
Page 4-31 gives rates used by Bechtel based on our calculations
using the referenced procedures
DebtEquity Capital Charge Rate
5050 153
8020 139
Table 69 displays the calculation of the 153 capital charge
rate (Line 7 of Table 69 is not used in the calculation and
should be deleted)
32389
Page 6
116 No water purchase charge from the Water Authority was added to the
operating expense based on the statement that no resource costs
will be charged
$020 per 1000 gallons is rule of thumb for USA installations in
absence of client data
Boiler make up water (p4-17) is treated in a demineralizer
train If deemed necessary comparison with reverse osmosis
process can be performed in Phase II
Water requirements were estimated to be
Cubic Metres Per Year
20 MW 50 MW 400 MW
Mine amp Shale Processing 455000 761000 773000
Power Block 3000 6000 42000
Infrastructure 80000 140000 448000
Total 538000 907000 1263000
117 Annual average operating costs shown on Table 6-1 are in error
Financing Option 5050 8020
Cost Shown 56606 48945
Corrected Cost 60396 53236
Average mining and shale processing costs are developed year by
year in the Mining Report Appendix 5 Table 12-10
32389
Page 7
118 We would be interested in receiving the breakdown of these current
power cost figures (ie capital charges fuel cost number of
operators etc) Further economic analysis employing these
figures can be developed in Phase II
119 Manpower requirements for the three case studies were estimated as
fol lows
Mining amp Shale Processing
Power Block
Operations
Maintenance
Management
20 MW 50 MW 400 MW
75 163 396
54 78 175
46 73 455
10 10 10
185 324 1036
Page 14-4 of the Mine Report is for mine and shale processing
only It should be noted that most of these manpower requirements
involved new jobs for Jordanian people
120 At the April 1988 Amman Meeting it was agreed that the following
costs would be omitted
o Permits and Licenses
o Local Taxes
o Import Taxes
If necessary such costs can be developed and added into a revised
economic analysis as part of the Phase II program
121 6 average inflation rate is the figure recommended by Bechtel
based on USA conditions for use in long term economic analyses of
new power ventures
32389
Page 8
122 This matter is referred to ORNL who prepared a rate of return
analysis
Bechtels conclusion is based on computed busbar costscumulative
benefits compared to alternate fuels in the timeframe 1995 to 2000
Relative Busbar Power Cost Net 25 Year
Mills per KWH Benefits - Million US$
Sultani Oil Shale 71-83 Base Cost
Imported Coal
$50tonne 68-88 778
$70tonne 78-107 2531
Imported Oil
$17Bbl 56-76 (18) $24Bbl 61-96 1810
The above results are based on a capacity factor of 75 which is
considered to be a reasonable target for a new plant over its 25 year
life The average selling price of 6 cents per KWH cited in the
questionnaire is based on existing plant costs which may not include
all cost elements of new capacity evaluated in this study
32389
Page 9
TECHNICAL COMMENTS
21 See answer to Item 116
Total power plant raw wate consumption rates and annual
consumptions including the water requirements for wetting ash at the truck loading p int within the power plant are given in Tables 43 and 44 for 50 MW unit and Tables 53 and 54 for 20 MW unit
The raw water requirements for 4x0 MW plant were factored
excepting the mine where a revised mine pldn is employed to reduce water request The quantities shown on these tables exclude raw
water requirements for housing complex mine and ash wetting if
required at the ash disposal site
Total power plant requirements shown in the above referred tables
are
50 MW 20 MW
Rate gpm 207 102 (See Drawing M004)
Annual Use
Gallons 1400000 675000
Cooling tower blowndown supplemented with raw water is used for
wetting ash at the truck loading point within the power plant Raw water quantities attributable for ash wetting at the power
truck loading point are
50 MW 20 MW
Rate gpm 75 325
Annual Use
Gallons 500000 215000
These quantities are included in the quantities shown in
the above referred tables
32389
Page 10
22 We recognize the POTENTIAL for leaching toxic compounds from the
spent ash However this matter is not yet defined well enough to
recommend specific action steps The Prefeasibility Study page
7-12 recommends creation of a ground water dispersion model to
determine whether more specific contaminated water mitigation
plans are needed It is anticipated that the leachate rate will
be low and that aquifer dispersion will keep problem compounds
bel3w health standards thresholds
23 Noted
We have not received up to date resource study material which
defines 50 billion tons resource base Please furnish
The resource base at Sultani alone is adequate to support two 400
MW power projects capacity subject water availability The
2-million cubic metre per year water allowance for oilshale will
limit development to about 600 MW
24 Selection of a combustion temperature is a balance between carbon
combustion efficiency and heat loss due carbonate decomposition
For purposes of the Prefeasibility Study we have opted for high
combustion efficiency At lower efficiency larger shale
mineprocessing plants will be needed
25 Bottom ash is cooled by water exchange before discharge
Cooling water is supplied to the ash screw coolers as specified by
Pyropower See Drawing MOO5 2140 gpm flow for 50 MW and 860 gpm
flow for 20 MW Heat removed by the cooling water from the ash
screw coolers is dissipated to atmosphere via a wet cooling
tower Pyropower should indicate the temperature of the ash
discharged to be 5OOF
32389
Page 11
Initially we had considered using a heat exchanger to cool the ash
and improve the cycle efficiency Considering low cost of fuel
the additional capital costs and the system complexities it was
decided not to employ such heat recovery systems for this project
26 The suggested alternates were looked at briefly and the potential
for wind blown air pollution from the ash disposal areas are too
great to warrant dry disposal unless GO(] and World Bank are
willing to accept such a potential problem Wetting the ash is
tne only practical solution Hopefully some cementation will
occur helping to reduce future leaching potential
27 JEA requirements are noted This is a conceptual study not a
final design Optimal design analysis can be performed during
Phase II
2829
JEA requirements are noted and can be incorporated into the Phase
II design
210 The transformer size is adequate for base load operation A
higher capacity can be considered at the final design stage if the
Client prefers
211 From our experience it does not appear to be economical to
provide additional dry cooling towers to take care of maximum
ambient temperatures which may prevail only for a short period of
time in a year To study this an annual dry bulb temperature
duration curve is required Also adding additional dry cooling
towers will change the plant performance It should also be noted
that the dry cooling towers are very expensive and the size should
be selected carefly considering performance and cost and not on the basis of maximum ambient temperatures This can be studied
during Phase II
32389
Page 12
212 The plant gross output varies with condenser pressure
Condenser
Pressure Design 55 in HgA Annual Ave 35 in HgA
Unit Size MW 20 50 4xlO0 20 50 4xlO0
Gross Output MW 234 593 496 2415 607 TBD
Net Output MW 1975 501 400 205 515 TBD
To be developed in Phase II
Output for 4x100 MW is estimated by others
213 The fan power consumption of the CFB boiler is about 30 to 35 of
the total auxiliary power The fan power consumption of the dry
cooling tower is about 20 to 25 of the total auxiliary power
214 Table 1-1 does not include plant net output Therefore do not
understand the comment
215 Commercial operating experience with coal fueled CFBC units in LISA
and Europe has been uniformly good showing high on stream
availability in early years (See Table 2-6 which reports on
Pyropower experience)
We expect operations with high ash content fuel like oilshale will
have unique scale up problems such as
o Solid handling in and out
o Internal solids circulation
o Erosioncorrosion steam generator intervals
o Heat recovery from bottom ash
Consequently we are recommending these items be worked out in a
single 50 MW prototype
32389
Page 13
216 Maximum dry cooling is used in this study A small wet cooling
tower is used on circulating service water system
217 Horizontal condensate pump is adequate with dry cooling tower and it is cheaper Vertical condensate pumps with cans can be
considered in the final design if required
218 A concrete shell brick lined flue stack will be larger in diameter and costs more than a steel lined stack Brick lined stack can be
considered in the final design
219 Demineralized water tank capacity for 50 MW is 76 cu meters or 20000 gallons not 1000 cu meters For 20 MW plant it is 38 cu
meters or 10000 gallons
220 It is US practice to use an average continuous blowdown rate of
1 and maximum biowdown rate of 3 for this type of plants
221 This can be studied during Phase II
222 Same as 221
223 Same as 221
224 The recommended action plan calls for continuing support studies covering the referenced items Additional effort is needed to
further define these matters and confirm the conceptual plan
The next step is to develop an outline for a project plan including
o Work Scope
o Schedule
o Budget
accommodate the increase in the number of employees and
equipment Truck bays to accommodate the 136 tonne trucks
will be added The truck bays used for the 77 tonne
trucks will be used for the maintenance of other
equipment The warehouse change house training room
offices and cafeteria will be expanded accordingly
6025 Mining and Processing Economics
Details of the oil shale mining and processing plant
economics for the 400 MW plant are included in the Mining
Report (Appendix 5) These details are of the same
magnitude as prepared for the 20 MW and 50 MW plants
The summary of the cash flow analysis for the mine and
shale processing plant is presented in Table 6-1
Table 6-1
SUMMARY OF 400 MW PLANT OIL SHALE MINING AND PROCESSING COSTS
5050 Debt-Equity 8020 Debt-Equity
US $1000 US $1000
Capital Cost
Mine Development 30915 30915
Mine Equipment 66012 66012
Process Plant Facilities 50889 50889
Spare Parts 5000 5000
Working Capital 10000 10000
Capi tal ized Interest
During Construction 24423 39075
TOTAL 187239 201891
Operating Costs and Other Costs
Annual Cost 60386 53236
Product Mined and Processed
Annual Tonnes x 1000 7783 7783
Unit Cost
US $Tonne (weighted average)
US $l06Btu (weighted average) 776
156
684
138
Year 12 costs taken as 25 year average
6-6
-Au
Table 610 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
- FCC plant sizes equivalent to proposed power application
Prefeasibility Study Oil Shale Fueled Power Generation
VOO94GEampJRI26
i
PYROFLOW UNITS IN THE US
COLORADOUTE IOYA STATE UNIV UNIV OFNUCLA CO NORTHERNAMES IA BF GOODRICH110 1o0MW(a) 2x170000 Ibhr HENRYILCEDAR FALLS IA 120000 Ibhr GENERALGULF OILu EiN P MOTORSSbtUpStart-UIL 1987 O A 1I N000 TC
NORT10 PONTIACH B MIRANCHWV00000 lbhr
CORN PRODUCTSSM NORTH-CAROLINA STOCKTOD CA
400000 lbbhl t
RUMF RD ME
CEMENT CO CALIF PORTLAND-COLTON CA
190000 Iblhr Start-Up 1985 TRUMTFTWN NYU
3I75ERTOWN N
etar t-Up loss ACE COGENERATIONCABI
TRONA CA Oper t~on l -Start-UP 1990 ~ rt upz 091Start-up loss Start-up PNeLAI 1991
MTKESFICOENERATIO-N1
BASFIELDp Start-uStar-Up WESTCA9 199otgoUp 1 MAHONEV PA|00000 Ibhr A Oz 2X365000 Ibhr
SETtr-Ups 188B CHAT TANOOGA TN
G ULF OIL EXPLORATION 8ta-rt-u) 1085BAKERSFIELD NORTH BRANCHCA SPRING GROVE PANORTH BRANCH WV 400000 IbhtOperational 19835 5 0 0 I b h 9 0 0 0 Iblh r- tart-Upi 1991 S t r - U p s l e s s
SOUTHEAST PAPER MFG CO UNIVOF NORTH CAROLINArDUBLIN GA UHAPEL HILL NO400000 IbhrStart-Ups logo Start-Ups2X250O000 1loseIbhr B
- Withdrawing ash from combustor - Withdrawing fly ash
a Internal solids circulation of the steam generator
m Erosioncorrosion of steam generatorinternals
Heat recovery from bottom ash
U Operation with low calorific-value fuel
Prefeasblity Study O Shari Fueled Power Generation
VOO7AI 27
Impact of Scale-Up
Project Size
20 MW
50 MW
100 MW
50 MW boiler in 100 MW plant
Potential Risk
Design Scale-upOperation of to 100 MW Initial Plant Plant
Low Significant
Modest Modest
High Low for duplicate units
Modest Low for duplicate units
Prefeasibility Study Oil Shaje Fueled Power Generation
VOO71-4GEAL4n2
i
Conclusions
Defined risk of CFBC boiler is acceptable
U Operating experience with commercial CFBC boilers built and under construction will strengthen confidencelevel and minimize risk for a plant built in 1995
SPrefeasibility Study Oil Shale Fueled Power Generation
V007GHAAE29
ENVIRONMENTAL ASSESSMENT
a Mine and shale processing
- Fugitive dust emissions
- Noise levels
- Leachability of disposal piles
Power plant
- Fugitive dust emissions
- Gaseous emissions
- Noise levels
- Water effluents
U Conclusions
Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel
Prefeasibility Study Oil Shale Fueled Power Generalon
- Coaloil prices will be at least 15 greater after 1995
- Discovery of indigenous conventional fuel resources is inadequate for power plant purposes
Prefeasibility Study
Oil Shale Fueled Power Generation
VOO) IDWFO
Feasibility(Contd)
N Suitable financing will be available
- For $200 million 50 MW prototypeproject
- For $1000 million 400 MW commercial project
Government of Jordan will make basic commitments
- Long-term power purchase agreement
- Long-term access to Sultani shale deposit
Adequate water and manpower resources
- Attractive tax incentives
Prefeasibility Study
Oil Shale Fueled Power Generaion
VO bull1DUJJRO 6
Timeliness
U Timely development of Jordan oil shale needs prompt action to create - Additional definitive information
- Suitable business plan
Prefeasibility Study
Oil Shale Fueled Power Generation
VooI DUJo 7
i
Expansion Conditions
U Continued expansion of powergeneration from oil shale in Jordan depends on water availability
Prospects for power export or importand domestic load growth will affect size of the needed shale-to-power program
Prefeasibility Sudy
Oil Shale Fueled Power Generation
yOWl lVuJO
Environmental Impacts
N Environmental impacts of shale development will be minimal
Prefeasibility Study Oi Shale Fueled Power Generation
i
Development Advantages
Will create significant new jobopportunities in Jordan
Will avoidreduce foreign exchangelosses for expanding alternate fuel imports
Prefeasibility Study
Oil Shale Fueled Power Generation
VOOIIULL tO
Recommended Action Plan
N Basic recommendation
N Conceptual development schedule
U Project development plan
Key plan elements
N Funding requirements
Prefeasibility Study Oil Shale Fueled Power Generation
VOO4II )U OII
i
Basic Recommendation
N Expand efforts to develop an oil shaleshyfueled power generation program at the Sultani deposit
- Conduct required supporting studies
- Define facilities costs and business plans
- Obtain project funding
Prefeasibility Study
Oil Shale Fueled Power Generation
VON I II)ILL 12
C
Conceptual DevelopmentSchedule
1989-1990
- Conduct supporting studies - Define costsbusiness plans for 50
MW prototype and 400 MW commercial projects
- Develop project financing
N 1990-1993 - Build and operate the prototype project
N 1994-1996 - Expand the 50 MW prototype to 100 MW scale
U 1996-2000 - Expand the project to 400 MW scale
N 2000-2005 - Build a second 400 MW commercial project if needed
i 1 Prefeasiblity Study
dOil Shale Fueled Power Generation
VW IMLITO 13
Conceptual Development Plan
Months
1 Project development plan - Define project
costs1busness plans
-24 -12 0 12 24 36 48 60 72 84 96 108 120
2 Secure funding
3 Build and operate 50 MW prototype
Dergn and procurement
Mine development
Plant construction
Startup and testing
Operations
L- -
4 Expand prototype to 100 MW
Design and procurement
bullConstruction
Startup
5 Expand project to 400 MW
2nd 100 MW unit
3rd100 MW unit
i 44
4th 100 MW unit -
O Project dacision point
i Prefeasib~ity Study Oil Shale Fueled Power Generation
17958562aJocdanV 3-14-89 rsO
18
Phase I - ProjectDevelopment Plan
n Program development
Seminar workshop on prefeasibilitystudy Oate project development plan woek scope schedule arid budget
U Carry out project planning program
- Conduct continuing support studies - Test Sultani shale in existing FBC
- Firm up designs and specifications
- Update costs and economic analysis
- Develop business plans and requirements
Explore project funding alternatives
i Prefeasibility Study
Oil Shale Fueled Power Generation
VO MItUOR 14 -0
Key Plan Elements
N Project feasibility analysis
- Firm up designs and equipmentspecifications for all facilities
- Update cost estimates based on preliminary designs and specifications
Explore arrangements for contract mining and mine development
Update forecasts for demand growthand for retirements of older generating capacity
- Create updated economic analysis
Preleasibility StudyO1 Shae Fueled Power Generation
VOO1IOLWRI
Key Plan Elements (Contd)
Business entity requirement
- Explore optionsconditions for a new company to managebuildoperate the project
- Explore optionsconditions for obtaining a concession agreement for Sultani development
Explore optionsconditions for water rights commitment
Prefeasibility Study Oil Shale Fueled Power Generation
VMIOIA)lj 16S
i
Key Plan Elements (Contd)
U Continuing supporting studies
- Combustion tests (additional pilot tests for design and warranty purposes contract for large-scale burn operations in existing plants if appropriate)
- Additional core drilling and core analysis
- Oil shale crushing tests
- Spent ash leaching tests
- Geotechnical data base including soils analysis
- Environmental baseline data
Prefeasibility Study O Shae Fueled Power Generation
VMMMUldMOA
Steps Required to Develop an Oil Shale-to-Power Project
Create a development business plan - Schedule - Decision tree
Develop a work scope and budget for the development plan program including - Firming up designsspecificationscosts
- Developing business entity requirements - Continuing support studies
Carry out development plan program
Assemble all planning results in a report for discussion with financial institutions
Explore project finance opportunities
Finalize business arrangements
Implement prototype project
i Prefeasibility Study
Oil Shale Fueled Power Generation
VM1-11UJROLI
MARCH 15 JEA QUESTIONS (M S ARAFAH) ON PREFEASIBILITY
STUDY DRAFT REPORT
Rt
DIR EScBSULIVAN PHD OFJCEop~BUREAU FOR SCIENCE AND~TECHNOLOGYAGENCY - --FOR INTERNATIONAL DEVELOPMhINTSWASHINGON DC x20523---------4
4 -
-SUBJ E CT - -C O H~ E T 4N l
Dr Mr sullivan ------shy
c-rommnents We ~efr-preaereorPla -tobYou lete dted Jan 91989 regardn~i4po4t P ea e1 f i nd y ubel ow our -e ot r XcOrcerned Jordanian deipartments
- --A ar o~nnYu Y o turjlt~ lt K
4 C~mments
~1 N i gFIN I~fANDECONOMIC1COIMEN S -
It sidicaed that Beohtel and US AIDWash ingtonj~4- re ojy nen ing that E 2hould und ertake the n e tshyihaisAre ~our c leometprogram n order shye-t im~ ate d f n t v design and budget cost
4Al1so Lthe study ncal--ttsutnilndcaei~ A-1 A thas ~ l 1 be eeded idb~~~~~ rn o ei t n i la itheMWa~-~5s~ 4
hrPro hehgemetTh trOfT ses~fnr4 BOT)Vmanu- a n-mnf~cure 4 r~j or contra c4-or ivoIlveiintijn I 4 4investmnt ude smi ~w 2 Zha tev e r --~4~prce e ec r it v p4~ f JA gertiy geeated-at 4 JEA 3 a l b u y ~the same average~~ A
~jithia oncot in4 ordrtan ecpoemic asess thespePower generatjoon J ordan3 oi sha I eroic c inr~etJordan 4
2P ge i1- 1 Aj iit eu that OPin he atocontr~ct 4with owner4 ofext3ing (oconstriiction r(FB rml-t
qu i of S 11 t to test large tonnagen j es StaniUti n d ajIe -for se veralIQf 31 hi
evrEAPreferpilot qr the dP 1prt7n -that the4mPIt
andi to(7 he instalI 1e 2 310 A
_
JODN ELECTRICITYAUTHORIT LL
Dac
operated in Jordan i n or~der~~t ~n nuex~on mnining crushing and haidi igQhre~ and sash Maeia nd aSootoget enough olr ndaita needed for einolre
CEBbole~ -i s~
ccordance with Jordaian oil shale
large to~ bfig
1 3 le 1-2 Page 1-7 Cost Of Pwer~i It i S menti-oned that the conmecial oil hle~ lt~project (4 X1OOmw) 1is ninacompetative roqt~range-~while table 12 indicates thattcost of-pow Ais~mill
q kwiihcii r 1
average wih i ii -much higher ihantheshy-ost of ~Power gnrtofomJEA therimaPower s ta tions Please~ indicate on what basi o ~~ shave-~made your-statement
PK
14 Pae 2 Sction 4-0sIt 1nlkly that theChousing and off- -site infrastructur-ommnity fakilitieR) to be onsidered for both the demo and prototyp prjcs oeoverwe~4 hnk that their~c_6t is raterojects Mo
iwcv~- age -1 1 Mine O(perationIIt is indicate~d that mining cot eevdfoMine contractor~ are ficomiplee h
r and iyudi-t~con qidder contract mnn opio fr4 the min4 cmflt2ng are reIanddrepres~ent the real costs derived from Phspat miin contractors in
lestfor the eo rPooypuat in order tlt7
P I eadenote tha detthe new exchangerate ofthJraian~ Di~nner you may add 20j6 Kto the quoted
1 6 P Ias e consider the followin ecn hage_
171- The new exchange ra teof tUSD=54o0 fils1 72-W2 The new~ aerage tariff for selIn~electricityhas decrreased to 120 8 f ilIsicwh
17- Page 1-7 TbIe 1-2 W bev th tthe cap ita1 cot for the pwhokand forthe min n d ash hMnd1ing equipen
P B~2Anaor a -Tl 8156152 8176 1Q MYf -t -Now 520 t 1U
JDNEECRICIT AU-RA L14lLiL
2 ~are very high We suggest~ thta You rerconsie (- telowerus e~+d accuracy est a rangethan +30
Page4-22 Table 4-5weno0ti ced( that- PyroPowe ha ddeta(IiacCst fori the bo1ilerlocation and terha dutdetlease isxtr fo~ l C~ io~ s~ e~~ 1a~ a if and indicate theonldjusted ~percentagefor construction foin Jordan
19 Page-7 Table 11-2 -Yo aeue ihrinterest rate on Equity thatn on1DehI~laseinclude~ adetaied explanation of thisrr -tni kepin in miUndie JEA is1thaIt a non profit~ shyorgaiztion unik oher private UJSA utility~in ktation
~-~110- Regarding shy
the ra4ital Rt fthe project it is~requesed tobre k it intdo foreignMeanwhile cthe nd lorcal c-osfoeigptario i nt-re3t~shol becnierdo-h
rr n ontiondonnotopdbon the 9 cnieelocal portion~onth
1-1- 237~Pa
oningeny 9tooi s high~~ a lower 4value -should be~
4~ gt ~112- -Tbles t1-1 -8-8~ inclu~de t~he c~alculationscuultie nt enefits for of Th shyunttypes l i4s difeen geeatnmrer likely tocluae
-~ Q~ J7present vk1u for tenet tthe~benefits in feralterntives -t-oa s the
49
ehliyoi shale
Wea gree with you9 tha t th e percentage used ~ an for thenua~l 0 ~amp-M rahr CFBo ndsomewha~t highervrate be n ededma y for a C B l n Me n h l ~ a e r
indir e ta~ts the -estimatedma i variablec st i ddition t he fi-xed-9i 1 mislkih We --
thinktttiis too lowK -5
shy
1-14- e 4-29
opprza tion-o to The o i1s h1 costs-nc I deAbo 1h
Pa10 mman ormTSI62 a
IB I
JORD N EtECTICI1~ 4 E~)~Is-s
Date ib-_
~ ~riii~g~nd~o9~ru~hng h~tnlin cot~u~tv yo
i Dae Jnryit
1ts c 7 4-
i smiig iniand fh co I eY
susendi ca tI t icag th t1 ~an~approximate 15 ~pita L tYII I (-~a~ge or he owe bl ockj f aniitjes isof +the capthe)t~ial7cpi~lrharge Uoratelformny SI~Uj(uiity installa~tions~ whle page 6-1T9 talJshyit is mentioned that~ the Capital rate pe-r JEA isshyi5~PeaseJustify this~matter since~w o
i16- Pae 6-1 6
1 I4~t is mentioned that the costs of 4process Water are ~ 4 ~0 2$1 000 gallons
r~j~lt IHave~You considered additionalvalue ofbying waterfrom~ the Wa ters Aito i ~or ditoa cost~f o revrseoqoesplant if ground water is used
~~ I1 7- Table 6-1 Page 6-6 Please explain how did You come ou ihteoil~ shale miniing and proces~sing uit~Icost
ltII~I~ 8- Please note 1 t hatj the average JEA~productinr ot frmthermal I power stationsr (Istationbus-barCOSt)i sbewen 6 3-17 3 fils 4kwh You may use this~
l4~ 19-i For ~4 X 100~AMW Plat iti etindo pag e14-4 VolI 11 that4 at tota I of W42 14 epoye W II eemplo~yer] And on page 69yo1Iiti mentioned that a~ tot 1 f1 ~p yeI iNbe enp1oyed a
is~ high asrmetitexeds100personorthe ~41X100~MWh~~j nsatnpPrlae
I 1 The 4 following iftemns are a sumed to1 be excluded from theraPi ta 1 cot xoI
120-1 Perits I icen es 7
1_207~3 Imprt ~xe on s7pare par ts -and c(7orfmurab -ma~teria Is
04f4 4
~4 R j4 4
D4
~ ~ ~ AIf eS taxesq in acrac ihteJraand regulations should be considered aw
21- p1ea4s e indic ate Your Ju t f c io r us ga 6
44122- Table 977App 5Page4 9-1 4L IK Car1Yiniae that the hIRR of the 4 Otplantis rather unattractive (66)most
-( Cns1er4 ngthe logical base 4csek c pwhen cii 6OL
average sell~ing prc CkhampDEratio L801~2O~Aoreover4M the ne siellin prcwh o JEA ati theamptime~ Abeing os4ltp n~ot exceed 4 Ckwh~-However Ipage 1shy~ and 14 0 T indicate that ecnms for a commeri
S4A4scale joil 4 shale projc ~
appear Piomisig-nug o4Ywarrant continued dee fgfluht 4 feaibiit 4tudy wihil cost sevea~lili
do ar~sf Plas lear wether the ~x step jqs~$j~~lt 4
gtt 9o be considered arCcording4to jthe 4unattractiveresul to mentioned in IRR7 Table 97 gt4
a C4 44fET2 4 144-4444 P a g 1 T b6 l
htte~We ~ ~ ae~ rqieetfrteX ~ noie ~~ ~ 444 MW un t44 r te4l w w e o p r d i th e w t r n rre u f4m or4444~ the4444 54M4rto y e Pg~A~44EHiveL det ile an l A44
s o awa er c n um t a4r f rofsho in P6Io erT
e ch 2 50 M W aPln wa e d 41004 MW4 1 consumption_____________
ma4~2 k e u p houin~44 p A44 4444444 C O 4ltI4
a nd a sh et in etc 4 2 4 1 -24 P a g e4 2 - 1 A P P 5
4Yo 4_ j1 4 4~h444 N44 44
1gro nd tce t hir fthe w bern coqir mna t efora4e 4X10A M 444444 4 r i n to 4 4 4lo w w ehA 7 n 2 cinCie h rh4 n ttthh1eb -e 4 44t Of3 E4O
ea h n~ ffl 4 4Jl44 4 4444 4giv
6 ig re sofrat4 de in cl ar f w w at5 c hrw pe o
s h b 444 o t h e g nd L 44 h u i n C
r 4ne a4 t44 e L(704 2 4 p ae) 2 - o Au P dn 5ai 7~e r 44 I Y (1t 44a
ve7 rn e qu 1saharvthe y
and n~~~o speci~~~l4 p n l nh i n t x
r ~rA M e d r o t eu n 8 1 wTtl t t h
- c re e N I wo6
~ n n a i n a t d h l7 A PP6 gt
J
S2~3- Page 2-4 ~ ~ It ~is i
that oil eindicated the- sha le r our~ Cesin Jordan are 10 billion tons -The anulp e reere maiy exeed 50 4 billion tons ~
~ 24- 4Page~2 -l1 iujntr We beiv thtCBcmuto~ep i s high and~alSo
~~ ~ -2 ~~ Page 4-1~6 j - shy
Please~~ indicates your procedure to cool the omn ashand atwa icagd-eprtr
A Have you~ considered~ additional he~at exchanger topcool th ash and to imrve h cycleef ficiency
-~2~6 Page 4-16 It s~ indicated that ash from each silo i Amixed19 ~with~fabout 20 waterKb weight to minimize generation of dust~during trnprtto to mine and disposalHave you~ coniidered other 4lternativeto
~ ~eliminate dustiiig -and avoid use ofwat r uring it ransportationi such as~ using closed trucks or closed
of ~fans conUMnPo wihrlaintthe total plant auiir poe osupin 1~21- Table 5_-3 and I ~
Th~~ is- somneere c6ntradiction regardingplnneotpu~t in both am tables 21-~ Tabl~e 1-33
We noticed tha~t yourall9 cacacapac t fatro75 tion ae asdnWe thilt ~that 7capacityshyfacto is tobo high for- an oil shale fired plant duketo lack of existing simila~r ~plants handl~~~firing oil adshale ~K
216~ The study iniae thtawet~coigtower wi11~used Actually a b
dry cooling should be consideda5ini ~HTP S inZ atomnmz so water rnumption4the cycle~ efficiency willbe reducedHenre YO33~reconsider calculating the cyclefficiy
U~~~~~ codnt umconsidered ofhorizontal -aretypethe~ the vertical cian type can alsobeh considered
shy ~ ~ ~ I~~
2~2 Kconcrete shy
shjell stepl fltstack is onidereconcrete shell brick flue Rt c ~s beCaconsidered3V
2-19~- Deminiraized water~ tank3 capacity~ is -76 ui(meterThe recommnended tank cameter- ui tyi 00cbc
220Designconditions Pa~ge (4-74)te5 hat bow 3down percentage splusmn ~fomrpra til re i hou I be 3~)~
PoD Z 2 m a ad~ - e 5 1 2 iJS~ ~ p A f amp ~ ~ y1
4
JO R ECTICITY AUTHORTIT 4L
~ 4
Date~
t etats ttthe quantityof s i S ~1 000Tons ra Sthis tuntity 11- be transporited for severIy --to tu ofI pit a~te torg P KM ra~erm Spower plIatS about 12 midilidoni CUIA(- met ryea
h e ndd mp e he (d u p in i n L
area wil evric power plant6t Please zn1 a te~tiv s tudY for dumping th r~ a enoug
-from the power plantr~~h~
S 2- Please provide deald-ifrat ao etbaaiedrawing hwn TH11 R thaU and~pV ra~te takcing illto o 6it v- consumptionn _uig themrining equipment
alternate~ study 0o Jine operation for 1 shiftday Vand twoshifts day -lt
224- Conceptua~l pflR 1 for mi ing anusdtransportation of oil- shale a 0 dmj of hs f u r therV examinedh iV~sdpatI ho u1d be
orderj to poe~ehicalq and~eoomca1 fesblt of t his operation
SYour are requested te) study and consider all- above - iPoin s at your earliest in rder -to be peete y oiAnimain on March 29-301989 peetdb~o 4 n
S9incerly-You S
WDIRECTORGENERAL -
I~ CCMR WLINTON ~vs
5N
Pa D~t~IoAmmn -Jordtn -Tel 815615 20 Bl76 15 -19j A VINO- AFf TY
MARCH 21 RESPONSE TO JEA QUESTIONS
Bechtel Power Corporation Engineers - Constructors
Fifty Beale Street San Francisco California Mail Address P 0 Box 3965 San Franclco CA 94119
March 21 1989
Mr M S Arafah Director General Jordan Electricity Authority PO Box 2310 Amman Jordan
Subject Jordan Oil Shale Prefeasibility Study
Dear Mr Arafah
Your letter of 15 March 1989 with comments on the Oil Shale to Power Prefeasibility Study draft report has been referred to me for reply
The attached responses to each item in the reference letter follows the order submitted
Also attached are three revised pages for the draft report - Volume I
Page 6-1 Page 6-21 Page 6-23
Please copy these revised pages into the report previously sent to you
We plan to review this material with JEA during the March 2930 and April 1 meetings in Amman
rsuVertrul yours
W Linton Project Manager
WHLdc
Attachments Questionnaire Response Three revised pages
cc C J Aulisio R R Buta G D Gould T J Wilbanks
32389
Page 1
RESPONSE TO MARCH 15 1989 QUESTIONAIRE
OIL SHALE TO POWER PREFEASIBILITY STUDY
This study examines economic prospects in terms of a 1995-2000 timeframe
FIRANCIAL AND ECONOMIC COMMENTS
11 It is likely that a BOT deal can be structured at present JEA
generation costs for either 20 MW or 50 MW size units if GOJ is
willing to subsidize the incremental power generation cost
Furthermore these incremental costs can be recovered during the 25
year operation of a Commercial Scale Project
12 A 3rd Party Test was proposed as an alternate means to raising
$100+ for an independent JEA sponsored 20 MW Demonstration
program
13 71 millsKWH for Shale Power
VS
JEA 1987 costs
Purchased Power 17 filsKWH = 51 mills
Produced Power 1360 filsKWH = 41 mills
19952000 Costs - Expected to be 30 to 40 higher and in line
with the cost estimate presented in this study
It also is important to recognize that the busbar cost of power
generated by any new power source can not be compared directly
with the cost of existing older installed capacity because of the
lower capital cost component of the latter (See enclosed Figure
1-1 which demonstrates how total capital carrying costs decline as
the investment is paid off) Any new capacity whether coal oil
or oil shale will be an unreasonable disadvantage compared with
costs for existing older capacity
l
024
o2
0De return
E 016Total carrying charge
012 qu return
S -008
ety taxes and n rcw vshy000 X 0 5 10 15 20 25
Figure 1-1 Year-by-year Carrying Charge Components for 15-yearTax Recovery Period
1-7
30
32389
Page 2
14 Infrastructure Cost
Total People
OperatorFamilies Installed Cost
20 MW $10000000 185700 $54000Operator
50 MW 15000000 3241200 46000Operator
400 MW 45000000 10364000 43000Operator
Factored allowance for grass roots desert installation
including housing and community facilities was developed as
follows for the 50 MW case study
Infrastructure
50 MW
Family Housing 200 30K = $ 6 Million
Bachelor Housing 100 20K = 2 M
HospitalClinic (8 Beds) 11 M
SchoolMosque I1 M
Stores Services amp Recreation = 2 M
Facilities
Roads Electricity Water Sewage = 3 M
$15 Million
Infrastructure costs for the 20 MW and 400 MW cases was ratioed
from this breakdown
At this conceptual level costs are order-of-magnitude In a Phase
II program these infrastructure costs can be developed in detail
32389
Page 3
15 Contract Mining Alternatives
Page 4-11 Mine Operation
Based on Bechtels evaluation of the mine contractors price as found in Section 15 of the Mining Report it was concluded that
the mine contractors price does not include costs for such things
as developing the mine with a box-cut ramp haul roads
developing an area for the waste material maintaining the
haulroads constructing the mine services facilities diversion
ditches sedimentation ponds water well crushing the oil shale
pre-mixing the oil shale at the mine and other items associated
with operating a mine to support a power plant If it is proven
that the mine contractors price includes cost for the above
mentioned scope of work in additi-n to drill blast load and
haul then the contractors price can be used but in the meantime
the all inclusive cost developed by Bechtel should be used
Contract Mining appears to be attractive for the smaller size
plants but not for the larger commercial scale operation Some
third party must provide the necessary capital for trucks
loading mining machines etc under a contract arrangement
16 Reassessment due to Dinar value change needs further study and can
not be evaluated given present budget limitations If average
labor rate of $300hr still valid then little change involve with
study
If deemed necessary reexamination of project economics can be
done in Phase IIwhen funded
17 Costs in this study are based on recent similar Bechtel experience
on Mount Poso project and on Montana I project The Mount Poso
project is a 50 MW unit firing coal in a Pyropower boiler The
Montana I project is a 35 MW unit firing coal in a Keeler Dorr
Oliver FBC boiler utilizing dry cooling
32389
Page 4
18 The Pyropower quote of $186000000 to futnish and erect the steam
generator stack and baghouse has been adjusted to include
engineering construction indirect cost etc to be consistant
with the rest of the costs shown in Table 65 p 6-10 No
further adjustment for location was made
19 Equity funding has the lowest priority of payoff in case of a
liquidation and carries greater risk Hence a higher rate of
return is needed to attract these funds Debt funding is a first
mortgage and has first priority for payoff in case of liquidation
and carries less risk Hence it requires lower rate of return
than equity funding
The risk taking equity owner will ask for greater interest rate
to make funds available The only way to minimize this expense is
to find a loaning agency willing to provide 90 or perhaps 95 of
the investment cost It is likely that banks will require some
minimum equity participation
This Prefeasibility Study was not based on a non-profit utility
operation
Even though JEA is a non-profit organization its service
contributors are profit making groups It is visualized that the
Jordan Oil Shale Co (JOSCO) will be a stand alone business
enterprise servicing JEA under long term contract To secure
funding for the proposed project JOSCO will need attractive
enough contract terms to attract both equity and debt capital
110 Additional work is needed to develop the requested information
This work can be preformed as part of the Phase II program
111 Bechtel includes contingency in all of its estimates to cover
error emissions and unforeseen items within the defined scope of
the project The level of contingency is dependent upon the
amount of scope definition For a prefeasible study such as this
15 contingency is lower than normal
32389
Page 5
112 Tables 89 through 816 include a present value calculation to
establish the relative benefit for a shale project vs coal and
oil
113 The variable maintenance cost of 1 millsKWH has been adjusted for CFB plants with an additional $200000 per year or 06 millsKWH
This yields the following
Variable Maintenance - 10 millsKWH
CFB Adjustment - 06
Fixed Maintenance Cost - 40
Total Cost 56 MillsKWH
114 Page 4-29
The royalty costs are included in the weighted average oil shale
costs for the 50 megawatt plant
Page 4-8
Shale fuel costs include return on equity and royalty These are
two separate cost items Royalty is the last item mentioned in
the sentence and it therefore reads as royalty and not return on
royalty
Page 4-31 gives rates used by Bechtel based on our calculations
using the referenced procedures
DebtEquity Capital Charge Rate
5050 153
8020 139
Table 69 displays the calculation of the 153 capital charge
rate (Line 7 of Table 69 is not used in the calculation and
should be deleted)
32389
Page 6
116 No water purchase charge from the Water Authority was added to the
operating expense based on the statement that no resource costs
will be charged
$020 per 1000 gallons is rule of thumb for USA installations in
absence of client data
Boiler make up water (p4-17) is treated in a demineralizer
train If deemed necessary comparison with reverse osmosis
process can be performed in Phase II
Water requirements were estimated to be
Cubic Metres Per Year
20 MW 50 MW 400 MW
Mine amp Shale Processing 455000 761000 773000
Power Block 3000 6000 42000
Infrastructure 80000 140000 448000
Total 538000 907000 1263000
117 Annual average operating costs shown on Table 6-1 are in error
Financing Option 5050 8020
Cost Shown 56606 48945
Corrected Cost 60396 53236
Average mining and shale processing costs are developed year by
year in the Mining Report Appendix 5 Table 12-10
32389
Page 7
118 We would be interested in receiving the breakdown of these current
power cost figures (ie capital charges fuel cost number of
operators etc) Further economic analysis employing these
figures can be developed in Phase II
119 Manpower requirements for the three case studies were estimated as
fol lows
Mining amp Shale Processing
Power Block
Operations
Maintenance
Management
20 MW 50 MW 400 MW
75 163 396
54 78 175
46 73 455
10 10 10
185 324 1036
Page 14-4 of the Mine Report is for mine and shale processing
only It should be noted that most of these manpower requirements
involved new jobs for Jordanian people
120 At the April 1988 Amman Meeting it was agreed that the following
costs would be omitted
o Permits and Licenses
o Local Taxes
o Import Taxes
If necessary such costs can be developed and added into a revised
economic analysis as part of the Phase II program
121 6 average inflation rate is the figure recommended by Bechtel
based on USA conditions for use in long term economic analyses of
new power ventures
32389
Page 8
122 This matter is referred to ORNL who prepared a rate of return
analysis
Bechtels conclusion is based on computed busbar costscumulative
benefits compared to alternate fuels in the timeframe 1995 to 2000
Relative Busbar Power Cost Net 25 Year
Mills per KWH Benefits - Million US$
Sultani Oil Shale 71-83 Base Cost
Imported Coal
$50tonne 68-88 778
$70tonne 78-107 2531
Imported Oil
$17Bbl 56-76 (18) $24Bbl 61-96 1810
The above results are based on a capacity factor of 75 which is
considered to be a reasonable target for a new plant over its 25 year
life The average selling price of 6 cents per KWH cited in the
questionnaire is based on existing plant costs which may not include
all cost elements of new capacity evaluated in this study
32389
Page 9
TECHNICAL COMMENTS
21 See answer to Item 116
Total power plant raw wate consumption rates and annual
consumptions including the water requirements for wetting ash at the truck loading p int within the power plant are given in Tables 43 and 44 for 50 MW unit and Tables 53 and 54 for 20 MW unit
The raw water requirements for 4x0 MW plant were factored
excepting the mine where a revised mine pldn is employed to reduce water request The quantities shown on these tables exclude raw
water requirements for housing complex mine and ash wetting if
required at the ash disposal site
Total power plant requirements shown in the above referred tables
are
50 MW 20 MW
Rate gpm 207 102 (See Drawing M004)
Annual Use
Gallons 1400000 675000
Cooling tower blowndown supplemented with raw water is used for
wetting ash at the truck loading point within the power plant Raw water quantities attributable for ash wetting at the power
truck loading point are
50 MW 20 MW
Rate gpm 75 325
Annual Use
Gallons 500000 215000
These quantities are included in the quantities shown in
the above referred tables
32389
Page 10
22 We recognize the POTENTIAL for leaching toxic compounds from the
spent ash However this matter is not yet defined well enough to
recommend specific action steps The Prefeasibility Study page
7-12 recommends creation of a ground water dispersion model to
determine whether more specific contaminated water mitigation
plans are needed It is anticipated that the leachate rate will
be low and that aquifer dispersion will keep problem compounds
bel3w health standards thresholds
23 Noted
We have not received up to date resource study material which
defines 50 billion tons resource base Please furnish
The resource base at Sultani alone is adequate to support two 400
MW power projects capacity subject water availability The
2-million cubic metre per year water allowance for oilshale will
limit development to about 600 MW
24 Selection of a combustion temperature is a balance between carbon
combustion efficiency and heat loss due carbonate decomposition
For purposes of the Prefeasibility Study we have opted for high
combustion efficiency At lower efficiency larger shale
mineprocessing plants will be needed
25 Bottom ash is cooled by water exchange before discharge
Cooling water is supplied to the ash screw coolers as specified by
Pyropower See Drawing MOO5 2140 gpm flow for 50 MW and 860 gpm
flow for 20 MW Heat removed by the cooling water from the ash
screw coolers is dissipated to atmosphere via a wet cooling
tower Pyropower should indicate the temperature of the ash
discharged to be 5OOF
32389
Page 11
Initially we had considered using a heat exchanger to cool the ash
and improve the cycle efficiency Considering low cost of fuel
the additional capital costs and the system complexities it was
decided not to employ such heat recovery systems for this project
26 The suggested alternates were looked at briefly and the potential
for wind blown air pollution from the ash disposal areas are too
great to warrant dry disposal unless GO(] and World Bank are
willing to accept such a potential problem Wetting the ash is
tne only practical solution Hopefully some cementation will
occur helping to reduce future leaching potential
27 JEA requirements are noted This is a conceptual study not a
final design Optimal design analysis can be performed during
Phase II
2829
JEA requirements are noted and can be incorporated into the Phase
II design
210 The transformer size is adequate for base load operation A
higher capacity can be considered at the final design stage if the
Client prefers
211 From our experience it does not appear to be economical to
provide additional dry cooling towers to take care of maximum
ambient temperatures which may prevail only for a short period of
time in a year To study this an annual dry bulb temperature
duration curve is required Also adding additional dry cooling
towers will change the plant performance It should also be noted
that the dry cooling towers are very expensive and the size should
be selected carefly considering performance and cost and not on the basis of maximum ambient temperatures This can be studied
during Phase II
32389
Page 12
212 The plant gross output varies with condenser pressure
Condenser
Pressure Design 55 in HgA Annual Ave 35 in HgA
Unit Size MW 20 50 4xlO0 20 50 4xlO0
Gross Output MW 234 593 496 2415 607 TBD
Net Output MW 1975 501 400 205 515 TBD
To be developed in Phase II
Output for 4x100 MW is estimated by others
213 The fan power consumption of the CFB boiler is about 30 to 35 of
the total auxiliary power The fan power consumption of the dry
cooling tower is about 20 to 25 of the total auxiliary power
214 Table 1-1 does not include plant net output Therefore do not
understand the comment
215 Commercial operating experience with coal fueled CFBC units in LISA
and Europe has been uniformly good showing high on stream
availability in early years (See Table 2-6 which reports on
Pyropower experience)
We expect operations with high ash content fuel like oilshale will
have unique scale up problems such as
o Solid handling in and out
o Internal solids circulation
o Erosioncorrosion steam generator intervals
o Heat recovery from bottom ash
Consequently we are recommending these items be worked out in a
single 50 MW prototype
32389
Page 13
216 Maximum dry cooling is used in this study A small wet cooling
tower is used on circulating service water system
217 Horizontal condensate pump is adequate with dry cooling tower and it is cheaper Vertical condensate pumps with cans can be
considered in the final design if required
218 A concrete shell brick lined flue stack will be larger in diameter and costs more than a steel lined stack Brick lined stack can be
considered in the final design
219 Demineralized water tank capacity for 50 MW is 76 cu meters or 20000 gallons not 1000 cu meters For 20 MW plant it is 38 cu
meters or 10000 gallons
220 It is US practice to use an average continuous blowdown rate of
1 and maximum biowdown rate of 3 for this type of plants
221 This can be studied during Phase II
222 Same as 221
223 Same as 221
224 The recommended action plan calls for continuing support studies covering the referenced items Additional effort is needed to
further define these matters and confirm the conceptual plan
The next step is to develop an outline for a project plan including
o Work Scope
o Schedule
o Budget
accommodate the increase in the number of employees and
equipment Truck bays to accommodate the 136 tonne trucks
will be added The truck bays used for the 77 tonne
trucks will be used for the maintenance of other
equipment The warehouse change house training room
offices and cafeteria will be expanded accordingly
6025 Mining and Processing Economics
Details of the oil shale mining and processing plant
economics for the 400 MW plant are included in the Mining
Report (Appendix 5) These details are of the same
magnitude as prepared for the 20 MW and 50 MW plants
The summary of the cash flow analysis for the mine and
shale processing plant is presented in Table 6-1
Table 6-1
SUMMARY OF 400 MW PLANT OIL SHALE MINING AND PROCESSING COSTS
5050 Debt-Equity 8020 Debt-Equity
US $1000 US $1000
Capital Cost
Mine Development 30915 30915
Mine Equipment 66012 66012
Process Plant Facilities 50889 50889
Spare Parts 5000 5000
Working Capital 10000 10000
Capi tal ized Interest
During Construction 24423 39075
TOTAL 187239 201891
Operating Costs and Other Costs
Annual Cost 60386 53236
Product Mined and Processed
Annual Tonnes x 1000 7783 7783
Unit Cost
US $Tonne (weighted average)
US $l06Btu (weighted average) 776
156
684
138
Year 12 costs taken as 25 year average
6-6
-Au
Table 610 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
- FCC plant sizes equivalent to proposed power application
Prefeasibility Study Oil Shale Fueled Power Generation
VOO94GEampJRI26
i
PYROFLOW UNITS IN THE US
COLORADOUTE IOYA STATE UNIV UNIV OFNUCLA CO NORTHERNAMES IA BF GOODRICH110 1o0MW(a) 2x170000 Ibhr HENRYILCEDAR FALLS IA 120000 Ibhr GENERALGULF OILu EiN P MOTORSSbtUpStart-UIL 1987 O A 1I N000 TC
NORT10 PONTIACH B MIRANCHWV00000 lbhr
CORN PRODUCTSSM NORTH-CAROLINA STOCKTOD CA
400000 lbbhl t
RUMF RD ME
CEMENT CO CALIF PORTLAND-COLTON CA
190000 Iblhr Start-Up 1985 TRUMTFTWN NYU
3I75ERTOWN N
etar t-Up loss ACE COGENERATIONCABI
TRONA CA Oper t~on l -Start-UP 1990 ~ rt upz 091Start-up loss Start-up PNeLAI 1991
MTKESFICOENERATIO-N1
BASFIELDp Start-uStar-Up WESTCA9 199otgoUp 1 MAHONEV PA|00000 Ibhr A Oz 2X365000 Ibhr
SETtr-Ups 188B CHAT TANOOGA TN
G ULF OIL EXPLORATION 8ta-rt-u) 1085BAKERSFIELD NORTH BRANCHCA SPRING GROVE PANORTH BRANCH WV 400000 IbhtOperational 19835 5 0 0 I b h 9 0 0 0 Iblh r- tart-Upi 1991 S t r - U p s l e s s
SOUTHEAST PAPER MFG CO UNIVOF NORTH CAROLINArDUBLIN GA UHAPEL HILL NO400000 IbhrStart-Ups logo Start-Ups2X250O000 1loseIbhr B
- Withdrawing ash from combustor - Withdrawing fly ash
a Internal solids circulation of the steam generator
m Erosioncorrosion of steam generatorinternals
Heat recovery from bottom ash
U Operation with low calorific-value fuel
Prefeasblity Study O Shari Fueled Power Generation
VOO7AI 27
Impact of Scale-Up
Project Size
20 MW
50 MW
100 MW
50 MW boiler in 100 MW plant
Potential Risk
Design Scale-upOperation of to 100 MW Initial Plant Plant
Low Significant
Modest Modest
High Low for duplicate units
Modest Low for duplicate units
Prefeasibility Study Oil Shaje Fueled Power Generation
VOO71-4GEAL4n2
i
Conclusions
Defined risk of CFBC boiler is acceptable
U Operating experience with commercial CFBC boilers built and under construction will strengthen confidencelevel and minimize risk for a plant built in 1995
SPrefeasibility Study Oil Shale Fueled Power Generation
V007GHAAE29
ENVIRONMENTAL ASSESSMENT
a Mine and shale processing
- Fugitive dust emissions
- Noise levels
- Leachability of disposal piles
Power plant
- Fugitive dust emissions
- Gaseous emissions
- Noise levels
- Water effluents
U Conclusions
Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel
Prefeasibility Study Oil Shale Fueled Power Generalon
- Coaloil prices will be at least 15 greater after 1995
- Discovery of indigenous conventional fuel resources is inadequate for power plant purposes
Prefeasibility Study
Oil Shale Fueled Power Generation
VOO) IDWFO
Feasibility(Contd)
N Suitable financing will be available
- For $200 million 50 MW prototypeproject
- For $1000 million 400 MW commercial project
Government of Jordan will make basic commitments
- Long-term power purchase agreement
- Long-term access to Sultani shale deposit
Adequate water and manpower resources
- Attractive tax incentives
Prefeasibility Study
Oil Shale Fueled Power Generaion
VO bull1DUJJRO 6
Timeliness
U Timely development of Jordan oil shale needs prompt action to create - Additional definitive information
- Suitable business plan
Prefeasibility Study
Oil Shale Fueled Power Generation
VooI DUJo 7
i
Expansion Conditions
U Continued expansion of powergeneration from oil shale in Jordan depends on water availability
Prospects for power export or importand domestic load growth will affect size of the needed shale-to-power program
Prefeasibility Sudy
Oil Shale Fueled Power Generation
yOWl lVuJO
Environmental Impacts
N Environmental impacts of shale development will be minimal
Prefeasibility Study Oi Shale Fueled Power Generation
i
Development Advantages
Will create significant new jobopportunities in Jordan
Will avoidreduce foreign exchangelosses for expanding alternate fuel imports
Prefeasibility Study
Oil Shale Fueled Power Generation
VOOIIULL tO
Recommended Action Plan
N Basic recommendation
N Conceptual development schedule
U Project development plan
Key plan elements
N Funding requirements
Prefeasibility Study Oil Shale Fueled Power Generation
VOO4II )U OII
i
Basic Recommendation
N Expand efforts to develop an oil shaleshyfueled power generation program at the Sultani deposit
- Conduct required supporting studies
- Define facilities costs and business plans
- Obtain project funding
Prefeasibility Study
Oil Shale Fueled Power Generation
VON I II)ILL 12
C
Conceptual DevelopmentSchedule
1989-1990
- Conduct supporting studies - Define costsbusiness plans for 50
MW prototype and 400 MW commercial projects
- Develop project financing
N 1990-1993 - Build and operate the prototype project
N 1994-1996 - Expand the 50 MW prototype to 100 MW scale
U 1996-2000 - Expand the project to 400 MW scale
N 2000-2005 - Build a second 400 MW commercial project if needed
i 1 Prefeasiblity Study
dOil Shale Fueled Power Generation
VW IMLITO 13
Conceptual Development Plan
Months
1 Project development plan - Define project
costs1busness plans
-24 -12 0 12 24 36 48 60 72 84 96 108 120
2 Secure funding
3 Build and operate 50 MW prototype
Dergn and procurement
Mine development
Plant construction
Startup and testing
Operations
L- -
4 Expand prototype to 100 MW
Design and procurement
bullConstruction
Startup
5 Expand project to 400 MW
2nd 100 MW unit
3rd100 MW unit
i 44
4th 100 MW unit -
O Project dacision point
i Prefeasib~ity Study Oil Shale Fueled Power Generation
17958562aJocdanV 3-14-89 rsO
18
Phase I - ProjectDevelopment Plan
n Program development
Seminar workshop on prefeasibilitystudy Oate project development plan woek scope schedule arid budget
U Carry out project planning program
- Conduct continuing support studies - Test Sultani shale in existing FBC
- Firm up designs and specifications
- Update costs and economic analysis
- Develop business plans and requirements
Explore project funding alternatives
i Prefeasibility Study
Oil Shale Fueled Power Generation
VO MItUOR 14 -0
Key Plan Elements
N Project feasibility analysis
- Firm up designs and equipmentspecifications for all facilities
- Update cost estimates based on preliminary designs and specifications
Explore arrangements for contract mining and mine development
Update forecasts for demand growthand for retirements of older generating capacity
- Create updated economic analysis
Preleasibility StudyO1 Shae Fueled Power Generation
VOO1IOLWRI
Key Plan Elements (Contd)
Business entity requirement
- Explore optionsconditions for a new company to managebuildoperate the project
- Explore optionsconditions for obtaining a concession agreement for Sultani development
Explore optionsconditions for water rights commitment
Prefeasibility Study Oil Shale Fueled Power Generation
VMIOIA)lj 16S
i
Key Plan Elements (Contd)
U Continuing supporting studies
- Combustion tests (additional pilot tests for design and warranty purposes contract for large-scale burn operations in existing plants if appropriate)
- Additional core drilling and core analysis
- Oil shale crushing tests
- Spent ash leaching tests
- Geotechnical data base including soils analysis
- Environmental baseline data
Prefeasibility Study O Shae Fueled Power Generation
VMMMUldMOA
Steps Required to Develop an Oil Shale-to-Power Project
Create a development business plan - Schedule - Decision tree
Develop a work scope and budget for the development plan program including - Firming up designsspecificationscosts
- Developing business entity requirements - Continuing support studies
Carry out development plan program
Assemble all planning results in a report for discussion with financial institutions
Explore project finance opportunities
Finalize business arrangements
Implement prototype project
i Prefeasibility Study
Oil Shale Fueled Power Generation
VM1-11UJROLI
MARCH 15 JEA QUESTIONS (M S ARAFAH) ON PREFEASIBILITY
STUDY DRAFT REPORT
Rt
DIR EScBSULIVAN PHD OFJCEop~BUREAU FOR SCIENCE AND~TECHNOLOGYAGENCY - --FOR INTERNATIONAL DEVELOPMhINTSWASHINGON DC x20523---------4
4 -
-SUBJ E CT - -C O H~ E T 4N l
Dr Mr sullivan ------shy
c-rommnents We ~efr-preaereorPla -tobYou lete dted Jan 91989 regardn~i4po4t P ea e1 f i nd y ubel ow our -e ot r XcOrcerned Jordanian deipartments
- --A ar o~nnYu Y o turjlt~ lt K
4 C~mments
~1 N i gFIN I~fANDECONOMIC1COIMEN S -
It sidicaed that Beohtel and US AIDWash ingtonj~4- re ojy nen ing that E 2hould und ertake the n e tshyihaisAre ~our c leometprogram n order shye-t im~ ate d f n t v design and budget cost
4Al1so Lthe study ncal--ttsutnilndcaei~ A-1 A thas ~ l 1 be eeded idb~~~~~ rn o ei t n i la itheMWa~-~5s~ 4
hrPro hehgemetTh trOfT ses~fnr4 BOT)Vmanu- a n-mnf~cure 4 r~j or contra c4-or ivoIlveiintijn I 4 4investmnt ude smi ~w 2 Zha tev e r --~4~prce e ec r it v p4~ f JA gertiy geeated-at 4 JEA 3 a l b u y ~the same average~~ A
~jithia oncot in4 ordrtan ecpoemic asess thespePower generatjoon J ordan3 oi sha I eroic c inr~etJordan 4
2P ge i1- 1 Aj iit eu that OPin he atocontr~ct 4with owner4 ofext3ing (oconstriiction r(FB rml-t
qu i of S 11 t to test large tonnagen j es StaniUti n d ajIe -for se veralIQf 31 hi
evrEAPreferpilot qr the dP 1prt7n -that the4mPIt
andi to(7 he instalI 1e 2 310 A
_
JODN ELECTRICITYAUTHORIT LL
Dac
operated in Jordan i n or~der~~t ~n nuex~on mnining crushing and haidi igQhre~ and sash Maeia nd aSootoget enough olr ndaita needed for einolre
CEBbole~ -i s~
ccordance with Jordaian oil shale
large to~ bfig
1 3 le 1-2 Page 1-7 Cost Of Pwer~i It i S menti-oned that the conmecial oil hle~ lt~project (4 X1OOmw) 1is ninacompetative roqt~range-~while table 12 indicates thattcost of-pow Ais~mill
q kwiihcii r 1
average wih i ii -much higher ihantheshy-ost of ~Power gnrtofomJEA therimaPower s ta tions Please~ indicate on what basi o ~~ shave-~made your-statement
PK
14 Pae 2 Sction 4-0sIt 1nlkly that theChousing and off- -site infrastructur-ommnity fakilitieR) to be onsidered for both the demo and prototyp prjcs oeoverwe~4 hnk that their~c_6t is raterojects Mo
iwcv~- age -1 1 Mine O(perationIIt is indicate~d that mining cot eevdfoMine contractor~ are ficomiplee h
r and iyudi-t~con qidder contract mnn opio fr4 the min4 cmflt2ng are reIanddrepres~ent the real costs derived from Phspat miin contractors in
lestfor the eo rPooypuat in order tlt7
P I eadenote tha detthe new exchangerate ofthJraian~ Di~nner you may add 20j6 Kto the quoted
1 6 P Ias e consider the followin ecn hage_
171- The new exchange ra teof tUSD=54o0 fils1 72-W2 The new~ aerage tariff for selIn~electricityhas decrreased to 120 8 f ilIsicwh
17- Page 1-7 TbIe 1-2 W bev th tthe cap ita1 cot for the pwhokand forthe min n d ash hMnd1ing equipen
P B~2Anaor a -Tl 8156152 8176 1Q MYf -t -Now 520 t 1U
JDNEECRICIT AU-RA L14lLiL
2 ~are very high We suggest~ thta You rerconsie (- telowerus e~+d accuracy est a rangethan +30
Page4-22 Table 4-5weno0ti ced( that- PyroPowe ha ddeta(IiacCst fori the bo1ilerlocation and terha dutdetlease isxtr fo~ l C~ io~ s~ e~~ 1a~ a if and indicate theonldjusted ~percentagefor construction foin Jordan
19 Page-7 Table 11-2 -Yo aeue ihrinterest rate on Equity thatn on1DehI~laseinclude~ adetaied explanation of thisrr -tni kepin in miUndie JEA is1thaIt a non profit~ shyorgaiztion unik oher private UJSA utility~in ktation
~-~110- Regarding shy
the ra4ital Rt fthe project it is~requesed tobre k it intdo foreignMeanwhile cthe nd lorcal c-osfoeigptario i nt-re3t~shol becnierdo-h
rr n ontiondonnotopdbon the 9 cnieelocal portion~onth
1-1- 237~Pa
oningeny 9tooi s high~~ a lower 4value -should be~
4~ gt ~112- -Tbles t1-1 -8-8~ inclu~de t~he c~alculationscuultie nt enefits for of Th shyunttypes l i4s difeen geeatnmrer likely tocluae
-~ Q~ J7present vk1u for tenet tthe~benefits in feralterntives -t-oa s the
49
ehliyoi shale
Wea gree with you9 tha t th e percentage used ~ an for thenua~l 0 ~amp-M rahr CFBo ndsomewha~t highervrate be n ededma y for a C B l n Me n h l ~ a e r
indir e ta~ts the -estimatedma i variablec st i ddition t he fi-xed-9i 1 mislkih We --
thinktttiis too lowK -5
shy
1-14- e 4-29
opprza tion-o to The o i1s h1 costs-nc I deAbo 1h
Pa10 mman ormTSI62 a
IB I
JORD N EtECTICI1~ 4 E~)~Is-s
Date ib-_
~ ~riii~g~nd~o9~ru~hng h~tnlin cot~u~tv yo
i Dae Jnryit
1ts c 7 4-
i smiig iniand fh co I eY
susendi ca tI t icag th t1 ~an~approximate 15 ~pita L tYII I (-~a~ge or he owe bl ockj f aniitjes isof +the capthe)t~ial7cpi~lrharge Uoratelformny SI~Uj(uiity installa~tions~ whle page 6-1T9 talJshyit is mentioned that~ the Capital rate pe-r JEA isshyi5~PeaseJustify this~matter since~w o
i16- Pae 6-1 6
1 I4~t is mentioned that the costs of 4process Water are ~ 4 ~0 2$1 000 gallons
r~j~lt IHave~You considered additionalvalue ofbying waterfrom~ the Wa ters Aito i ~or ditoa cost~f o revrseoqoesplant if ground water is used
~~ I1 7- Table 6-1 Page 6-6 Please explain how did You come ou ihteoil~ shale miniing and proces~sing uit~Icost
ltII~I~ 8- Please note 1 t hatj the average JEA~productinr ot frmthermal I power stationsr (Istationbus-barCOSt)i sbewen 6 3-17 3 fils 4kwh You may use this~
l4~ 19-i For ~4 X 100~AMW Plat iti etindo pag e14-4 VolI 11 that4 at tota I of W42 14 epoye W II eemplo~yer] And on page 69yo1Iiti mentioned that a~ tot 1 f1 ~p yeI iNbe enp1oyed a
is~ high asrmetitexeds100personorthe ~41X100~MWh~~j nsatnpPrlae
I 1 The 4 following iftemns are a sumed to1 be excluded from theraPi ta 1 cot xoI
120-1 Perits I icen es 7
1_207~3 Imprt ~xe on s7pare par ts -and c(7orfmurab -ma~teria Is
04f4 4
~4 R j4 4
D4
~ ~ ~ AIf eS taxesq in acrac ihteJraand regulations should be considered aw
21- p1ea4s e indic ate Your Ju t f c io r us ga 6
44122- Table 977App 5Page4 9-1 4L IK Car1Yiniae that the hIRR of the 4 Otplantis rather unattractive (66)most
-( Cns1er4 ngthe logical base 4csek c pwhen cii 6OL
average sell~ing prc CkhampDEratio L801~2O~Aoreover4M the ne siellin prcwh o JEA ati theamptime~ Abeing os4ltp n~ot exceed 4 Ckwh~-However Ipage 1shy~ and 14 0 T indicate that ecnms for a commeri
S4A4scale joil 4 shale projc ~
appear Piomisig-nug o4Ywarrant continued dee fgfluht 4 feaibiit 4tudy wihil cost sevea~lili
do ar~sf Plas lear wether the ~x step jqs~$j~~lt 4
gtt 9o be considered arCcording4to jthe 4unattractiveresul to mentioned in IRR7 Table 97 gt4
a C4 44fET2 4 144-4444 P a g 1 T b6 l
htte~We ~ ~ ae~ rqieetfrteX ~ noie ~~ ~ 444 MW un t44 r te4l w w e o p r d i th e w t r n rre u f4m or4444~ the4444 54M4rto y e Pg~A~44EHiveL det ile an l A44
s o awa er c n um t a4r f rofsho in P6Io erT
e ch 2 50 M W aPln wa e d 41004 MW4 1 consumption_____________
ma4~2 k e u p houin~44 p A44 4444444 C O 4ltI4
a nd a sh et in etc 4 2 4 1 -24 P a g e4 2 - 1 A P P 5
4Yo 4_ j1 4 4~h444 N44 44
1gro nd tce t hir fthe w bern coqir mna t efora4e 4X10A M 444444 4 r i n to 4 4 4lo w w ehA 7 n 2 cinCie h rh4 n ttthh1eb -e 4 44t Of3 E4O
ea h n~ ffl 4 4Jl44 4 4444 4giv
6 ig re sofrat4 de in cl ar f w w at5 c hrw pe o
s h b 444 o t h e g nd L 44 h u i n C
r 4ne a4 t44 e L(704 2 4 p ae) 2 - o Au P dn 5ai 7~e r 44 I Y (1t 44a
ve7 rn e qu 1saharvthe y
and n~~~o speci~~~l4 p n l nh i n t x
r ~rA M e d r o t eu n 8 1 wTtl t t h
- c re e N I wo6
~ n n a i n a t d h l7 A PP6 gt
J
S2~3- Page 2-4 ~ ~ It ~is i
that oil eindicated the- sha le r our~ Cesin Jordan are 10 billion tons -The anulp e reere maiy exeed 50 4 billion tons ~
~ 24- 4Page~2 -l1 iujntr We beiv thtCBcmuto~ep i s high and~alSo
~~ ~ -2 ~~ Page 4-1~6 j - shy
Please~~ indicates your procedure to cool the omn ashand atwa icagd-eprtr
A Have you~ considered~ additional he~at exchanger topcool th ash and to imrve h cycleef ficiency
-~2~6 Page 4-16 It s~ indicated that ash from each silo i Amixed19 ~with~fabout 20 waterKb weight to minimize generation of dust~during trnprtto to mine and disposalHave you~ coniidered other 4lternativeto
~ ~eliminate dustiiig -and avoid use ofwat r uring it ransportationi such as~ using closed trucks or closed
of ~fans conUMnPo wihrlaintthe total plant auiir poe osupin 1~21- Table 5_-3 and I ~
Th~~ is- somneere c6ntradiction regardingplnneotpu~t in both am tables 21-~ Tabl~e 1-33
We noticed tha~t yourall9 cacacapac t fatro75 tion ae asdnWe thilt ~that 7capacityshyfacto is tobo high for- an oil shale fired plant duketo lack of existing simila~r ~plants handl~~~firing oil adshale ~K
216~ The study iniae thtawet~coigtower wi11~used Actually a b
dry cooling should be consideda5ini ~HTP S inZ atomnmz so water rnumption4the cycle~ efficiency willbe reducedHenre YO33~reconsider calculating the cyclefficiy
U~~~~~ codnt umconsidered ofhorizontal -aretypethe~ the vertical cian type can alsobeh considered
shy ~ ~ ~ I~~
2~2 Kconcrete shy
shjell stepl fltstack is onidereconcrete shell brick flue Rt c ~s beCaconsidered3V
2-19~- Deminiraized water~ tank3 capacity~ is -76 ui(meterThe recommnended tank cameter- ui tyi 00cbc
220Designconditions Pa~ge (4-74)te5 hat bow 3down percentage splusmn ~fomrpra til re i hou I be 3~)~
PoD Z 2 m a ad~ - e 5 1 2 iJS~ ~ p A f amp ~ ~ y1
4
JO R ECTICITY AUTHORTIT 4L
~ 4
Date~
t etats ttthe quantityof s i S ~1 000Tons ra Sthis tuntity 11- be transporited for severIy --to tu ofI pit a~te torg P KM ra~erm Spower plIatS about 12 midilidoni CUIA(- met ryea
h e ndd mp e he (d u p in i n L
area wil evric power plant6t Please zn1 a te~tiv s tudY for dumping th r~ a enoug
-from the power plantr~~h~
S 2- Please provide deald-ifrat ao etbaaiedrawing hwn TH11 R thaU and~pV ra~te takcing illto o 6it v- consumptionn _uig themrining equipment
alternate~ study 0o Jine operation for 1 shiftday Vand twoshifts day -lt
224- Conceptua~l pflR 1 for mi ing anusdtransportation of oil- shale a 0 dmj of hs f u r therV examinedh iV~sdpatI ho u1d be
orderj to poe~ehicalq and~eoomca1 fesblt of t his operation
SYour are requested te) study and consider all- above - iPoin s at your earliest in rder -to be peete y oiAnimain on March 29-301989 peetdb~o 4 n
S9incerly-You S
WDIRECTORGENERAL -
I~ CCMR WLINTON ~vs
5N
Pa D~t~IoAmmn -Jordtn -Tel 815615 20 Bl76 15 -19j A VINO- AFf TY
MARCH 21 RESPONSE TO JEA QUESTIONS
Bechtel Power Corporation Engineers - Constructors
Fifty Beale Street San Francisco California Mail Address P 0 Box 3965 San Franclco CA 94119
March 21 1989
Mr M S Arafah Director General Jordan Electricity Authority PO Box 2310 Amman Jordan
Subject Jordan Oil Shale Prefeasibility Study
Dear Mr Arafah
Your letter of 15 March 1989 with comments on the Oil Shale to Power Prefeasibility Study draft report has been referred to me for reply
The attached responses to each item in the reference letter follows the order submitted
Also attached are three revised pages for the draft report - Volume I
Page 6-1 Page 6-21 Page 6-23
Please copy these revised pages into the report previously sent to you
We plan to review this material with JEA during the March 2930 and April 1 meetings in Amman
rsuVertrul yours
W Linton Project Manager
WHLdc
Attachments Questionnaire Response Three revised pages
cc C J Aulisio R R Buta G D Gould T J Wilbanks
32389
Page 1
RESPONSE TO MARCH 15 1989 QUESTIONAIRE
OIL SHALE TO POWER PREFEASIBILITY STUDY
This study examines economic prospects in terms of a 1995-2000 timeframe
FIRANCIAL AND ECONOMIC COMMENTS
11 It is likely that a BOT deal can be structured at present JEA
generation costs for either 20 MW or 50 MW size units if GOJ is
willing to subsidize the incremental power generation cost
Furthermore these incremental costs can be recovered during the 25
year operation of a Commercial Scale Project
12 A 3rd Party Test was proposed as an alternate means to raising
$100+ for an independent JEA sponsored 20 MW Demonstration
program
13 71 millsKWH for Shale Power
VS
JEA 1987 costs
Purchased Power 17 filsKWH = 51 mills
Produced Power 1360 filsKWH = 41 mills
19952000 Costs - Expected to be 30 to 40 higher and in line
with the cost estimate presented in this study
It also is important to recognize that the busbar cost of power
generated by any new power source can not be compared directly
with the cost of existing older installed capacity because of the
lower capital cost component of the latter (See enclosed Figure
1-1 which demonstrates how total capital carrying costs decline as
the investment is paid off) Any new capacity whether coal oil
or oil shale will be an unreasonable disadvantage compared with
costs for existing older capacity
l
024
o2
0De return
E 016Total carrying charge
012 qu return
S -008
ety taxes and n rcw vshy000 X 0 5 10 15 20 25
Figure 1-1 Year-by-year Carrying Charge Components for 15-yearTax Recovery Period
1-7
30
32389
Page 2
14 Infrastructure Cost
Total People
OperatorFamilies Installed Cost
20 MW $10000000 185700 $54000Operator
50 MW 15000000 3241200 46000Operator
400 MW 45000000 10364000 43000Operator
Factored allowance for grass roots desert installation
including housing and community facilities was developed as
follows for the 50 MW case study
Infrastructure
50 MW
Family Housing 200 30K = $ 6 Million
Bachelor Housing 100 20K = 2 M
HospitalClinic (8 Beds) 11 M
SchoolMosque I1 M
Stores Services amp Recreation = 2 M
Facilities
Roads Electricity Water Sewage = 3 M
$15 Million
Infrastructure costs for the 20 MW and 400 MW cases was ratioed
from this breakdown
At this conceptual level costs are order-of-magnitude In a Phase
II program these infrastructure costs can be developed in detail
32389
Page 3
15 Contract Mining Alternatives
Page 4-11 Mine Operation
Based on Bechtels evaluation of the mine contractors price as found in Section 15 of the Mining Report it was concluded that
the mine contractors price does not include costs for such things
as developing the mine with a box-cut ramp haul roads
developing an area for the waste material maintaining the
haulroads constructing the mine services facilities diversion
ditches sedimentation ponds water well crushing the oil shale
pre-mixing the oil shale at the mine and other items associated
with operating a mine to support a power plant If it is proven
that the mine contractors price includes cost for the above
mentioned scope of work in additi-n to drill blast load and
haul then the contractors price can be used but in the meantime
the all inclusive cost developed by Bechtel should be used
Contract Mining appears to be attractive for the smaller size
plants but not for the larger commercial scale operation Some
third party must provide the necessary capital for trucks
loading mining machines etc under a contract arrangement
16 Reassessment due to Dinar value change needs further study and can
not be evaluated given present budget limitations If average
labor rate of $300hr still valid then little change involve with
study
If deemed necessary reexamination of project economics can be
done in Phase IIwhen funded
17 Costs in this study are based on recent similar Bechtel experience
on Mount Poso project and on Montana I project The Mount Poso
project is a 50 MW unit firing coal in a Pyropower boiler The
Montana I project is a 35 MW unit firing coal in a Keeler Dorr
Oliver FBC boiler utilizing dry cooling
32389
Page 4
18 The Pyropower quote of $186000000 to futnish and erect the steam
generator stack and baghouse has been adjusted to include
engineering construction indirect cost etc to be consistant
with the rest of the costs shown in Table 65 p 6-10 No
further adjustment for location was made
19 Equity funding has the lowest priority of payoff in case of a
liquidation and carries greater risk Hence a higher rate of
return is needed to attract these funds Debt funding is a first
mortgage and has first priority for payoff in case of liquidation
and carries less risk Hence it requires lower rate of return
than equity funding
The risk taking equity owner will ask for greater interest rate
to make funds available The only way to minimize this expense is
to find a loaning agency willing to provide 90 or perhaps 95 of
the investment cost It is likely that banks will require some
minimum equity participation
This Prefeasibility Study was not based on a non-profit utility
operation
Even though JEA is a non-profit organization its service
contributors are profit making groups It is visualized that the
Jordan Oil Shale Co (JOSCO) will be a stand alone business
enterprise servicing JEA under long term contract To secure
funding for the proposed project JOSCO will need attractive
enough contract terms to attract both equity and debt capital
110 Additional work is needed to develop the requested information
This work can be preformed as part of the Phase II program
111 Bechtel includes contingency in all of its estimates to cover
error emissions and unforeseen items within the defined scope of
the project The level of contingency is dependent upon the
amount of scope definition For a prefeasible study such as this
15 contingency is lower than normal
32389
Page 5
112 Tables 89 through 816 include a present value calculation to
establish the relative benefit for a shale project vs coal and
oil
113 The variable maintenance cost of 1 millsKWH has been adjusted for CFB plants with an additional $200000 per year or 06 millsKWH
This yields the following
Variable Maintenance - 10 millsKWH
CFB Adjustment - 06
Fixed Maintenance Cost - 40
Total Cost 56 MillsKWH
114 Page 4-29
The royalty costs are included in the weighted average oil shale
costs for the 50 megawatt plant
Page 4-8
Shale fuel costs include return on equity and royalty These are
two separate cost items Royalty is the last item mentioned in
the sentence and it therefore reads as royalty and not return on
royalty
Page 4-31 gives rates used by Bechtel based on our calculations
using the referenced procedures
DebtEquity Capital Charge Rate
5050 153
8020 139
Table 69 displays the calculation of the 153 capital charge
rate (Line 7 of Table 69 is not used in the calculation and
should be deleted)
32389
Page 6
116 No water purchase charge from the Water Authority was added to the
operating expense based on the statement that no resource costs
will be charged
$020 per 1000 gallons is rule of thumb for USA installations in
absence of client data
Boiler make up water (p4-17) is treated in a demineralizer
train If deemed necessary comparison with reverse osmosis
process can be performed in Phase II
Water requirements were estimated to be
Cubic Metres Per Year
20 MW 50 MW 400 MW
Mine amp Shale Processing 455000 761000 773000
Power Block 3000 6000 42000
Infrastructure 80000 140000 448000
Total 538000 907000 1263000
117 Annual average operating costs shown on Table 6-1 are in error
Financing Option 5050 8020
Cost Shown 56606 48945
Corrected Cost 60396 53236
Average mining and shale processing costs are developed year by
year in the Mining Report Appendix 5 Table 12-10
32389
Page 7
118 We would be interested in receiving the breakdown of these current
power cost figures (ie capital charges fuel cost number of
operators etc) Further economic analysis employing these
figures can be developed in Phase II
119 Manpower requirements for the three case studies were estimated as
fol lows
Mining amp Shale Processing
Power Block
Operations
Maintenance
Management
20 MW 50 MW 400 MW
75 163 396
54 78 175
46 73 455
10 10 10
185 324 1036
Page 14-4 of the Mine Report is for mine and shale processing
only It should be noted that most of these manpower requirements
involved new jobs for Jordanian people
120 At the April 1988 Amman Meeting it was agreed that the following
costs would be omitted
o Permits and Licenses
o Local Taxes
o Import Taxes
If necessary such costs can be developed and added into a revised
economic analysis as part of the Phase II program
121 6 average inflation rate is the figure recommended by Bechtel
based on USA conditions for use in long term economic analyses of
new power ventures
32389
Page 8
122 This matter is referred to ORNL who prepared a rate of return
analysis
Bechtels conclusion is based on computed busbar costscumulative
benefits compared to alternate fuels in the timeframe 1995 to 2000
Relative Busbar Power Cost Net 25 Year
Mills per KWH Benefits - Million US$
Sultani Oil Shale 71-83 Base Cost
Imported Coal
$50tonne 68-88 778
$70tonne 78-107 2531
Imported Oil
$17Bbl 56-76 (18) $24Bbl 61-96 1810
The above results are based on a capacity factor of 75 which is
considered to be a reasonable target for a new plant over its 25 year
life The average selling price of 6 cents per KWH cited in the
questionnaire is based on existing plant costs which may not include
all cost elements of new capacity evaluated in this study
32389
Page 9
TECHNICAL COMMENTS
21 See answer to Item 116
Total power plant raw wate consumption rates and annual
consumptions including the water requirements for wetting ash at the truck loading p int within the power plant are given in Tables 43 and 44 for 50 MW unit and Tables 53 and 54 for 20 MW unit
The raw water requirements for 4x0 MW plant were factored
excepting the mine where a revised mine pldn is employed to reduce water request The quantities shown on these tables exclude raw
water requirements for housing complex mine and ash wetting if
required at the ash disposal site
Total power plant requirements shown in the above referred tables
are
50 MW 20 MW
Rate gpm 207 102 (See Drawing M004)
Annual Use
Gallons 1400000 675000
Cooling tower blowndown supplemented with raw water is used for
wetting ash at the truck loading point within the power plant Raw water quantities attributable for ash wetting at the power
truck loading point are
50 MW 20 MW
Rate gpm 75 325
Annual Use
Gallons 500000 215000
These quantities are included in the quantities shown in
the above referred tables
32389
Page 10
22 We recognize the POTENTIAL for leaching toxic compounds from the
spent ash However this matter is not yet defined well enough to
recommend specific action steps The Prefeasibility Study page
7-12 recommends creation of a ground water dispersion model to
determine whether more specific contaminated water mitigation
plans are needed It is anticipated that the leachate rate will
be low and that aquifer dispersion will keep problem compounds
bel3w health standards thresholds
23 Noted
We have not received up to date resource study material which
defines 50 billion tons resource base Please furnish
The resource base at Sultani alone is adequate to support two 400
MW power projects capacity subject water availability The
2-million cubic metre per year water allowance for oilshale will
limit development to about 600 MW
24 Selection of a combustion temperature is a balance between carbon
combustion efficiency and heat loss due carbonate decomposition
For purposes of the Prefeasibility Study we have opted for high
combustion efficiency At lower efficiency larger shale
mineprocessing plants will be needed
25 Bottom ash is cooled by water exchange before discharge
Cooling water is supplied to the ash screw coolers as specified by
Pyropower See Drawing MOO5 2140 gpm flow for 50 MW and 860 gpm
flow for 20 MW Heat removed by the cooling water from the ash
screw coolers is dissipated to atmosphere via a wet cooling
tower Pyropower should indicate the temperature of the ash
discharged to be 5OOF
32389
Page 11
Initially we had considered using a heat exchanger to cool the ash
and improve the cycle efficiency Considering low cost of fuel
the additional capital costs and the system complexities it was
decided not to employ such heat recovery systems for this project
26 The suggested alternates were looked at briefly and the potential
for wind blown air pollution from the ash disposal areas are too
great to warrant dry disposal unless GO(] and World Bank are
willing to accept such a potential problem Wetting the ash is
tne only practical solution Hopefully some cementation will
occur helping to reduce future leaching potential
27 JEA requirements are noted This is a conceptual study not a
final design Optimal design analysis can be performed during
Phase II
2829
JEA requirements are noted and can be incorporated into the Phase
II design
210 The transformer size is adequate for base load operation A
higher capacity can be considered at the final design stage if the
Client prefers
211 From our experience it does not appear to be economical to
provide additional dry cooling towers to take care of maximum
ambient temperatures which may prevail only for a short period of
time in a year To study this an annual dry bulb temperature
duration curve is required Also adding additional dry cooling
towers will change the plant performance It should also be noted
that the dry cooling towers are very expensive and the size should
be selected carefly considering performance and cost and not on the basis of maximum ambient temperatures This can be studied
during Phase II
32389
Page 12
212 The plant gross output varies with condenser pressure
Condenser
Pressure Design 55 in HgA Annual Ave 35 in HgA
Unit Size MW 20 50 4xlO0 20 50 4xlO0
Gross Output MW 234 593 496 2415 607 TBD
Net Output MW 1975 501 400 205 515 TBD
To be developed in Phase II
Output for 4x100 MW is estimated by others
213 The fan power consumption of the CFB boiler is about 30 to 35 of
the total auxiliary power The fan power consumption of the dry
cooling tower is about 20 to 25 of the total auxiliary power
214 Table 1-1 does not include plant net output Therefore do not
understand the comment
215 Commercial operating experience with coal fueled CFBC units in LISA
and Europe has been uniformly good showing high on stream
availability in early years (See Table 2-6 which reports on
Pyropower experience)
We expect operations with high ash content fuel like oilshale will
have unique scale up problems such as
o Solid handling in and out
o Internal solids circulation
o Erosioncorrosion steam generator intervals
o Heat recovery from bottom ash
Consequently we are recommending these items be worked out in a
single 50 MW prototype
32389
Page 13
216 Maximum dry cooling is used in this study A small wet cooling
tower is used on circulating service water system
217 Horizontal condensate pump is adequate with dry cooling tower and it is cheaper Vertical condensate pumps with cans can be
considered in the final design if required
218 A concrete shell brick lined flue stack will be larger in diameter and costs more than a steel lined stack Brick lined stack can be
considered in the final design
219 Demineralized water tank capacity for 50 MW is 76 cu meters or 20000 gallons not 1000 cu meters For 20 MW plant it is 38 cu
meters or 10000 gallons
220 It is US practice to use an average continuous blowdown rate of
1 and maximum biowdown rate of 3 for this type of plants
221 This can be studied during Phase II
222 Same as 221
223 Same as 221
224 The recommended action plan calls for continuing support studies covering the referenced items Additional effort is needed to
further define these matters and confirm the conceptual plan
The next step is to develop an outline for a project plan including
o Work Scope
o Schedule
o Budget
accommodate the increase in the number of employees and
equipment Truck bays to accommodate the 136 tonne trucks
will be added The truck bays used for the 77 tonne
trucks will be used for the maintenance of other
equipment The warehouse change house training room
offices and cafeteria will be expanded accordingly
6025 Mining and Processing Economics
Details of the oil shale mining and processing plant
economics for the 400 MW plant are included in the Mining
Report (Appendix 5) These details are of the same
magnitude as prepared for the 20 MW and 50 MW plants
The summary of the cash flow analysis for the mine and
shale processing plant is presented in Table 6-1
Table 6-1
SUMMARY OF 400 MW PLANT OIL SHALE MINING AND PROCESSING COSTS
5050 Debt-Equity 8020 Debt-Equity
US $1000 US $1000
Capital Cost
Mine Development 30915 30915
Mine Equipment 66012 66012
Process Plant Facilities 50889 50889
Spare Parts 5000 5000
Working Capital 10000 10000
Capi tal ized Interest
During Construction 24423 39075
TOTAL 187239 201891
Operating Costs and Other Costs
Annual Cost 60386 53236
Product Mined and Processed
Annual Tonnes x 1000 7783 7783
Unit Cost
US $Tonne (weighted average)
US $l06Btu (weighted average) 776
156
684
138
Year 12 costs taken as 25 year average
6-6
-Au
Table 610 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
- FCC plant sizes equivalent to proposed power application
Prefeasibility Study Oil Shale Fueled Power Generation
VOO94GEampJRI26
i
PYROFLOW UNITS IN THE US
COLORADOUTE IOYA STATE UNIV UNIV OFNUCLA CO NORTHERNAMES IA BF GOODRICH110 1o0MW(a) 2x170000 Ibhr HENRYILCEDAR FALLS IA 120000 Ibhr GENERALGULF OILu EiN P MOTORSSbtUpStart-UIL 1987 O A 1I N000 TC
NORT10 PONTIACH B MIRANCHWV00000 lbhr
CORN PRODUCTSSM NORTH-CAROLINA STOCKTOD CA
400000 lbbhl t
RUMF RD ME
CEMENT CO CALIF PORTLAND-COLTON CA
190000 Iblhr Start-Up 1985 TRUMTFTWN NYU
3I75ERTOWN N
etar t-Up loss ACE COGENERATIONCABI
TRONA CA Oper t~on l -Start-UP 1990 ~ rt upz 091Start-up loss Start-up PNeLAI 1991
MTKESFICOENERATIO-N1
BASFIELDp Start-uStar-Up WESTCA9 199otgoUp 1 MAHONEV PA|00000 Ibhr A Oz 2X365000 Ibhr
SETtr-Ups 188B CHAT TANOOGA TN
G ULF OIL EXPLORATION 8ta-rt-u) 1085BAKERSFIELD NORTH BRANCHCA SPRING GROVE PANORTH BRANCH WV 400000 IbhtOperational 19835 5 0 0 I b h 9 0 0 0 Iblh r- tart-Upi 1991 S t r - U p s l e s s
SOUTHEAST PAPER MFG CO UNIVOF NORTH CAROLINArDUBLIN GA UHAPEL HILL NO400000 IbhrStart-Ups logo Start-Ups2X250O000 1loseIbhr B
- Withdrawing ash from combustor - Withdrawing fly ash
a Internal solids circulation of the steam generator
m Erosioncorrosion of steam generatorinternals
Heat recovery from bottom ash
U Operation with low calorific-value fuel
Prefeasblity Study O Shari Fueled Power Generation
VOO7AI 27
Impact of Scale-Up
Project Size
20 MW
50 MW
100 MW
50 MW boiler in 100 MW plant
Potential Risk
Design Scale-upOperation of to 100 MW Initial Plant Plant
Low Significant
Modest Modest
High Low for duplicate units
Modest Low for duplicate units
Prefeasibility Study Oil Shaje Fueled Power Generation
VOO71-4GEAL4n2
i
Conclusions
Defined risk of CFBC boiler is acceptable
U Operating experience with commercial CFBC boilers built and under construction will strengthen confidencelevel and minimize risk for a plant built in 1995
SPrefeasibility Study Oil Shale Fueled Power Generation
V007GHAAE29
ENVIRONMENTAL ASSESSMENT
a Mine and shale processing
- Fugitive dust emissions
- Noise levels
- Leachability of disposal piles
Power plant
- Fugitive dust emissions
- Gaseous emissions
- Noise levels
- Water effluents
U Conclusions
Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel
Prefeasibility Study Oil Shale Fueled Power Generalon
- Coaloil prices will be at least 15 greater after 1995
- Discovery of indigenous conventional fuel resources is inadequate for power plant purposes
Prefeasibility Study
Oil Shale Fueled Power Generation
VOO) IDWFO
Feasibility(Contd)
N Suitable financing will be available
- For $200 million 50 MW prototypeproject
- For $1000 million 400 MW commercial project
Government of Jordan will make basic commitments
- Long-term power purchase agreement
- Long-term access to Sultani shale deposit
Adequate water and manpower resources
- Attractive tax incentives
Prefeasibility Study
Oil Shale Fueled Power Generaion
VO bull1DUJJRO 6
Timeliness
U Timely development of Jordan oil shale needs prompt action to create - Additional definitive information
- Suitable business plan
Prefeasibility Study
Oil Shale Fueled Power Generation
VooI DUJo 7
i
Expansion Conditions
U Continued expansion of powergeneration from oil shale in Jordan depends on water availability
Prospects for power export or importand domestic load growth will affect size of the needed shale-to-power program
Prefeasibility Sudy
Oil Shale Fueled Power Generation
yOWl lVuJO
Environmental Impacts
N Environmental impacts of shale development will be minimal
Prefeasibility Study Oi Shale Fueled Power Generation
i
Development Advantages
Will create significant new jobopportunities in Jordan
Will avoidreduce foreign exchangelosses for expanding alternate fuel imports
Prefeasibility Study
Oil Shale Fueled Power Generation
VOOIIULL tO
Recommended Action Plan
N Basic recommendation
N Conceptual development schedule
U Project development plan
Key plan elements
N Funding requirements
Prefeasibility Study Oil Shale Fueled Power Generation
VOO4II )U OII
i
Basic Recommendation
N Expand efforts to develop an oil shaleshyfueled power generation program at the Sultani deposit
- Conduct required supporting studies
- Define facilities costs and business plans
- Obtain project funding
Prefeasibility Study
Oil Shale Fueled Power Generation
VON I II)ILL 12
C
Conceptual DevelopmentSchedule
1989-1990
- Conduct supporting studies - Define costsbusiness plans for 50
MW prototype and 400 MW commercial projects
- Develop project financing
N 1990-1993 - Build and operate the prototype project
N 1994-1996 - Expand the 50 MW prototype to 100 MW scale
U 1996-2000 - Expand the project to 400 MW scale
N 2000-2005 - Build a second 400 MW commercial project if needed
i 1 Prefeasiblity Study
dOil Shale Fueled Power Generation
VW IMLITO 13
Conceptual Development Plan
Months
1 Project development plan - Define project
costs1busness plans
-24 -12 0 12 24 36 48 60 72 84 96 108 120
2 Secure funding
3 Build and operate 50 MW prototype
Dergn and procurement
Mine development
Plant construction
Startup and testing
Operations
L- -
4 Expand prototype to 100 MW
Design and procurement
bullConstruction
Startup
5 Expand project to 400 MW
2nd 100 MW unit
3rd100 MW unit
i 44
4th 100 MW unit -
O Project dacision point
i Prefeasib~ity Study Oil Shale Fueled Power Generation
17958562aJocdanV 3-14-89 rsO
18
Phase I - ProjectDevelopment Plan
n Program development
Seminar workshop on prefeasibilitystudy Oate project development plan woek scope schedule arid budget
U Carry out project planning program
- Conduct continuing support studies - Test Sultani shale in existing FBC
- Firm up designs and specifications
- Update costs and economic analysis
- Develop business plans and requirements
Explore project funding alternatives
i Prefeasibility Study
Oil Shale Fueled Power Generation
VO MItUOR 14 -0
Key Plan Elements
N Project feasibility analysis
- Firm up designs and equipmentspecifications for all facilities
- Update cost estimates based on preliminary designs and specifications
Explore arrangements for contract mining and mine development
Update forecasts for demand growthand for retirements of older generating capacity
- Create updated economic analysis
Preleasibility StudyO1 Shae Fueled Power Generation
VOO1IOLWRI
Key Plan Elements (Contd)
Business entity requirement
- Explore optionsconditions for a new company to managebuildoperate the project
- Explore optionsconditions for obtaining a concession agreement for Sultani development
Explore optionsconditions for water rights commitment
Prefeasibility Study Oil Shale Fueled Power Generation
VMIOIA)lj 16S
i
Key Plan Elements (Contd)
U Continuing supporting studies
- Combustion tests (additional pilot tests for design and warranty purposes contract for large-scale burn operations in existing plants if appropriate)
- Additional core drilling and core analysis
- Oil shale crushing tests
- Spent ash leaching tests
- Geotechnical data base including soils analysis
- Environmental baseline data
Prefeasibility Study O Shae Fueled Power Generation
VMMMUldMOA
Steps Required to Develop an Oil Shale-to-Power Project
Create a development business plan - Schedule - Decision tree
Develop a work scope and budget for the development plan program including - Firming up designsspecificationscosts
- Developing business entity requirements - Continuing support studies
Carry out development plan program
Assemble all planning results in a report for discussion with financial institutions
Explore project finance opportunities
Finalize business arrangements
Implement prototype project
i Prefeasibility Study
Oil Shale Fueled Power Generation
VM1-11UJROLI
MARCH 15 JEA QUESTIONS (M S ARAFAH) ON PREFEASIBILITY
STUDY DRAFT REPORT
Rt
DIR EScBSULIVAN PHD OFJCEop~BUREAU FOR SCIENCE AND~TECHNOLOGYAGENCY - --FOR INTERNATIONAL DEVELOPMhINTSWASHINGON DC x20523---------4
4 -
-SUBJ E CT - -C O H~ E T 4N l
Dr Mr sullivan ------shy
c-rommnents We ~efr-preaereorPla -tobYou lete dted Jan 91989 regardn~i4po4t P ea e1 f i nd y ubel ow our -e ot r XcOrcerned Jordanian deipartments
- --A ar o~nnYu Y o turjlt~ lt K
4 C~mments
~1 N i gFIN I~fANDECONOMIC1COIMEN S -
It sidicaed that Beohtel and US AIDWash ingtonj~4- re ojy nen ing that E 2hould und ertake the n e tshyihaisAre ~our c leometprogram n order shye-t im~ ate d f n t v design and budget cost
4Al1so Lthe study ncal--ttsutnilndcaei~ A-1 A thas ~ l 1 be eeded idb~~~~~ rn o ei t n i la itheMWa~-~5s~ 4
hrPro hehgemetTh trOfT ses~fnr4 BOT)Vmanu- a n-mnf~cure 4 r~j or contra c4-or ivoIlveiintijn I 4 4investmnt ude smi ~w 2 Zha tev e r --~4~prce e ec r it v p4~ f JA gertiy geeated-at 4 JEA 3 a l b u y ~the same average~~ A
~jithia oncot in4 ordrtan ecpoemic asess thespePower generatjoon J ordan3 oi sha I eroic c inr~etJordan 4
2P ge i1- 1 Aj iit eu that OPin he atocontr~ct 4with owner4 ofext3ing (oconstriiction r(FB rml-t
qu i of S 11 t to test large tonnagen j es StaniUti n d ajIe -for se veralIQf 31 hi
evrEAPreferpilot qr the dP 1prt7n -that the4mPIt
andi to(7 he instalI 1e 2 310 A
_
JODN ELECTRICITYAUTHORIT LL
Dac
operated in Jordan i n or~der~~t ~n nuex~on mnining crushing and haidi igQhre~ and sash Maeia nd aSootoget enough olr ndaita needed for einolre
CEBbole~ -i s~
ccordance with Jordaian oil shale
large to~ bfig
1 3 le 1-2 Page 1-7 Cost Of Pwer~i It i S menti-oned that the conmecial oil hle~ lt~project (4 X1OOmw) 1is ninacompetative roqt~range-~while table 12 indicates thattcost of-pow Ais~mill
q kwiihcii r 1
average wih i ii -much higher ihantheshy-ost of ~Power gnrtofomJEA therimaPower s ta tions Please~ indicate on what basi o ~~ shave-~made your-statement
PK
14 Pae 2 Sction 4-0sIt 1nlkly that theChousing and off- -site infrastructur-ommnity fakilitieR) to be onsidered for both the demo and prototyp prjcs oeoverwe~4 hnk that their~c_6t is raterojects Mo
iwcv~- age -1 1 Mine O(perationIIt is indicate~d that mining cot eevdfoMine contractor~ are ficomiplee h
r and iyudi-t~con qidder contract mnn opio fr4 the min4 cmflt2ng are reIanddrepres~ent the real costs derived from Phspat miin contractors in
lestfor the eo rPooypuat in order tlt7
P I eadenote tha detthe new exchangerate ofthJraian~ Di~nner you may add 20j6 Kto the quoted
1 6 P Ias e consider the followin ecn hage_
171- The new exchange ra teof tUSD=54o0 fils1 72-W2 The new~ aerage tariff for selIn~electricityhas decrreased to 120 8 f ilIsicwh
17- Page 1-7 TbIe 1-2 W bev th tthe cap ita1 cot for the pwhokand forthe min n d ash hMnd1ing equipen
P B~2Anaor a -Tl 8156152 8176 1Q MYf -t -Now 520 t 1U
JDNEECRICIT AU-RA L14lLiL
2 ~are very high We suggest~ thta You rerconsie (- telowerus e~+d accuracy est a rangethan +30
Page4-22 Table 4-5weno0ti ced( that- PyroPowe ha ddeta(IiacCst fori the bo1ilerlocation and terha dutdetlease isxtr fo~ l C~ io~ s~ e~~ 1a~ a if and indicate theonldjusted ~percentagefor construction foin Jordan
19 Page-7 Table 11-2 -Yo aeue ihrinterest rate on Equity thatn on1DehI~laseinclude~ adetaied explanation of thisrr -tni kepin in miUndie JEA is1thaIt a non profit~ shyorgaiztion unik oher private UJSA utility~in ktation
~-~110- Regarding shy
the ra4ital Rt fthe project it is~requesed tobre k it intdo foreignMeanwhile cthe nd lorcal c-osfoeigptario i nt-re3t~shol becnierdo-h
rr n ontiondonnotopdbon the 9 cnieelocal portion~onth
1-1- 237~Pa
oningeny 9tooi s high~~ a lower 4value -should be~
4~ gt ~112- -Tbles t1-1 -8-8~ inclu~de t~he c~alculationscuultie nt enefits for of Th shyunttypes l i4s difeen geeatnmrer likely tocluae
-~ Q~ J7present vk1u for tenet tthe~benefits in feralterntives -t-oa s the
49
ehliyoi shale
Wea gree with you9 tha t th e percentage used ~ an for thenua~l 0 ~amp-M rahr CFBo ndsomewha~t highervrate be n ededma y for a C B l n Me n h l ~ a e r
indir e ta~ts the -estimatedma i variablec st i ddition t he fi-xed-9i 1 mislkih We --
thinktttiis too lowK -5
shy
1-14- e 4-29
opprza tion-o to The o i1s h1 costs-nc I deAbo 1h
Pa10 mman ormTSI62 a
IB I
JORD N EtECTICI1~ 4 E~)~Is-s
Date ib-_
~ ~riii~g~nd~o9~ru~hng h~tnlin cot~u~tv yo
i Dae Jnryit
1ts c 7 4-
i smiig iniand fh co I eY
susendi ca tI t icag th t1 ~an~approximate 15 ~pita L tYII I (-~a~ge or he owe bl ockj f aniitjes isof +the capthe)t~ial7cpi~lrharge Uoratelformny SI~Uj(uiity installa~tions~ whle page 6-1T9 talJshyit is mentioned that~ the Capital rate pe-r JEA isshyi5~PeaseJustify this~matter since~w o
i16- Pae 6-1 6
1 I4~t is mentioned that the costs of 4process Water are ~ 4 ~0 2$1 000 gallons
r~j~lt IHave~You considered additionalvalue ofbying waterfrom~ the Wa ters Aito i ~or ditoa cost~f o revrseoqoesplant if ground water is used
~~ I1 7- Table 6-1 Page 6-6 Please explain how did You come ou ihteoil~ shale miniing and proces~sing uit~Icost
ltII~I~ 8- Please note 1 t hatj the average JEA~productinr ot frmthermal I power stationsr (Istationbus-barCOSt)i sbewen 6 3-17 3 fils 4kwh You may use this~
l4~ 19-i For ~4 X 100~AMW Plat iti etindo pag e14-4 VolI 11 that4 at tota I of W42 14 epoye W II eemplo~yer] And on page 69yo1Iiti mentioned that a~ tot 1 f1 ~p yeI iNbe enp1oyed a
is~ high asrmetitexeds100personorthe ~41X100~MWh~~j nsatnpPrlae
I 1 The 4 following iftemns are a sumed to1 be excluded from theraPi ta 1 cot xoI
120-1 Perits I icen es 7
1_207~3 Imprt ~xe on s7pare par ts -and c(7orfmurab -ma~teria Is
04f4 4
~4 R j4 4
D4
~ ~ ~ AIf eS taxesq in acrac ihteJraand regulations should be considered aw
21- p1ea4s e indic ate Your Ju t f c io r us ga 6
44122- Table 977App 5Page4 9-1 4L IK Car1Yiniae that the hIRR of the 4 Otplantis rather unattractive (66)most
-( Cns1er4 ngthe logical base 4csek c pwhen cii 6OL
average sell~ing prc CkhampDEratio L801~2O~Aoreover4M the ne siellin prcwh o JEA ati theamptime~ Abeing os4ltp n~ot exceed 4 Ckwh~-However Ipage 1shy~ and 14 0 T indicate that ecnms for a commeri
S4A4scale joil 4 shale projc ~
appear Piomisig-nug o4Ywarrant continued dee fgfluht 4 feaibiit 4tudy wihil cost sevea~lili
do ar~sf Plas lear wether the ~x step jqs~$j~~lt 4
gtt 9o be considered arCcording4to jthe 4unattractiveresul to mentioned in IRR7 Table 97 gt4
a C4 44fET2 4 144-4444 P a g 1 T b6 l
htte~We ~ ~ ae~ rqieetfrteX ~ noie ~~ ~ 444 MW un t44 r te4l w w e o p r d i th e w t r n rre u f4m or4444~ the4444 54M4rto y e Pg~A~44EHiveL det ile an l A44
s o awa er c n um t a4r f rofsho in P6Io erT
e ch 2 50 M W aPln wa e d 41004 MW4 1 consumption_____________
ma4~2 k e u p houin~44 p A44 4444444 C O 4ltI4
a nd a sh et in etc 4 2 4 1 -24 P a g e4 2 - 1 A P P 5
4Yo 4_ j1 4 4~h444 N44 44
1gro nd tce t hir fthe w bern coqir mna t efora4e 4X10A M 444444 4 r i n to 4 4 4lo w w ehA 7 n 2 cinCie h rh4 n ttthh1eb -e 4 44t Of3 E4O
ea h n~ ffl 4 4Jl44 4 4444 4giv
6 ig re sofrat4 de in cl ar f w w at5 c hrw pe o
s h b 444 o t h e g nd L 44 h u i n C
r 4ne a4 t44 e L(704 2 4 p ae) 2 - o Au P dn 5ai 7~e r 44 I Y (1t 44a
ve7 rn e qu 1saharvthe y
and n~~~o speci~~~l4 p n l nh i n t x
r ~rA M e d r o t eu n 8 1 wTtl t t h
- c re e N I wo6
~ n n a i n a t d h l7 A PP6 gt
J
S2~3- Page 2-4 ~ ~ It ~is i
that oil eindicated the- sha le r our~ Cesin Jordan are 10 billion tons -The anulp e reere maiy exeed 50 4 billion tons ~
~ 24- 4Page~2 -l1 iujntr We beiv thtCBcmuto~ep i s high and~alSo
~~ ~ -2 ~~ Page 4-1~6 j - shy
Please~~ indicates your procedure to cool the omn ashand atwa icagd-eprtr
A Have you~ considered~ additional he~at exchanger topcool th ash and to imrve h cycleef ficiency
-~2~6 Page 4-16 It s~ indicated that ash from each silo i Amixed19 ~with~fabout 20 waterKb weight to minimize generation of dust~during trnprtto to mine and disposalHave you~ coniidered other 4lternativeto
~ ~eliminate dustiiig -and avoid use ofwat r uring it ransportationi such as~ using closed trucks or closed
of ~fans conUMnPo wihrlaintthe total plant auiir poe osupin 1~21- Table 5_-3 and I ~
Th~~ is- somneere c6ntradiction regardingplnneotpu~t in both am tables 21-~ Tabl~e 1-33
We noticed tha~t yourall9 cacacapac t fatro75 tion ae asdnWe thilt ~that 7capacityshyfacto is tobo high for- an oil shale fired plant duketo lack of existing simila~r ~plants handl~~~firing oil adshale ~K
216~ The study iniae thtawet~coigtower wi11~used Actually a b
dry cooling should be consideda5ini ~HTP S inZ atomnmz so water rnumption4the cycle~ efficiency willbe reducedHenre YO33~reconsider calculating the cyclefficiy
U~~~~~ codnt umconsidered ofhorizontal -aretypethe~ the vertical cian type can alsobeh considered
shy ~ ~ ~ I~~
2~2 Kconcrete shy
shjell stepl fltstack is onidereconcrete shell brick flue Rt c ~s beCaconsidered3V
2-19~- Deminiraized water~ tank3 capacity~ is -76 ui(meterThe recommnended tank cameter- ui tyi 00cbc
220Designconditions Pa~ge (4-74)te5 hat bow 3down percentage splusmn ~fomrpra til re i hou I be 3~)~
PoD Z 2 m a ad~ - e 5 1 2 iJS~ ~ p A f amp ~ ~ y1
4
JO R ECTICITY AUTHORTIT 4L
~ 4
Date~
t etats ttthe quantityof s i S ~1 000Tons ra Sthis tuntity 11- be transporited for severIy --to tu ofI pit a~te torg P KM ra~erm Spower plIatS about 12 midilidoni CUIA(- met ryea
h e ndd mp e he (d u p in i n L
area wil evric power plant6t Please zn1 a te~tiv s tudY for dumping th r~ a enoug
-from the power plantr~~h~
S 2- Please provide deald-ifrat ao etbaaiedrawing hwn TH11 R thaU and~pV ra~te takcing illto o 6it v- consumptionn _uig themrining equipment
alternate~ study 0o Jine operation for 1 shiftday Vand twoshifts day -lt
224- Conceptua~l pflR 1 for mi ing anusdtransportation of oil- shale a 0 dmj of hs f u r therV examinedh iV~sdpatI ho u1d be
orderj to poe~ehicalq and~eoomca1 fesblt of t his operation
SYour are requested te) study and consider all- above - iPoin s at your earliest in rder -to be peete y oiAnimain on March 29-301989 peetdb~o 4 n
S9incerly-You S
WDIRECTORGENERAL -
I~ CCMR WLINTON ~vs
5N
Pa D~t~IoAmmn -Jordtn -Tel 815615 20 Bl76 15 -19j A VINO- AFf TY
MARCH 21 RESPONSE TO JEA QUESTIONS
Bechtel Power Corporation Engineers - Constructors
Fifty Beale Street San Francisco California Mail Address P 0 Box 3965 San Franclco CA 94119
March 21 1989
Mr M S Arafah Director General Jordan Electricity Authority PO Box 2310 Amman Jordan
Subject Jordan Oil Shale Prefeasibility Study
Dear Mr Arafah
Your letter of 15 March 1989 with comments on the Oil Shale to Power Prefeasibility Study draft report has been referred to me for reply
The attached responses to each item in the reference letter follows the order submitted
Also attached are three revised pages for the draft report - Volume I
Page 6-1 Page 6-21 Page 6-23
Please copy these revised pages into the report previously sent to you
We plan to review this material with JEA during the March 2930 and April 1 meetings in Amman
rsuVertrul yours
W Linton Project Manager
WHLdc
Attachments Questionnaire Response Three revised pages
cc C J Aulisio R R Buta G D Gould T J Wilbanks
32389
Page 1
RESPONSE TO MARCH 15 1989 QUESTIONAIRE
OIL SHALE TO POWER PREFEASIBILITY STUDY
This study examines economic prospects in terms of a 1995-2000 timeframe
FIRANCIAL AND ECONOMIC COMMENTS
11 It is likely that a BOT deal can be structured at present JEA
generation costs for either 20 MW or 50 MW size units if GOJ is
willing to subsidize the incremental power generation cost
Furthermore these incremental costs can be recovered during the 25
year operation of a Commercial Scale Project
12 A 3rd Party Test was proposed as an alternate means to raising
$100+ for an independent JEA sponsored 20 MW Demonstration
program
13 71 millsKWH for Shale Power
VS
JEA 1987 costs
Purchased Power 17 filsKWH = 51 mills
Produced Power 1360 filsKWH = 41 mills
19952000 Costs - Expected to be 30 to 40 higher and in line
with the cost estimate presented in this study
It also is important to recognize that the busbar cost of power
generated by any new power source can not be compared directly
with the cost of existing older installed capacity because of the
lower capital cost component of the latter (See enclosed Figure
1-1 which demonstrates how total capital carrying costs decline as
the investment is paid off) Any new capacity whether coal oil
or oil shale will be an unreasonable disadvantage compared with
costs for existing older capacity
l
024
o2
0De return
E 016Total carrying charge
012 qu return
S -008
ety taxes and n rcw vshy000 X 0 5 10 15 20 25
Figure 1-1 Year-by-year Carrying Charge Components for 15-yearTax Recovery Period
1-7
30
32389
Page 2
14 Infrastructure Cost
Total People
OperatorFamilies Installed Cost
20 MW $10000000 185700 $54000Operator
50 MW 15000000 3241200 46000Operator
400 MW 45000000 10364000 43000Operator
Factored allowance for grass roots desert installation
including housing and community facilities was developed as
follows for the 50 MW case study
Infrastructure
50 MW
Family Housing 200 30K = $ 6 Million
Bachelor Housing 100 20K = 2 M
HospitalClinic (8 Beds) 11 M
SchoolMosque I1 M
Stores Services amp Recreation = 2 M
Facilities
Roads Electricity Water Sewage = 3 M
$15 Million
Infrastructure costs for the 20 MW and 400 MW cases was ratioed
from this breakdown
At this conceptual level costs are order-of-magnitude In a Phase
II program these infrastructure costs can be developed in detail
32389
Page 3
15 Contract Mining Alternatives
Page 4-11 Mine Operation
Based on Bechtels evaluation of the mine contractors price as found in Section 15 of the Mining Report it was concluded that
the mine contractors price does not include costs for such things
as developing the mine with a box-cut ramp haul roads
developing an area for the waste material maintaining the
haulroads constructing the mine services facilities diversion
ditches sedimentation ponds water well crushing the oil shale
pre-mixing the oil shale at the mine and other items associated
with operating a mine to support a power plant If it is proven
that the mine contractors price includes cost for the above
mentioned scope of work in additi-n to drill blast load and
haul then the contractors price can be used but in the meantime
the all inclusive cost developed by Bechtel should be used
Contract Mining appears to be attractive for the smaller size
plants but not for the larger commercial scale operation Some
third party must provide the necessary capital for trucks
loading mining machines etc under a contract arrangement
16 Reassessment due to Dinar value change needs further study and can
not be evaluated given present budget limitations If average
labor rate of $300hr still valid then little change involve with
study
If deemed necessary reexamination of project economics can be
done in Phase IIwhen funded
17 Costs in this study are based on recent similar Bechtel experience
on Mount Poso project and on Montana I project The Mount Poso
project is a 50 MW unit firing coal in a Pyropower boiler The
Montana I project is a 35 MW unit firing coal in a Keeler Dorr
Oliver FBC boiler utilizing dry cooling
32389
Page 4
18 The Pyropower quote of $186000000 to futnish and erect the steam
generator stack and baghouse has been adjusted to include
engineering construction indirect cost etc to be consistant
with the rest of the costs shown in Table 65 p 6-10 No
further adjustment for location was made
19 Equity funding has the lowest priority of payoff in case of a
liquidation and carries greater risk Hence a higher rate of
return is needed to attract these funds Debt funding is a first
mortgage and has first priority for payoff in case of liquidation
and carries less risk Hence it requires lower rate of return
than equity funding
The risk taking equity owner will ask for greater interest rate
to make funds available The only way to minimize this expense is
to find a loaning agency willing to provide 90 or perhaps 95 of
the investment cost It is likely that banks will require some
minimum equity participation
This Prefeasibility Study was not based on a non-profit utility
operation
Even though JEA is a non-profit organization its service
contributors are profit making groups It is visualized that the
Jordan Oil Shale Co (JOSCO) will be a stand alone business
enterprise servicing JEA under long term contract To secure
funding for the proposed project JOSCO will need attractive
enough contract terms to attract both equity and debt capital
110 Additional work is needed to develop the requested information
This work can be preformed as part of the Phase II program
111 Bechtel includes contingency in all of its estimates to cover
error emissions and unforeseen items within the defined scope of
the project The level of contingency is dependent upon the
amount of scope definition For a prefeasible study such as this
15 contingency is lower than normal
32389
Page 5
112 Tables 89 through 816 include a present value calculation to
establish the relative benefit for a shale project vs coal and
oil
113 The variable maintenance cost of 1 millsKWH has been adjusted for CFB plants with an additional $200000 per year or 06 millsKWH
This yields the following
Variable Maintenance - 10 millsKWH
CFB Adjustment - 06
Fixed Maintenance Cost - 40
Total Cost 56 MillsKWH
114 Page 4-29
The royalty costs are included in the weighted average oil shale
costs for the 50 megawatt plant
Page 4-8
Shale fuel costs include return on equity and royalty These are
two separate cost items Royalty is the last item mentioned in
the sentence and it therefore reads as royalty and not return on
royalty
Page 4-31 gives rates used by Bechtel based on our calculations
using the referenced procedures
DebtEquity Capital Charge Rate
5050 153
8020 139
Table 69 displays the calculation of the 153 capital charge
rate (Line 7 of Table 69 is not used in the calculation and
should be deleted)
32389
Page 6
116 No water purchase charge from the Water Authority was added to the
operating expense based on the statement that no resource costs
will be charged
$020 per 1000 gallons is rule of thumb for USA installations in
absence of client data
Boiler make up water (p4-17) is treated in a demineralizer
train If deemed necessary comparison with reverse osmosis
process can be performed in Phase II
Water requirements were estimated to be
Cubic Metres Per Year
20 MW 50 MW 400 MW
Mine amp Shale Processing 455000 761000 773000
Power Block 3000 6000 42000
Infrastructure 80000 140000 448000
Total 538000 907000 1263000
117 Annual average operating costs shown on Table 6-1 are in error
Financing Option 5050 8020
Cost Shown 56606 48945
Corrected Cost 60396 53236
Average mining and shale processing costs are developed year by
year in the Mining Report Appendix 5 Table 12-10
32389
Page 7
118 We would be interested in receiving the breakdown of these current
power cost figures (ie capital charges fuel cost number of
operators etc) Further economic analysis employing these
figures can be developed in Phase II
119 Manpower requirements for the three case studies were estimated as
fol lows
Mining amp Shale Processing
Power Block
Operations
Maintenance
Management
20 MW 50 MW 400 MW
75 163 396
54 78 175
46 73 455
10 10 10
185 324 1036
Page 14-4 of the Mine Report is for mine and shale processing
only It should be noted that most of these manpower requirements
involved new jobs for Jordanian people
120 At the April 1988 Amman Meeting it was agreed that the following
costs would be omitted
o Permits and Licenses
o Local Taxes
o Import Taxes
If necessary such costs can be developed and added into a revised
economic analysis as part of the Phase II program
121 6 average inflation rate is the figure recommended by Bechtel
based on USA conditions for use in long term economic analyses of
new power ventures
32389
Page 8
122 This matter is referred to ORNL who prepared a rate of return
analysis
Bechtels conclusion is based on computed busbar costscumulative
benefits compared to alternate fuels in the timeframe 1995 to 2000
Relative Busbar Power Cost Net 25 Year
Mills per KWH Benefits - Million US$
Sultani Oil Shale 71-83 Base Cost
Imported Coal
$50tonne 68-88 778
$70tonne 78-107 2531
Imported Oil
$17Bbl 56-76 (18) $24Bbl 61-96 1810
The above results are based on a capacity factor of 75 which is
considered to be a reasonable target for a new plant over its 25 year
life The average selling price of 6 cents per KWH cited in the
questionnaire is based on existing plant costs which may not include
all cost elements of new capacity evaluated in this study
32389
Page 9
TECHNICAL COMMENTS
21 See answer to Item 116
Total power plant raw wate consumption rates and annual
consumptions including the water requirements for wetting ash at the truck loading p int within the power plant are given in Tables 43 and 44 for 50 MW unit and Tables 53 and 54 for 20 MW unit
The raw water requirements for 4x0 MW plant were factored
excepting the mine where a revised mine pldn is employed to reduce water request The quantities shown on these tables exclude raw
water requirements for housing complex mine and ash wetting if
required at the ash disposal site
Total power plant requirements shown in the above referred tables
are
50 MW 20 MW
Rate gpm 207 102 (See Drawing M004)
Annual Use
Gallons 1400000 675000
Cooling tower blowndown supplemented with raw water is used for
wetting ash at the truck loading point within the power plant Raw water quantities attributable for ash wetting at the power
truck loading point are
50 MW 20 MW
Rate gpm 75 325
Annual Use
Gallons 500000 215000
These quantities are included in the quantities shown in
the above referred tables
32389
Page 10
22 We recognize the POTENTIAL for leaching toxic compounds from the
spent ash However this matter is not yet defined well enough to
recommend specific action steps The Prefeasibility Study page
7-12 recommends creation of a ground water dispersion model to
determine whether more specific contaminated water mitigation
plans are needed It is anticipated that the leachate rate will
be low and that aquifer dispersion will keep problem compounds
bel3w health standards thresholds
23 Noted
We have not received up to date resource study material which
defines 50 billion tons resource base Please furnish
The resource base at Sultani alone is adequate to support two 400
MW power projects capacity subject water availability The
2-million cubic metre per year water allowance for oilshale will
limit development to about 600 MW
24 Selection of a combustion temperature is a balance between carbon
combustion efficiency and heat loss due carbonate decomposition
For purposes of the Prefeasibility Study we have opted for high
combustion efficiency At lower efficiency larger shale
mineprocessing plants will be needed
25 Bottom ash is cooled by water exchange before discharge
Cooling water is supplied to the ash screw coolers as specified by
Pyropower See Drawing MOO5 2140 gpm flow for 50 MW and 860 gpm
flow for 20 MW Heat removed by the cooling water from the ash
screw coolers is dissipated to atmosphere via a wet cooling
tower Pyropower should indicate the temperature of the ash
discharged to be 5OOF
32389
Page 11
Initially we had considered using a heat exchanger to cool the ash
and improve the cycle efficiency Considering low cost of fuel
the additional capital costs and the system complexities it was
decided not to employ such heat recovery systems for this project
26 The suggested alternates were looked at briefly and the potential
for wind blown air pollution from the ash disposal areas are too
great to warrant dry disposal unless GO(] and World Bank are
willing to accept such a potential problem Wetting the ash is
tne only practical solution Hopefully some cementation will
occur helping to reduce future leaching potential
27 JEA requirements are noted This is a conceptual study not a
final design Optimal design analysis can be performed during
Phase II
2829
JEA requirements are noted and can be incorporated into the Phase
II design
210 The transformer size is adequate for base load operation A
higher capacity can be considered at the final design stage if the
Client prefers
211 From our experience it does not appear to be economical to
provide additional dry cooling towers to take care of maximum
ambient temperatures which may prevail only for a short period of
time in a year To study this an annual dry bulb temperature
duration curve is required Also adding additional dry cooling
towers will change the plant performance It should also be noted
that the dry cooling towers are very expensive and the size should
be selected carefly considering performance and cost and not on the basis of maximum ambient temperatures This can be studied
during Phase II
32389
Page 12
212 The plant gross output varies with condenser pressure
Condenser
Pressure Design 55 in HgA Annual Ave 35 in HgA
Unit Size MW 20 50 4xlO0 20 50 4xlO0
Gross Output MW 234 593 496 2415 607 TBD
Net Output MW 1975 501 400 205 515 TBD
To be developed in Phase II
Output for 4x100 MW is estimated by others
213 The fan power consumption of the CFB boiler is about 30 to 35 of
the total auxiliary power The fan power consumption of the dry
cooling tower is about 20 to 25 of the total auxiliary power
214 Table 1-1 does not include plant net output Therefore do not
understand the comment
215 Commercial operating experience with coal fueled CFBC units in LISA
and Europe has been uniformly good showing high on stream
availability in early years (See Table 2-6 which reports on
Pyropower experience)
We expect operations with high ash content fuel like oilshale will
have unique scale up problems such as
o Solid handling in and out
o Internal solids circulation
o Erosioncorrosion steam generator intervals
o Heat recovery from bottom ash
Consequently we are recommending these items be worked out in a
single 50 MW prototype
32389
Page 13
216 Maximum dry cooling is used in this study A small wet cooling
tower is used on circulating service water system
217 Horizontal condensate pump is adequate with dry cooling tower and it is cheaper Vertical condensate pumps with cans can be
considered in the final design if required
218 A concrete shell brick lined flue stack will be larger in diameter and costs more than a steel lined stack Brick lined stack can be
considered in the final design
219 Demineralized water tank capacity for 50 MW is 76 cu meters or 20000 gallons not 1000 cu meters For 20 MW plant it is 38 cu
meters or 10000 gallons
220 It is US practice to use an average continuous blowdown rate of
1 and maximum biowdown rate of 3 for this type of plants
221 This can be studied during Phase II
222 Same as 221
223 Same as 221
224 The recommended action plan calls for continuing support studies covering the referenced items Additional effort is needed to
further define these matters and confirm the conceptual plan
The next step is to develop an outline for a project plan including
o Work Scope
o Schedule
o Budget
accommodate the increase in the number of employees and
equipment Truck bays to accommodate the 136 tonne trucks
will be added The truck bays used for the 77 tonne
trucks will be used for the maintenance of other
equipment The warehouse change house training room
offices and cafeteria will be expanded accordingly
6025 Mining and Processing Economics
Details of the oil shale mining and processing plant
economics for the 400 MW plant are included in the Mining
Report (Appendix 5) These details are of the same
magnitude as prepared for the 20 MW and 50 MW plants
The summary of the cash flow analysis for the mine and
shale processing plant is presented in Table 6-1
Table 6-1
SUMMARY OF 400 MW PLANT OIL SHALE MINING AND PROCESSING COSTS
5050 Debt-Equity 8020 Debt-Equity
US $1000 US $1000
Capital Cost
Mine Development 30915 30915
Mine Equipment 66012 66012
Process Plant Facilities 50889 50889
Spare Parts 5000 5000
Working Capital 10000 10000
Capi tal ized Interest
During Construction 24423 39075
TOTAL 187239 201891
Operating Costs and Other Costs
Annual Cost 60386 53236
Product Mined and Processed
Annual Tonnes x 1000 7783 7783
Unit Cost
US $Tonne (weighted average)
US $l06Btu (weighted average) 776
156
684
138
Year 12 costs taken as 25 year average
6-6
-Au
Table 610 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
- FCC plant sizes equivalent to proposed power application
Prefeasibility Study Oil Shale Fueled Power Generation
VOO94GEampJRI26
i
PYROFLOW UNITS IN THE US
COLORADOUTE IOYA STATE UNIV UNIV OFNUCLA CO NORTHERNAMES IA BF GOODRICH110 1o0MW(a) 2x170000 Ibhr HENRYILCEDAR FALLS IA 120000 Ibhr GENERALGULF OILu EiN P MOTORSSbtUpStart-UIL 1987 O A 1I N000 TC
NORT10 PONTIACH B MIRANCHWV00000 lbhr
CORN PRODUCTSSM NORTH-CAROLINA STOCKTOD CA
400000 lbbhl t
RUMF RD ME
CEMENT CO CALIF PORTLAND-COLTON CA
190000 Iblhr Start-Up 1985 TRUMTFTWN NYU
3I75ERTOWN N
etar t-Up loss ACE COGENERATIONCABI
TRONA CA Oper t~on l -Start-UP 1990 ~ rt upz 091Start-up loss Start-up PNeLAI 1991
MTKESFICOENERATIO-N1
BASFIELDp Start-uStar-Up WESTCA9 199otgoUp 1 MAHONEV PA|00000 Ibhr A Oz 2X365000 Ibhr
SETtr-Ups 188B CHAT TANOOGA TN
G ULF OIL EXPLORATION 8ta-rt-u) 1085BAKERSFIELD NORTH BRANCHCA SPRING GROVE PANORTH BRANCH WV 400000 IbhtOperational 19835 5 0 0 I b h 9 0 0 0 Iblh r- tart-Upi 1991 S t r - U p s l e s s
SOUTHEAST PAPER MFG CO UNIVOF NORTH CAROLINArDUBLIN GA UHAPEL HILL NO400000 IbhrStart-Ups logo Start-Ups2X250O000 1loseIbhr B
- Withdrawing ash from combustor - Withdrawing fly ash
a Internal solids circulation of the steam generator
m Erosioncorrosion of steam generatorinternals
Heat recovery from bottom ash
U Operation with low calorific-value fuel
Prefeasblity Study O Shari Fueled Power Generation
VOO7AI 27
Impact of Scale-Up
Project Size
20 MW
50 MW
100 MW
50 MW boiler in 100 MW plant
Potential Risk
Design Scale-upOperation of to 100 MW Initial Plant Plant
Low Significant
Modest Modest
High Low for duplicate units
Modest Low for duplicate units
Prefeasibility Study Oil Shaje Fueled Power Generation
VOO71-4GEAL4n2
i
Conclusions
Defined risk of CFBC boiler is acceptable
U Operating experience with commercial CFBC boilers built and under construction will strengthen confidencelevel and minimize risk for a plant built in 1995
SPrefeasibility Study Oil Shale Fueled Power Generation
V007GHAAE29
ENVIRONMENTAL ASSESSMENT
a Mine and shale processing
- Fugitive dust emissions
- Noise levels
- Leachability of disposal piles
Power plant
- Fugitive dust emissions
- Gaseous emissions
- Noise levels
- Water effluents
U Conclusions
Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel
Prefeasibility Study Oil Shale Fueled Power Generalon
- Coaloil prices will be at least 15 greater after 1995
- Discovery of indigenous conventional fuel resources is inadequate for power plant purposes
Prefeasibility Study
Oil Shale Fueled Power Generation
VOO) IDWFO
Feasibility(Contd)
N Suitable financing will be available
- For $200 million 50 MW prototypeproject
- For $1000 million 400 MW commercial project
Government of Jordan will make basic commitments
- Long-term power purchase agreement
- Long-term access to Sultani shale deposit
Adequate water and manpower resources
- Attractive tax incentives
Prefeasibility Study
Oil Shale Fueled Power Generaion
VO bull1DUJJRO 6
Timeliness
U Timely development of Jordan oil shale needs prompt action to create - Additional definitive information
- Suitable business plan
Prefeasibility Study
Oil Shale Fueled Power Generation
VooI DUJo 7
i
Expansion Conditions
U Continued expansion of powergeneration from oil shale in Jordan depends on water availability
Prospects for power export or importand domestic load growth will affect size of the needed shale-to-power program
Prefeasibility Sudy
Oil Shale Fueled Power Generation
yOWl lVuJO
Environmental Impacts
N Environmental impacts of shale development will be minimal
Prefeasibility Study Oi Shale Fueled Power Generation
i
Development Advantages
Will create significant new jobopportunities in Jordan
Will avoidreduce foreign exchangelosses for expanding alternate fuel imports
Prefeasibility Study
Oil Shale Fueled Power Generation
VOOIIULL tO
Recommended Action Plan
N Basic recommendation
N Conceptual development schedule
U Project development plan
Key plan elements
N Funding requirements
Prefeasibility Study Oil Shale Fueled Power Generation
VOO4II )U OII
i
Basic Recommendation
N Expand efforts to develop an oil shaleshyfueled power generation program at the Sultani deposit
- Conduct required supporting studies
- Define facilities costs and business plans
- Obtain project funding
Prefeasibility Study
Oil Shale Fueled Power Generation
VON I II)ILL 12
C
Conceptual DevelopmentSchedule
1989-1990
- Conduct supporting studies - Define costsbusiness plans for 50
MW prototype and 400 MW commercial projects
- Develop project financing
N 1990-1993 - Build and operate the prototype project
N 1994-1996 - Expand the 50 MW prototype to 100 MW scale
U 1996-2000 - Expand the project to 400 MW scale
N 2000-2005 - Build a second 400 MW commercial project if needed
i 1 Prefeasiblity Study
dOil Shale Fueled Power Generation
VW IMLITO 13
Conceptual Development Plan
Months
1 Project development plan - Define project
costs1busness plans
-24 -12 0 12 24 36 48 60 72 84 96 108 120
2 Secure funding
3 Build and operate 50 MW prototype
Dergn and procurement
Mine development
Plant construction
Startup and testing
Operations
L- -
4 Expand prototype to 100 MW
Design and procurement
bullConstruction
Startup
5 Expand project to 400 MW
2nd 100 MW unit
3rd100 MW unit
i 44
4th 100 MW unit -
O Project dacision point
i Prefeasib~ity Study Oil Shale Fueled Power Generation
17958562aJocdanV 3-14-89 rsO
18
Phase I - ProjectDevelopment Plan
n Program development
Seminar workshop on prefeasibilitystudy Oate project development plan woek scope schedule arid budget
U Carry out project planning program
- Conduct continuing support studies - Test Sultani shale in existing FBC
- Firm up designs and specifications
- Update costs and economic analysis
- Develop business plans and requirements
Explore project funding alternatives
i Prefeasibility Study
Oil Shale Fueled Power Generation
VO MItUOR 14 -0
Key Plan Elements
N Project feasibility analysis
- Firm up designs and equipmentspecifications for all facilities
- Update cost estimates based on preliminary designs and specifications
Explore arrangements for contract mining and mine development
Update forecasts for demand growthand for retirements of older generating capacity
- Create updated economic analysis
Preleasibility StudyO1 Shae Fueled Power Generation
VOO1IOLWRI
Key Plan Elements (Contd)
Business entity requirement
- Explore optionsconditions for a new company to managebuildoperate the project
- Explore optionsconditions for obtaining a concession agreement for Sultani development
Explore optionsconditions for water rights commitment
Prefeasibility Study Oil Shale Fueled Power Generation
VMIOIA)lj 16S
i
Key Plan Elements (Contd)
U Continuing supporting studies
- Combustion tests (additional pilot tests for design and warranty purposes contract for large-scale burn operations in existing plants if appropriate)
- Additional core drilling and core analysis
- Oil shale crushing tests
- Spent ash leaching tests
- Geotechnical data base including soils analysis
- Environmental baseline data
Prefeasibility Study O Shae Fueled Power Generation
VMMMUldMOA
Steps Required to Develop an Oil Shale-to-Power Project
Create a development business plan - Schedule - Decision tree
Develop a work scope and budget for the development plan program including - Firming up designsspecificationscosts
- Developing business entity requirements - Continuing support studies
Carry out development plan program
Assemble all planning results in a report for discussion with financial institutions
Explore project finance opportunities
Finalize business arrangements
Implement prototype project
i Prefeasibility Study
Oil Shale Fueled Power Generation
VM1-11UJROLI
MARCH 15 JEA QUESTIONS (M S ARAFAH) ON PREFEASIBILITY
STUDY DRAFT REPORT
Rt
DIR EScBSULIVAN PHD OFJCEop~BUREAU FOR SCIENCE AND~TECHNOLOGYAGENCY - --FOR INTERNATIONAL DEVELOPMhINTSWASHINGON DC x20523---------4
4 -
-SUBJ E CT - -C O H~ E T 4N l
Dr Mr sullivan ------shy
c-rommnents We ~efr-preaereorPla -tobYou lete dted Jan 91989 regardn~i4po4t P ea e1 f i nd y ubel ow our -e ot r XcOrcerned Jordanian deipartments
- --A ar o~nnYu Y o turjlt~ lt K
4 C~mments
~1 N i gFIN I~fANDECONOMIC1COIMEN S -
It sidicaed that Beohtel and US AIDWash ingtonj~4- re ojy nen ing that E 2hould und ertake the n e tshyihaisAre ~our c leometprogram n order shye-t im~ ate d f n t v design and budget cost
4Al1so Lthe study ncal--ttsutnilndcaei~ A-1 A thas ~ l 1 be eeded idb~~~~~ rn o ei t n i la itheMWa~-~5s~ 4
hrPro hehgemetTh trOfT ses~fnr4 BOT)Vmanu- a n-mnf~cure 4 r~j or contra c4-or ivoIlveiintijn I 4 4investmnt ude smi ~w 2 Zha tev e r --~4~prce e ec r it v p4~ f JA gertiy geeated-at 4 JEA 3 a l b u y ~the same average~~ A
~jithia oncot in4 ordrtan ecpoemic asess thespePower generatjoon J ordan3 oi sha I eroic c inr~etJordan 4
2P ge i1- 1 Aj iit eu that OPin he atocontr~ct 4with owner4 ofext3ing (oconstriiction r(FB rml-t
qu i of S 11 t to test large tonnagen j es StaniUti n d ajIe -for se veralIQf 31 hi
evrEAPreferpilot qr the dP 1prt7n -that the4mPIt
andi to(7 he instalI 1e 2 310 A
_
JODN ELECTRICITYAUTHORIT LL
Dac
operated in Jordan i n or~der~~t ~n nuex~on mnining crushing and haidi igQhre~ and sash Maeia nd aSootoget enough olr ndaita needed for einolre
CEBbole~ -i s~
ccordance with Jordaian oil shale
large to~ bfig
1 3 le 1-2 Page 1-7 Cost Of Pwer~i It i S menti-oned that the conmecial oil hle~ lt~project (4 X1OOmw) 1is ninacompetative roqt~range-~while table 12 indicates thattcost of-pow Ais~mill
q kwiihcii r 1
average wih i ii -much higher ihantheshy-ost of ~Power gnrtofomJEA therimaPower s ta tions Please~ indicate on what basi o ~~ shave-~made your-statement
PK
14 Pae 2 Sction 4-0sIt 1nlkly that theChousing and off- -site infrastructur-ommnity fakilitieR) to be onsidered for both the demo and prototyp prjcs oeoverwe~4 hnk that their~c_6t is raterojects Mo
iwcv~- age -1 1 Mine O(perationIIt is indicate~d that mining cot eevdfoMine contractor~ are ficomiplee h
r and iyudi-t~con qidder contract mnn opio fr4 the min4 cmflt2ng are reIanddrepres~ent the real costs derived from Phspat miin contractors in
lestfor the eo rPooypuat in order tlt7
P I eadenote tha detthe new exchangerate ofthJraian~ Di~nner you may add 20j6 Kto the quoted
1 6 P Ias e consider the followin ecn hage_
171- The new exchange ra teof tUSD=54o0 fils1 72-W2 The new~ aerage tariff for selIn~electricityhas decrreased to 120 8 f ilIsicwh
17- Page 1-7 TbIe 1-2 W bev th tthe cap ita1 cot for the pwhokand forthe min n d ash hMnd1ing equipen
P B~2Anaor a -Tl 8156152 8176 1Q MYf -t -Now 520 t 1U
JDNEECRICIT AU-RA L14lLiL
2 ~are very high We suggest~ thta You rerconsie (- telowerus e~+d accuracy est a rangethan +30
Page4-22 Table 4-5weno0ti ced( that- PyroPowe ha ddeta(IiacCst fori the bo1ilerlocation and terha dutdetlease isxtr fo~ l C~ io~ s~ e~~ 1a~ a if and indicate theonldjusted ~percentagefor construction foin Jordan
19 Page-7 Table 11-2 -Yo aeue ihrinterest rate on Equity thatn on1DehI~laseinclude~ adetaied explanation of thisrr -tni kepin in miUndie JEA is1thaIt a non profit~ shyorgaiztion unik oher private UJSA utility~in ktation
~-~110- Regarding shy
the ra4ital Rt fthe project it is~requesed tobre k it intdo foreignMeanwhile cthe nd lorcal c-osfoeigptario i nt-re3t~shol becnierdo-h
rr n ontiondonnotopdbon the 9 cnieelocal portion~onth
1-1- 237~Pa
oningeny 9tooi s high~~ a lower 4value -should be~
4~ gt ~112- -Tbles t1-1 -8-8~ inclu~de t~he c~alculationscuultie nt enefits for of Th shyunttypes l i4s difeen geeatnmrer likely tocluae
-~ Q~ J7present vk1u for tenet tthe~benefits in feralterntives -t-oa s the
49
ehliyoi shale
Wea gree with you9 tha t th e percentage used ~ an for thenua~l 0 ~amp-M rahr CFBo ndsomewha~t highervrate be n ededma y for a C B l n Me n h l ~ a e r
indir e ta~ts the -estimatedma i variablec st i ddition t he fi-xed-9i 1 mislkih We --
thinktttiis too lowK -5
shy
1-14- e 4-29
opprza tion-o to The o i1s h1 costs-nc I deAbo 1h
Pa10 mman ormTSI62 a
IB I
JORD N EtECTICI1~ 4 E~)~Is-s
Date ib-_
~ ~riii~g~nd~o9~ru~hng h~tnlin cot~u~tv yo
i Dae Jnryit
1ts c 7 4-
i smiig iniand fh co I eY
susendi ca tI t icag th t1 ~an~approximate 15 ~pita L tYII I (-~a~ge or he owe bl ockj f aniitjes isof +the capthe)t~ial7cpi~lrharge Uoratelformny SI~Uj(uiity installa~tions~ whle page 6-1T9 talJshyit is mentioned that~ the Capital rate pe-r JEA isshyi5~PeaseJustify this~matter since~w o
i16- Pae 6-1 6
1 I4~t is mentioned that the costs of 4process Water are ~ 4 ~0 2$1 000 gallons
r~j~lt IHave~You considered additionalvalue ofbying waterfrom~ the Wa ters Aito i ~or ditoa cost~f o revrseoqoesplant if ground water is used
~~ I1 7- Table 6-1 Page 6-6 Please explain how did You come ou ihteoil~ shale miniing and proces~sing uit~Icost
ltII~I~ 8- Please note 1 t hatj the average JEA~productinr ot frmthermal I power stationsr (Istationbus-barCOSt)i sbewen 6 3-17 3 fils 4kwh You may use this~
l4~ 19-i For ~4 X 100~AMW Plat iti etindo pag e14-4 VolI 11 that4 at tota I of W42 14 epoye W II eemplo~yer] And on page 69yo1Iiti mentioned that a~ tot 1 f1 ~p yeI iNbe enp1oyed a
is~ high asrmetitexeds100personorthe ~41X100~MWh~~j nsatnpPrlae
I 1 The 4 following iftemns are a sumed to1 be excluded from theraPi ta 1 cot xoI
120-1 Perits I icen es 7
1_207~3 Imprt ~xe on s7pare par ts -and c(7orfmurab -ma~teria Is
04f4 4
~4 R j4 4
D4
~ ~ ~ AIf eS taxesq in acrac ihteJraand regulations should be considered aw
21- p1ea4s e indic ate Your Ju t f c io r us ga 6
44122- Table 977App 5Page4 9-1 4L IK Car1Yiniae that the hIRR of the 4 Otplantis rather unattractive (66)most
-( Cns1er4 ngthe logical base 4csek c pwhen cii 6OL
average sell~ing prc CkhampDEratio L801~2O~Aoreover4M the ne siellin prcwh o JEA ati theamptime~ Abeing os4ltp n~ot exceed 4 Ckwh~-However Ipage 1shy~ and 14 0 T indicate that ecnms for a commeri
S4A4scale joil 4 shale projc ~
appear Piomisig-nug o4Ywarrant continued dee fgfluht 4 feaibiit 4tudy wihil cost sevea~lili
do ar~sf Plas lear wether the ~x step jqs~$j~~lt 4
gtt 9o be considered arCcording4to jthe 4unattractiveresul to mentioned in IRR7 Table 97 gt4
a C4 44fET2 4 144-4444 P a g 1 T b6 l
htte~We ~ ~ ae~ rqieetfrteX ~ noie ~~ ~ 444 MW un t44 r te4l w w e o p r d i th e w t r n rre u f4m or4444~ the4444 54M4rto y e Pg~A~44EHiveL det ile an l A44
s o awa er c n um t a4r f rofsho in P6Io erT
e ch 2 50 M W aPln wa e d 41004 MW4 1 consumption_____________
ma4~2 k e u p houin~44 p A44 4444444 C O 4ltI4
a nd a sh et in etc 4 2 4 1 -24 P a g e4 2 - 1 A P P 5
4Yo 4_ j1 4 4~h444 N44 44
1gro nd tce t hir fthe w bern coqir mna t efora4e 4X10A M 444444 4 r i n to 4 4 4lo w w ehA 7 n 2 cinCie h rh4 n ttthh1eb -e 4 44t Of3 E4O
ea h n~ ffl 4 4Jl44 4 4444 4giv
6 ig re sofrat4 de in cl ar f w w at5 c hrw pe o
s h b 444 o t h e g nd L 44 h u i n C
r 4ne a4 t44 e L(704 2 4 p ae) 2 - o Au P dn 5ai 7~e r 44 I Y (1t 44a
ve7 rn e qu 1saharvthe y
and n~~~o speci~~~l4 p n l nh i n t x
r ~rA M e d r o t eu n 8 1 wTtl t t h
- c re e N I wo6
~ n n a i n a t d h l7 A PP6 gt
J
S2~3- Page 2-4 ~ ~ It ~is i
that oil eindicated the- sha le r our~ Cesin Jordan are 10 billion tons -The anulp e reere maiy exeed 50 4 billion tons ~
~ 24- 4Page~2 -l1 iujntr We beiv thtCBcmuto~ep i s high and~alSo
~~ ~ -2 ~~ Page 4-1~6 j - shy
Please~~ indicates your procedure to cool the omn ashand atwa icagd-eprtr
A Have you~ considered~ additional he~at exchanger topcool th ash and to imrve h cycleef ficiency
-~2~6 Page 4-16 It s~ indicated that ash from each silo i Amixed19 ~with~fabout 20 waterKb weight to minimize generation of dust~during trnprtto to mine and disposalHave you~ coniidered other 4lternativeto
~ ~eliminate dustiiig -and avoid use ofwat r uring it ransportationi such as~ using closed trucks or closed
of ~fans conUMnPo wihrlaintthe total plant auiir poe osupin 1~21- Table 5_-3 and I ~
Th~~ is- somneere c6ntradiction regardingplnneotpu~t in both am tables 21-~ Tabl~e 1-33
We noticed tha~t yourall9 cacacapac t fatro75 tion ae asdnWe thilt ~that 7capacityshyfacto is tobo high for- an oil shale fired plant duketo lack of existing simila~r ~plants handl~~~firing oil adshale ~K
216~ The study iniae thtawet~coigtower wi11~used Actually a b
dry cooling should be consideda5ini ~HTP S inZ atomnmz so water rnumption4the cycle~ efficiency willbe reducedHenre YO33~reconsider calculating the cyclefficiy
U~~~~~ codnt umconsidered ofhorizontal -aretypethe~ the vertical cian type can alsobeh considered
shy ~ ~ ~ I~~
2~2 Kconcrete shy
shjell stepl fltstack is onidereconcrete shell brick flue Rt c ~s beCaconsidered3V
2-19~- Deminiraized water~ tank3 capacity~ is -76 ui(meterThe recommnended tank cameter- ui tyi 00cbc
220Designconditions Pa~ge (4-74)te5 hat bow 3down percentage splusmn ~fomrpra til re i hou I be 3~)~
PoD Z 2 m a ad~ - e 5 1 2 iJS~ ~ p A f amp ~ ~ y1
4
JO R ECTICITY AUTHORTIT 4L
~ 4
Date~
t etats ttthe quantityof s i S ~1 000Tons ra Sthis tuntity 11- be transporited for severIy --to tu ofI pit a~te torg P KM ra~erm Spower plIatS about 12 midilidoni CUIA(- met ryea
h e ndd mp e he (d u p in i n L
area wil evric power plant6t Please zn1 a te~tiv s tudY for dumping th r~ a enoug
-from the power plantr~~h~
S 2- Please provide deald-ifrat ao etbaaiedrawing hwn TH11 R thaU and~pV ra~te takcing illto o 6it v- consumptionn _uig themrining equipment
alternate~ study 0o Jine operation for 1 shiftday Vand twoshifts day -lt
224- Conceptua~l pflR 1 for mi ing anusdtransportation of oil- shale a 0 dmj of hs f u r therV examinedh iV~sdpatI ho u1d be
orderj to poe~ehicalq and~eoomca1 fesblt of t his operation
SYour are requested te) study and consider all- above - iPoin s at your earliest in rder -to be peete y oiAnimain on March 29-301989 peetdb~o 4 n
S9incerly-You S
WDIRECTORGENERAL -
I~ CCMR WLINTON ~vs
5N
Pa D~t~IoAmmn -Jordtn -Tel 815615 20 Bl76 15 -19j A VINO- AFf TY
MARCH 21 RESPONSE TO JEA QUESTIONS
Bechtel Power Corporation Engineers - Constructors
Fifty Beale Street San Francisco California Mail Address P 0 Box 3965 San Franclco CA 94119
March 21 1989
Mr M S Arafah Director General Jordan Electricity Authority PO Box 2310 Amman Jordan
Subject Jordan Oil Shale Prefeasibility Study
Dear Mr Arafah
Your letter of 15 March 1989 with comments on the Oil Shale to Power Prefeasibility Study draft report has been referred to me for reply
The attached responses to each item in the reference letter follows the order submitted
Also attached are three revised pages for the draft report - Volume I
Page 6-1 Page 6-21 Page 6-23
Please copy these revised pages into the report previously sent to you
We plan to review this material with JEA during the March 2930 and April 1 meetings in Amman
rsuVertrul yours
W Linton Project Manager
WHLdc
Attachments Questionnaire Response Three revised pages
cc C J Aulisio R R Buta G D Gould T J Wilbanks
32389
Page 1
RESPONSE TO MARCH 15 1989 QUESTIONAIRE
OIL SHALE TO POWER PREFEASIBILITY STUDY
This study examines economic prospects in terms of a 1995-2000 timeframe
FIRANCIAL AND ECONOMIC COMMENTS
11 It is likely that a BOT deal can be structured at present JEA
generation costs for either 20 MW or 50 MW size units if GOJ is
willing to subsidize the incremental power generation cost
Furthermore these incremental costs can be recovered during the 25
year operation of a Commercial Scale Project
12 A 3rd Party Test was proposed as an alternate means to raising
$100+ for an independent JEA sponsored 20 MW Demonstration
program
13 71 millsKWH for Shale Power
VS
JEA 1987 costs
Purchased Power 17 filsKWH = 51 mills
Produced Power 1360 filsKWH = 41 mills
19952000 Costs - Expected to be 30 to 40 higher and in line
with the cost estimate presented in this study
It also is important to recognize that the busbar cost of power
generated by any new power source can not be compared directly
with the cost of existing older installed capacity because of the
lower capital cost component of the latter (See enclosed Figure
1-1 which demonstrates how total capital carrying costs decline as
the investment is paid off) Any new capacity whether coal oil
or oil shale will be an unreasonable disadvantage compared with
costs for existing older capacity
l
024
o2
0De return
E 016Total carrying charge
012 qu return
S -008
ety taxes and n rcw vshy000 X 0 5 10 15 20 25
Figure 1-1 Year-by-year Carrying Charge Components for 15-yearTax Recovery Period
1-7
30
32389
Page 2
14 Infrastructure Cost
Total People
OperatorFamilies Installed Cost
20 MW $10000000 185700 $54000Operator
50 MW 15000000 3241200 46000Operator
400 MW 45000000 10364000 43000Operator
Factored allowance for grass roots desert installation
including housing and community facilities was developed as
follows for the 50 MW case study
Infrastructure
50 MW
Family Housing 200 30K = $ 6 Million
Bachelor Housing 100 20K = 2 M
HospitalClinic (8 Beds) 11 M
SchoolMosque I1 M
Stores Services amp Recreation = 2 M
Facilities
Roads Electricity Water Sewage = 3 M
$15 Million
Infrastructure costs for the 20 MW and 400 MW cases was ratioed
from this breakdown
At this conceptual level costs are order-of-magnitude In a Phase
II program these infrastructure costs can be developed in detail
32389
Page 3
15 Contract Mining Alternatives
Page 4-11 Mine Operation
Based on Bechtels evaluation of the mine contractors price as found in Section 15 of the Mining Report it was concluded that
the mine contractors price does not include costs for such things
as developing the mine with a box-cut ramp haul roads
developing an area for the waste material maintaining the
haulroads constructing the mine services facilities diversion
ditches sedimentation ponds water well crushing the oil shale
pre-mixing the oil shale at the mine and other items associated
with operating a mine to support a power plant If it is proven
that the mine contractors price includes cost for the above
mentioned scope of work in additi-n to drill blast load and
haul then the contractors price can be used but in the meantime
the all inclusive cost developed by Bechtel should be used
Contract Mining appears to be attractive for the smaller size
plants but not for the larger commercial scale operation Some
third party must provide the necessary capital for trucks
loading mining machines etc under a contract arrangement
16 Reassessment due to Dinar value change needs further study and can
not be evaluated given present budget limitations If average
labor rate of $300hr still valid then little change involve with
study
If deemed necessary reexamination of project economics can be
done in Phase IIwhen funded
17 Costs in this study are based on recent similar Bechtel experience
on Mount Poso project and on Montana I project The Mount Poso
project is a 50 MW unit firing coal in a Pyropower boiler The
Montana I project is a 35 MW unit firing coal in a Keeler Dorr
Oliver FBC boiler utilizing dry cooling
32389
Page 4
18 The Pyropower quote of $186000000 to futnish and erect the steam
generator stack and baghouse has been adjusted to include
engineering construction indirect cost etc to be consistant
with the rest of the costs shown in Table 65 p 6-10 No
further adjustment for location was made
19 Equity funding has the lowest priority of payoff in case of a
liquidation and carries greater risk Hence a higher rate of
return is needed to attract these funds Debt funding is a first
mortgage and has first priority for payoff in case of liquidation
and carries less risk Hence it requires lower rate of return
than equity funding
The risk taking equity owner will ask for greater interest rate
to make funds available The only way to minimize this expense is
to find a loaning agency willing to provide 90 or perhaps 95 of
the investment cost It is likely that banks will require some
minimum equity participation
This Prefeasibility Study was not based on a non-profit utility
operation
Even though JEA is a non-profit organization its service
contributors are profit making groups It is visualized that the
Jordan Oil Shale Co (JOSCO) will be a stand alone business
enterprise servicing JEA under long term contract To secure
funding for the proposed project JOSCO will need attractive
enough contract terms to attract both equity and debt capital
110 Additional work is needed to develop the requested information
This work can be preformed as part of the Phase II program
111 Bechtel includes contingency in all of its estimates to cover
error emissions and unforeseen items within the defined scope of
the project The level of contingency is dependent upon the
amount of scope definition For a prefeasible study such as this
15 contingency is lower than normal
32389
Page 5
112 Tables 89 through 816 include a present value calculation to
establish the relative benefit for a shale project vs coal and
oil
113 The variable maintenance cost of 1 millsKWH has been adjusted for CFB plants with an additional $200000 per year or 06 millsKWH
This yields the following
Variable Maintenance - 10 millsKWH
CFB Adjustment - 06
Fixed Maintenance Cost - 40
Total Cost 56 MillsKWH
114 Page 4-29
The royalty costs are included in the weighted average oil shale
costs for the 50 megawatt plant
Page 4-8
Shale fuel costs include return on equity and royalty These are
two separate cost items Royalty is the last item mentioned in
the sentence and it therefore reads as royalty and not return on
royalty
Page 4-31 gives rates used by Bechtel based on our calculations
using the referenced procedures
DebtEquity Capital Charge Rate
5050 153
8020 139
Table 69 displays the calculation of the 153 capital charge
rate (Line 7 of Table 69 is not used in the calculation and
should be deleted)
32389
Page 6
116 No water purchase charge from the Water Authority was added to the
operating expense based on the statement that no resource costs
will be charged
$020 per 1000 gallons is rule of thumb for USA installations in
absence of client data
Boiler make up water (p4-17) is treated in a demineralizer
train If deemed necessary comparison with reverse osmosis
process can be performed in Phase II
Water requirements were estimated to be
Cubic Metres Per Year
20 MW 50 MW 400 MW
Mine amp Shale Processing 455000 761000 773000
Power Block 3000 6000 42000
Infrastructure 80000 140000 448000
Total 538000 907000 1263000
117 Annual average operating costs shown on Table 6-1 are in error
Financing Option 5050 8020
Cost Shown 56606 48945
Corrected Cost 60396 53236
Average mining and shale processing costs are developed year by
year in the Mining Report Appendix 5 Table 12-10
32389
Page 7
118 We would be interested in receiving the breakdown of these current
power cost figures (ie capital charges fuel cost number of
operators etc) Further economic analysis employing these
figures can be developed in Phase II
119 Manpower requirements for the three case studies were estimated as
fol lows
Mining amp Shale Processing
Power Block
Operations
Maintenance
Management
20 MW 50 MW 400 MW
75 163 396
54 78 175
46 73 455
10 10 10
185 324 1036
Page 14-4 of the Mine Report is for mine and shale processing
only It should be noted that most of these manpower requirements
involved new jobs for Jordanian people
120 At the April 1988 Amman Meeting it was agreed that the following
costs would be omitted
o Permits and Licenses
o Local Taxes
o Import Taxes
If necessary such costs can be developed and added into a revised
economic analysis as part of the Phase II program
121 6 average inflation rate is the figure recommended by Bechtel
based on USA conditions for use in long term economic analyses of
new power ventures
32389
Page 8
122 This matter is referred to ORNL who prepared a rate of return
analysis
Bechtels conclusion is based on computed busbar costscumulative
benefits compared to alternate fuels in the timeframe 1995 to 2000
Relative Busbar Power Cost Net 25 Year
Mills per KWH Benefits - Million US$
Sultani Oil Shale 71-83 Base Cost
Imported Coal
$50tonne 68-88 778
$70tonne 78-107 2531
Imported Oil
$17Bbl 56-76 (18) $24Bbl 61-96 1810
The above results are based on a capacity factor of 75 which is
considered to be a reasonable target for a new plant over its 25 year
life The average selling price of 6 cents per KWH cited in the
questionnaire is based on existing plant costs which may not include
all cost elements of new capacity evaluated in this study
32389
Page 9
TECHNICAL COMMENTS
21 See answer to Item 116
Total power plant raw wate consumption rates and annual
consumptions including the water requirements for wetting ash at the truck loading p int within the power plant are given in Tables 43 and 44 for 50 MW unit and Tables 53 and 54 for 20 MW unit
The raw water requirements for 4x0 MW plant were factored
excepting the mine where a revised mine pldn is employed to reduce water request The quantities shown on these tables exclude raw
water requirements for housing complex mine and ash wetting if
required at the ash disposal site
Total power plant requirements shown in the above referred tables
are
50 MW 20 MW
Rate gpm 207 102 (See Drawing M004)
Annual Use
Gallons 1400000 675000
Cooling tower blowndown supplemented with raw water is used for
wetting ash at the truck loading point within the power plant Raw water quantities attributable for ash wetting at the power
truck loading point are
50 MW 20 MW
Rate gpm 75 325
Annual Use
Gallons 500000 215000
These quantities are included in the quantities shown in
the above referred tables
32389
Page 10
22 We recognize the POTENTIAL for leaching toxic compounds from the
spent ash However this matter is not yet defined well enough to
recommend specific action steps The Prefeasibility Study page
7-12 recommends creation of a ground water dispersion model to
determine whether more specific contaminated water mitigation
plans are needed It is anticipated that the leachate rate will
be low and that aquifer dispersion will keep problem compounds
bel3w health standards thresholds
23 Noted
We have not received up to date resource study material which
defines 50 billion tons resource base Please furnish
The resource base at Sultani alone is adequate to support two 400
MW power projects capacity subject water availability The
2-million cubic metre per year water allowance for oilshale will
limit development to about 600 MW
24 Selection of a combustion temperature is a balance between carbon
combustion efficiency and heat loss due carbonate decomposition
For purposes of the Prefeasibility Study we have opted for high
combustion efficiency At lower efficiency larger shale
mineprocessing plants will be needed
25 Bottom ash is cooled by water exchange before discharge
Cooling water is supplied to the ash screw coolers as specified by
Pyropower See Drawing MOO5 2140 gpm flow for 50 MW and 860 gpm
flow for 20 MW Heat removed by the cooling water from the ash
screw coolers is dissipated to atmosphere via a wet cooling
tower Pyropower should indicate the temperature of the ash
discharged to be 5OOF
32389
Page 11
Initially we had considered using a heat exchanger to cool the ash
and improve the cycle efficiency Considering low cost of fuel
the additional capital costs and the system complexities it was
decided not to employ such heat recovery systems for this project
26 The suggested alternates were looked at briefly and the potential
for wind blown air pollution from the ash disposal areas are too
great to warrant dry disposal unless GO(] and World Bank are
willing to accept such a potential problem Wetting the ash is
tne only practical solution Hopefully some cementation will
occur helping to reduce future leaching potential
27 JEA requirements are noted This is a conceptual study not a
final design Optimal design analysis can be performed during
Phase II
2829
JEA requirements are noted and can be incorporated into the Phase
II design
210 The transformer size is adequate for base load operation A
higher capacity can be considered at the final design stage if the
Client prefers
211 From our experience it does not appear to be economical to
provide additional dry cooling towers to take care of maximum
ambient temperatures which may prevail only for a short period of
time in a year To study this an annual dry bulb temperature
duration curve is required Also adding additional dry cooling
towers will change the plant performance It should also be noted
that the dry cooling towers are very expensive and the size should
be selected carefly considering performance and cost and not on the basis of maximum ambient temperatures This can be studied
during Phase II
32389
Page 12
212 The plant gross output varies with condenser pressure
Condenser
Pressure Design 55 in HgA Annual Ave 35 in HgA
Unit Size MW 20 50 4xlO0 20 50 4xlO0
Gross Output MW 234 593 496 2415 607 TBD
Net Output MW 1975 501 400 205 515 TBD
To be developed in Phase II
Output for 4x100 MW is estimated by others
213 The fan power consumption of the CFB boiler is about 30 to 35 of
the total auxiliary power The fan power consumption of the dry
cooling tower is about 20 to 25 of the total auxiliary power
214 Table 1-1 does not include plant net output Therefore do not
understand the comment
215 Commercial operating experience with coal fueled CFBC units in LISA
and Europe has been uniformly good showing high on stream
availability in early years (See Table 2-6 which reports on
Pyropower experience)
We expect operations with high ash content fuel like oilshale will
have unique scale up problems such as
o Solid handling in and out
o Internal solids circulation
o Erosioncorrosion steam generator intervals
o Heat recovery from bottom ash
Consequently we are recommending these items be worked out in a
single 50 MW prototype
32389
Page 13
216 Maximum dry cooling is used in this study A small wet cooling
tower is used on circulating service water system
217 Horizontal condensate pump is adequate with dry cooling tower and it is cheaper Vertical condensate pumps with cans can be
considered in the final design if required
218 A concrete shell brick lined flue stack will be larger in diameter and costs more than a steel lined stack Brick lined stack can be
considered in the final design
219 Demineralized water tank capacity for 50 MW is 76 cu meters or 20000 gallons not 1000 cu meters For 20 MW plant it is 38 cu
meters or 10000 gallons
220 It is US practice to use an average continuous blowdown rate of
1 and maximum biowdown rate of 3 for this type of plants
221 This can be studied during Phase II
222 Same as 221
223 Same as 221
224 The recommended action plan calls for continuing support studies covering the referenced items Additional effort is needed to
further define these matters and confirm the conceptual plan
The next step is to develop an outline for a project plan including
o Work Scope
o Schedule
o Budget
accommodate the increase in the number of employees and
equipment Truck bays to accommodate the 136 tonne trucks
will be added The truck bays used for the 77 tonne
trucks will be used for the maintenance of other
equipment The warehouse change house training room
offices and cafeteria will be expanded accordingly
6025 Mining and Processing Economics
Details of the oil shale mining and processing plant
economics for the 400 MW plant are included in the Mining
Report (Appendix 5) These details are of the same
magnitude as prepared for the 20 MW and 50 MW plants
The summary of the cash flow analysis for the mine and
shale processing plant is presented in Table 6-1
Table 6-1
SUMMARY OF 400 MW PLANT OIL SHALE MINING AND PROCESSING COSTS
5050 Debt-Equity 8020 Debt-Equity
US $1000 US $1000
Capital Cost
Mine Development 30915 30915
Mine Equipment 66012 66012
Process Plant Facilities 50889 50889
Spare Parts 5000 5000
Working Capital 10000 10000
Capi tal ized Interest
During Construction 24423 39075
TOTAL 187239 201891
Operating Costs and Other Costs
Annual Cost 60386 53236
Product Mined and Processed
Annual Tonnes x 1000 7783 7783
Unit Cost
US $Tonne (weighted average)
US $l06Btu (weighted average) 776
156
684
138
Year 12 costs taken as 25 year average
6-6
-Au
Table 610 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
- FCC plant sizes equivalent to proposed power application
Prefeasibility Study Oil Shale Fueled Power Generation
VOO94GEampJRI26
i
PYROFLOW UNITS IN THE US
COLORADOUTE IOYA STATE UNIV UNIV OFNUCLA CO NORTHERNAMES IA BF GOODRICH110 1o0MW(a) 2x170000 Ibhr HENRYILCEDAR FALLS IA 120000 Ibhr GENERALGULF OILu EiN P MOTORSSbtUpStart-UIL 1987 O A 1I N000 TC
NORT10 PONTIACH B MIRANCHWV00000 lbhr
CORN PRODUCTSSM NORTH-CAROLINA STOCKTOD CA
400000 lbbhl t
RUMF RD ME
CEMENT CO CALIF PORTLAND-COLTON CA
190000 Iblhr Start-Up 1985 TRUMTFTWN NYU
3I75ERTOWN N
etar t-Up loss ACE COGENERATIONCABI
TRONA CA Oper t~on l -Start-UP 1990 ~ rt upz 091Start-up loss Start-up PNeLAI 1991
MTKESFICOENERATIO-N1
BASFIELDp Start-uStar-Up WESTCA9 199otgoUp 1 MAHONEV PA|00000 Ibhr A Oz 2X365000 Ibhr
SETtr-Ups 188B CHAT TANOOGA TN
G ULF OIL EXPLORATION 8ta-rt-u) 1085BAKERSFIELD NORTH BRANCHCA SPRING GROVE PANORTH BRANCH WV 400000 IbhtOperational 19835 5 0 0 I b h 9 0 0 0 Iblh r- tart-Upi 1991 S t r - U p s l e s s
SOUTHEAST PAPER MFG CO UNIVOF NORTH CAROLINArDUBLIN GA UHAPEL HILL NO400000 IbhrStart-Ups logo Start-Ups2X250O000 1loseIbhr B
- Withdrawing ash from combustor - Withdrawing fly ash
a Internal solids circulation of the steam generator
m Erosioncorrosion of steam generatorinternals
Heat recovery from bottom ash
U Operation with low calorific-value fuel
Prefeasblity Study O Shari Fueled Power Generation
VOO7AI 27
Impact of Scale-Up
Project Size
20 MW
50 MW
100 MW
50 MW boiler in 100 MW plant
Potential Risk
Design Scale-upOperation of to 100 MW Initial Plant Plant
Low Significant
Modest Modest
High Low for duplicate units
Modest Low for duplicate units
Prefeasibility Study Oil Shaje Fueled Power Generation
VOO71-4GEAL4n2
i
Conclusions
Defined risk of CFBC boiler is acceptable
U Operating experience with commercial CFBC boilers built and under construction will strengthen confidencelevel and minimize risk for a plant built in 1995
SPrefeasibility Study Oil Shale Fueled Power Generation
V007GHAAE29
ENVIRONMENTAL ASSESSMENT
a Mine and shale processing
- Fugitive dust emissions
- Noise levels
- Leachability of disposal piles
Power plant
- Fugitive dust emissions
- Gaseous emissions
- Noise levels
- Water effluents
U Conclusions
Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel
Prefeasibility Study Oil Shale Fueled Power Generalon
- Coaloil prices will be at least 15 greater after 1995
- Discovery of indigenous conventional fuel resources is inadequate for power plant purposes
Prefeasibility Study
Oil Shale Fueled Power Generation
VOO) IDWFO
Feasibility(Contd)
N Suitable financing will be available
- For $200 million 50 MW prototypeproject
- For $1000 million 400 MW commercial project
Government of Jordan will make basic commitments
- Long-term power purchase agreement
- Long-term access to Sultani shale deposit
Adequate water and manpower resources
- Attractive tax incentives
Prefeasibility Study
Oil Shale Fueled Power Generaion
VO bull1DUJJRO 6
Timeliness
U Timely development of Jordan oil shale needs prompt action to create - Additional definitive information
- Suitable business plan
Prefeasibility Study
Oil Shale Fueled Power Generation
VooI DUJo 7
i
Expansion Conditions
U Continued expansion of powergeneration from oil shale in Jordan depends on water availability
Prospects for power export or importand domestic load growth will affect size of the needed shale-to-power program
Prefeasibility Sudy
Oil Shale Fueled Power Generation
yOWl lVuJO
Environmental Impacts
N Environmental impacts of shale development will be minimal
Prefeasibility Study Oi Shale Fueled Power Generation
i
Development Advantages
Will create significant new jobopportunities in Jordan
Will avoidreduce foreign exchangelosses for expanding alternate fuel imports
Prefeasibility Study
Oil Shale Fueled Power Generation
VOOIIULL tO
Recommended Action Plan
N Basic recommendation
N Conceptual development schedule
U Project development plan
Key plan elements
N Funding requirements
Prefeasibility Study Oil Shale Fueled Power Generation
VOO4II )U OII
i
Basic Recommendation
N Expand efforts to develop an oil shaleshyfueled power generation program at the Sultani deposit
- Conduct required supporting studies
- Define facilities costs and business plans
- Obtain project funding
Prefeasibility Study
Oil Shale Fueled Power Generation
VON I II)ILL 12
C
Conceptual DevelopmentSchedule
1989-1990
- Conduct supporting studies - Define costsbusiness plans for 50
MW prototype and 400 MW commercial projects
- Develop project financing
N 1990-1993 - Build and operate the prototype project
N 1994-1996 - Expand the 50 MW prototype to 100 MW scale
U 1996-2000 - Expand the project to 400 MW scale
N 2000-2005 - Build a second 400 MW commercial project if needed
i 1 Prefeasiblity Study
dOil Shale Fueled Power Generation
VW IMLITO 13
Conceptual Development Plan
Months
1 Project development plan - Define project
costs1busness plans
-24 -12 0 12 24 36 48 60 72 84 96 108 120
2 Secure funding
3 Build and operate 50 MW prototype
Dergn and procurement
Mine development
Plant construction
Startup and testing
Operations
L- -
4 Expand prototype to 100 MW
Design and procurement
bullConstruction
Startup
5 Expand project to 400 MW
2nd 100 MW unit
3rd100 MW unit
i 44
4th 100 MW unit -
O Project dacision point
i Prefeasib~ity Study Oil Shale Fueled Power Generation
17958562aJocdanV 3-14-89 rsO
18
Phase I - ProjectDevelopment Plan
n Program development
Seminar workshop on prefeasibilitystudy Oate project development plan woek scope schedule arid budget
U Carry out project planning program
- Conduct continuing support studies - Test Sultani shale in existing FBC
- Firm up designs and specifications
- Update costs and economic analysis
- Develop business plans and requirements
Explore project funding alternatives
i Prefeasibility Study
Oil Shale Fueled Power Generation
VO MItUOR 14 -0
Key Plan Elements
N Project feasibility analysis
- Firm up designs and equipmentspecifications for all facilities
- Update cost estimates based on preliminary designs and specifications
Explore arrangements for contract mining and mine development
Update forecasts for demand growthand for retirements of older generating capacity
- Create updated economic analysis
Preleasibility StudyO1 Shae Fueled Power Generation
VOO1IOLWRI
Key Plan Elements (Contd)
Business entity requirement
- Explore optionsconditions for a new company to managebuildoperate the project
- Explore optionsconditions for obtaining a concession agreement for Sultani development
Explore optionsconditions for water rights commitment
Prefeasibility Study Oil Shale Fueled Power Generation
VMIOIA)lj 16S
i
Key Plan Elements (Contd)
U Continuing supporting studies
- Combustion tests (additional pilot tests for design and warranty purposes contract for large-scale burn operations in existing plants if appropriate)
- Additional core drilling and core analysis
- Oil shale crushing tests
- Spent ash leaching tests
- Geotechnical data base including soils analysis
- Environmental baseline data
Prefeasibility Study O Shae Fueled Power Generation
VMMMUldMOA
Steps Required to Develop an Oil Shale-to-Power Project
Create a development business plan - Schedule - Decision tree
Develop a work scope and budget for the development plan program including - Firming up designsspecificationscosts
- Developing business entity requirements - Continuing support studies
Carry out development plan program
Assemble all planning results in a report for discussion with financial institutions
Explore project finance opportunities
Finalize business arrangements
Implement prototype project
i Prefeasibility Study
Oil Shale Fueled Power Generation
VM1-11UJROLI
MARCH 15 JEA QUESTIONS (M S ARAFAH) ON PREFEASIBILITY
STUDY DRAFT REPORT
Rt
DIR EScBSULIVAN PHD OFJCEop~BUREAU FOR SCIENCE AND~TECHNOLOGYAGENCY - --FOR INTERNATIONAL DEVELOPMhINTSWASHINGON DC x20523---------4
4 -
-SUBJ E CT - -C O H~ E T 4N l
Dr Mr sullivan ------shy
c-rommnents We ~efr-preaereorPla -tobYou lete dted Jan 91989 regardn~i4po4t P ea e1 f i nd y ubel ow our -e ot r XcOrcerned Jordanian deipartments
- --A ar o~nnYu Y o turjlt~ lt K
4 C~mments
~1 N i gFIN I~fANDECONOMIC1COIMEN S -
It sidicaed that Beohtel and US AIDWash ingtonj~4- re ojy nen ing that E 2hould und ertake the n e tshyihaisAre ~our c leometprogram n order shye-t im~ ate d f n t v design and budget cost
4Al1so Lthe study ncal--ttsutnilndcaei~ A-1 A thas ~ l 1 be eeded idb~~~~~ rn o ei t n i la itheMWa~-~5s~ 4
hrPro hehgemetTh trOfT ses~fnr4 BOT)Vmanu- a n-mnf~cure 4 r~j or contra c4-or ivoIlveiintijn I 4 4investmnt ude smi ~w 2 Zha tev e r --~4~prce e ec r it v p4~ f JA gertiy geeated-at 4 JEA 3 a l b u y ~the same average~~ A
~jithia oncot in4 ordrtan ecpoemic asess thespePower generatjoon J ordan3 oi sha I eroic c inr~etJordan 4
2P ge i1- 1 Aj iit eu that OPin he atocontr~ct 4with owner4 ofext3ing (oconstriiction r(FB rml-t
qu i of S 11 t to test large tonnagen j es StaniUti n d ajIe -for se veralIQf 31 hi
evrEAPreferpilot qr the dP 1prt7n -that the4mPIt
andi to(7 he instalI 1e 2 310 A
_
JODN ELECTRICITYAUTHORIT LL
Dac
operated in Jordan i n or~der~~t ~n nuex~on mnining crushing and haidi igQhre~ and sash Maeia nd aSootoget enough olr ndaita needed for einolre
CEBbole~ -i s~
ccordance with Jordaian oil shale
large to~ bfig
1 3 le 1-2 Page 1-7 Cost Of Pwer~i It i S menti-oned that the conmecial oil hle~ lt~project (4 X1OOmw) 1is ninacompetative roqt~range-~while table 12 indicates thattcost of-pow Ais~mill
q kwiihcii r 1
average wih i ii -much higher ihantheshy-ost of ~Power gnrtofomJEA therimaPower s ta tions Please~ indicate on what basi o ~~ shave-~made your-statement
PK
14 Pae 2 Sction 4-0sIt 1nlkly that theChousing and off- -site infrastructur-ommnity fakilitieR) to be onsidered for both the demo and prototyp prjcs oeoverwe~4 hnk that their~c_6t is raterojects Mo
iwcv~- age -1 1 Mine O(perationIIt is indicate~d that mining cot eevdfoMine contractor~ are ficomiplee h
r and iyudi-t~con qidder contract mnn opio fr4 the min4 cmflt2ng are reIanddrepres~ent the real costs derived from Phspat miin contractors in
lestfor the eo rPooypuat in order tlt7
P I eadenote tha detthe new exchangerate ofthJraian~ Di~nner you may add 20j6 Kto the quoted
1 6 P Ias e consider the followin ecn hage_
171- The new exchange ra teof tUSD=54o0 fils1 72-W2 The new~ aerage tariff for selIn~electricityhas decrreased to 120 8 f ilIsicwh
17- Page 1-7 TbIe 1-2 W bev th tthe cap ita1 cot for the pwhokand forthe min n d ash hMnd1ing equipen
P B~2Anaor a -Tl 8156152 8176 1Q MYf -t -Now 520 t 1U
JDNEECRICIT AU-RA L14lLiL
2 ~are very high We suggest~ thta You rerconsie (- telowerus e~+d accuracy est a rangethan +30
Page4-22 Table 4-5weno0ti ced( that- PyroPowe ha ddeta(IiacCst fori the bo1ilerlocation and terha dutdetlease isxtr fo~ l C~ io~ s~ e~~ 1a~ a if and indicate theonldjusted ~percentagefor construction foin Jordan
19 Page-7 Table 11-2 -Yo aeue ihrinterest rate on Equity thatn on1DehI~laseinclude~ adetaied explanation of thisrr -tni kepin in miUndie JEA is1thaIt a non profit~ shyorgaiztion unik oher private UJSA utility~in ktation
~-~110- Regarding shy
the ra4ital Rt fthe project it is~requesed tobre k it intdo foreignMeanwhile cthe nd lorcal c-osfoeigptario i nt-re3t~shol becnierdo-h
rr n ontiondonnotopdbon the 9 cnieelocal portion~onth
1-1- 237~Pa
oningeny 9tooi s high~~ a lower 4value -should be~
4~ gt ~112- -Tbles t1-1 -8-8~ inclu~de t~he c~alculationscuultie nt enefits for of Th shyunttypes l i4s difeen geeatnmrer likely tocluae
-~ Q~ J7present vk1u for tenet tthe~benefits in feralterntives -t-oa s the
49
ehliyoi shale
Wea gree with you9 tha t th e percentage used ~ an for thenua~l 0 ~amp-M rahr CFBo ndsomewha~t highervrate be n ededma y for a C B l n Me n h l ~ a e r
indir e ta~ts the -estimatedma i variablec st i ddition t he fi-xed-9i 1 mislkih We --
thinktttiis too lowK -5
shy
1-14- e 4-29
opprza tion-o to The o i1s h1 costs-nc I deAbo 1h
Pa10 mman ormTSI62 a
IB I
JORD N EtECTICI1~ 4 E~)~Is-s
Date ib-_
~ ~riii~g~nd~o9~ru~hng h~tnlin cot~u~tv yo
i Dae Jnryit
1ts c 7 4-
i smiig iniand fh co I eY
susendi ca tI t icag th t1 ~an~approximate 15 ~pita L tYII I (-~a~ge or he owe bl ockj f aniitjes isof +the capthe)t~ial7cpi~lrharge Uoratelformny SI~Uj(uiity installa~tions~ whle page 6-1T9 talJshyit is mentioned that~ the Capital rate pe-r JEA isshyi5~PeaseJustify this~matter since~w o
i16- Pae 6-1 6
1 I4~t is mentioned that the costs of 4process Water are ~ 4 ~0 2$1 000 gallons
r~j~lt IHave~You considered additionalvalue ofbying waterfrom~ the Wa ters Aito i ~or ditoa cost~f o revrseoqoesplant if ground water is used
~~ I1 7- Table 6-1 Page 6-6 Please explain how did You come ou ihteoil~ shale miniing and proces~sing uit~Icost
ltII~I~ 8- Please note 1 t hatj the average JEA~productinr ot frmthermal I power stationsr (Istationbus-barCOSt)i sbewen 6 3-17 3 fils 4kwh You may use this~
l4~ 19-i For ~4 X 100~AMW Plat iti etindo pag e14-4 VolI 11 that4 at tota I of W42 14 epoye W II eemplo~yer] And on page 69yo1Iiti mentioned that a~ tot 1 f1 ~p yeI iNbe enp1oyed a
is~ high asrmetitexeds100personorthe ~41X100~MWh~~j nsatnpPrlae
I 1 The 4 following iftemns are a sumed to1 be excluded from theraPi ta 1 cot xoI
120-1 Perits I icen es 7
1_207~3 Imprt ~xe on s7pare par ts -and c(7orfmurab -ma~teria Is
04f4 4
~4 R j4 4
D4
~ ~ ~ AIf eS taxesq in acrac ihteJraand regulations should be considered aw
21- p1ea4s e indic ate Your Ju t f c io r us ga 6
44122- Table 977App 5Page4 9-1 4L IK Car1Yiniae that the hIRR of the 4 Otplantis rather unattractive (66)most
-( Cns1er4 ngthe logical base 4csek c pwhen cii 6OL
average sell~ing prc CkhampDEratio L801~2O~Aoreover4M the ne siellin prcwh o JEA ati theamptime~ Abeing os4ltp n~ot exceed 4 Ckwh~-However Ipage 1shy~ and 14 0 T indicate that ecnms for a commeri
S4A4scale joil 4 shale projc ~
appear Piomisig-nug o4Ywarrant continued dee fgfluht 4 feaibiit 4tudy wihil cost sevea~lili
do ar~sf Plas lear wether the ~x step jqs~$j~~lt 4
gtt 9o be considered arCcording4to jthe 4unattractiveresul to mentioned in IRR7 Table 97 gt4
a C4 44fET2 4 144-4444 P a g 1 T b6 l
htte~We ~ ~ ae~ rqieetfrteX ~ noie ~~ ~ 444 MW un t44 r te4l w w e o p r d i th e w t r n rre u f4m or4444~ the4444 54M4rto y e Pg~A~44EHiveL det ile an l A44
s o awa er c n um t a4r f rofsho in P6Io erT
e ch 2 50 M W aPln wa e d 41004 MW4 1 consumption_____________
ma4~2 k e u p houin~44 p A44 4444444 C O 4ltI4
a nd a sh et in etc 4 2 4 1 -24 P a g e4 2 - 1 A P P 5
4Yo 4_ j1 4 4~h444 N44 44
1gro nd tce t hir fthe w bern coqir mna t efora4e 4X10A M 444444 4 r i n to 4 4 4lo w w ehA 7 n 2 cinCie h rh4 n ttthh1eb -e 4 44t Of3 E4O
ea h n~ ffl 4 4Jl44 4 4444 4giv
6 ig re sofrat4 de in cl ar f w w at5 c hrw pe o
s h b 444 o t h e g nd L 44 h u i n C
r 4ne a4 t44 e L(704 2 4 p ae) 2 - o Au P dn 5ai 7~e r 44 I Y (1t 44a
ve7 rn e qu 1saharvthe y
and n~~~o speci~~~l4 p n l nh i n t x
r ~rA M e d r o t eu n 8 1 wTtl t t h
- c re e N I wo6
~ n n a i n a t d h l7 A PP6 gt
J
S2~3- Page 2-4 ~ ~ It ~is i
that oil eindicated the- sha le r our~ Cesin Jordan are 10 billion tons -The anulp e reere maiy exeed 50 4 billion tons ~
~ 24- 4Page~2 -l1 iujntr We beiv thtCBcmuto~ep i s high and~alSo
~~ ~ -2 ~~ Page 4-1~6 j - shy
Please~~ indicates your procedure to cool the omn ashand atwa icagd-eprtr
A Have you~ considered~ additional he~at exchanger topcool th ash and to imrve h cycleef ficiency
-~2~6 Page 4-16 It s~ indicated that ash from each silo i Amixed19 ~with~fabout 20 waterKb weight to minimize generation of dust~during trnprtto to mine and disposalHave you~ coniidered other 4lternativeto
~ ~eliminate dustiiig -and avoid use ofwat r uring it ransportationi such as~ using closed trucks or closed
of ~fans conUMnPo wihrlaintthe total plant auiir poe osupin 1~21- Table 5_-3 and I ~
Th~~ is- somneere c6ntradiction regardingplnneotpu~t in both am tables 21-~ Tabl~e 1-33
We noticed tha~t yourall9 cacacapac t fatro75 tion ae asdnWe thilt ~that 7capacityshyfacto is tobo high for- an oil shale fired plant duketo lack of existing simila~r ~plants handl~~~firing oil adshale ~K
216~ The study iniae thtawet~coigtower wi11~used Actually a b
dry cooling should be consideda5ini ~HTP S inZ atomnmz so water rnumption4the cycle~ efficiency willbe reducedHenre YO33~reconsider calculating the cyclefficiy
U~~~~~ codnt umconsidered ofhorizontal -aretypethe~ the vertical cian type can alsobeh considered
shy ~ ~ ~ I~~
2~2 Kconcrete shy
shjell stepl fltstack is onidereconcrete shell brick flue Rt c ~s beCaconsidered3V
2-19~- Deminiraized water~ tank3 capacity~ is -76 ui(meterThe recommnended tank cameter- ui tyi 00cbc
220Designconditions Pa~ge (4-74)te5 hat bow 3down percentage splusmn ~fomrpra til re i hou I be 3~)~
PoD Z 2 m a ad~ - e 5 1 2 iJS~ ~ p A f amp ~ ~ y1
4
JO R ECTICITY AUTHORTIT 4L
~ 4
Date~
t etats ttthe quantityof s i S ~1 000Tons ra Sthis tuntity 11- be transporited for severIy --to tu ofI pit a~te torg P KM ra~erm Spower plIatS about 12 midilidoni CUIA(- met ryea
h e ndd mp e he (d u p in i n L
area wil evric power plant6t Please zn1 a te~tiv s tudY for dumping th r~ a enoug
-from the power plantr~~h~
S 2- Please provide deald-ifrat ao etbaaiedrawing hwn TH11 R thaU and~pV ra~te takcing illto o 6it v- consumptionn _uig themrining equipment
alternate~ study 0o Jine operation for 1 shiftday Vand twoshifts day -lt
224- Conceptua~l pflR 1 for mi ing anusdtransportation of oil- shale a 0 dmj of hs f u r therV examinedh iV~sdpatI ho u1d be
orderj to poe~ehicalq and~eoomca1 fesblt of t his operation
SYour are requested te) study and consider all- above - iPoin s at your earliest in rder -to be peete y oiAnimain on March 29-301989 peetdb~o 4 n
S9incerly-You S
WDIRECTORGENERAL -
I~ CCMR WLINTON ~vs
5N
Pa D~t~IoAmmn -Jordtn -Tel 815615 20 Bl76 15 -19j A VINO- AFf TY
MARCH 21 RESPONSE TO JEA QUESTIONS
Bechtel Power Corporation Engineers - Constructors
Fifty Beale Street San Francisco California Mail Address P 0 Box 3965 San Franclco CA 94119
March 21 1989
Mr M S Arafah Director General Jordan Electricity Authority PO Box 2310 Amman Jordan
Subject Jordan Oil Shale Prefeasibility Study
Dear Mr Arafah
Your letter of 15 March 1989 with comments on the Oil Shale to Power Prefeasibility Study draft report has been referred to me for reply
The attached responses to each item in the reference letter follows the order submitted
Also attached are three revised pages for the draft report - Volume I
Page 6-1 Page 6-21 Page 6-23
Please copy these revised pages into the report previously sent to you
We plan to review this material with JEA during the March 2930 and April 1 meetings in Amman
rsuVertrul yours
W Linton Project Manager
WHLdc
Attachments Questionnaire Response Three revised pages
cc C J Aulisio R R Buta G D Gould T J Wilbanks
32389
Page 1
RESPONSE TO MARCH 15 1989 QUESTIONAIRE
OIL SHALE TO POWER PREFEASIBILITY STUDY
This study examines economic prospects in terms of a 1995-2000 timeframe
FIRANCIAL AND ECONOMIC COMMENTS
11 It is likely that a BOT deal can be structured at present JEA
generation costs for either 20 MW or 50 MW size units if GOJ is
willing to subsidize the incremental power generation cost
Furthermore these incremental costs can be recovered during the 25
year operation of a Commercial Scale Project
12 A 3rd Party Test was proposed as an alternate means to raising
$100+ for an independent JEA sponsored 20 MW Demonstration
program
13 71 millsKWH for Shale Power
VS
JEA 1987 costs
Purchased Power 17 filsKWH = 51 mills
Produced Power 1360 filsKWH = 41 mills
19952000 Costs - Expected to be 30 to 40 higher and in line
with the cost estimate presented in this study
It also is important to recognize that the busbar cost of power
generated by any new power source can not be compared directly
with the cost of existing older installed capacity because of the
lower capital cost component of the latter (See enclosed Figure
1-1 which demonstrates how total capital carrying costs decline as
the investment is paid off) Any new capacity whether coal oil
or oil shale will be an unreasonable disadvantage compared with
costs for existing older capacity
l
024
o2
0De return
E 016Total carrying charge
012 qu return
S -008
ety taxes and n rcw vshy000 X 0 5 10 15 20 25
Figure 1-1 Year-by-year Carrying Charge Components for 15-yearTax Recovery Period
1-7
30
32389
Page 2
14 Infrastructure Cost
Total People
OperatorFamilies Installed Cost
20 MW $10000000 185700 $54000Operator
50 MW 15000000 3241200 46000Operator
400 MW 45000000 10364000 43000Operator
Factored allowance for grass roots desert installation
including housing and community facilities was developed as
follows for the 50 MW case study
Infrastructure
50 MW
Family Housing 200 30K = $ 6 Million
Bachelor Housing 100 20K = 2 M
HospitalClinic (8 Beds) 11 M
SchoolMosque I1 M
Stores Services amp Recreation = 2 M
Facilities
Roads Electricity Water Sewage = 3 M
$15 Million
Infrastructure costs for the 20 MW and 400 MW cases was ratioed
from this breakdown
At this conceptual level costs are order-of-magnitude In a Phase
II program these infrastructure costs can be developed in detail
32389
Page 3
15 Contract Mining Alternatives
Page 4-11 Mine Operation
Based on Bechtels evaluation of the mine contractors price as found in Section 15 of the Mining Report it was concluded that
the mine contractors price does not include costs for such things
as developing the mine with a box-cut ramp haul roads
developing an area for the waste material maintaining the
haulroads constructing the mine services facilities diversion
ditches sedimentation ponds water well crushing the oil shale
pre-mixing the oil shale at the mine and other items associated
with operating a mine to support a power plant If it is proven
that the mine contractors price includes cost for the above
mentioned scope of work in additi-n to drill blast load and
haul then the contractors price can be used but in the meantime
the all inclusive cost developed by Bechtel should be used
Contract Mining appears to be attractive for the smaller size
plants but not for the larger commercial scale operation Some
third party must provide the necessary capital for trucks
loading mining machines etc under a contract arrangement
16 Reassessment due to Dinar value change needs further study and can
not be evaluated given present budget limitations If average
labor rate of $300hr still valid then little change involve with
study
If deemed necessary reexamination of project economics can be
done in Phase IIwhen funded
17 Costs in this study are based on recent similar Bechtel experience
on Mount Poso project and on Montana I project The Mount Poso
project is a 50 MW unit firing coal in a Pyropower boiler The
Montana I project is a 35 MW unit firing coal in a Keeler Dorr
Oliver FBC boiler utilizing dry cooling
32389
Page 4
18 The Pyropower quote of $186000000 to futnish and erect the steam
generator stack and baghouse has been adjusted to include
engineering construction indirect cost etc to be consistant
with the rest of the costs shown in Table 65 p 6-10 No
further adjustment for location was made
19 Equity funding has the lowest priority of payoff in case of a
liquidation and carries greater risk Hence a higher rate of
return is needed to attract these funds Debt funding is a first
mortgage and has first priority for payoff in case of liquidation
and carries less risk Hence it requires lower rate of return
than equity funding
The risk taking equity owner will ask for greater interest rate
to make funds available The only way to minimize this expense is
to find a loaning agency willing to provide 90 or perhaps 95 of
the investment cost It is likely that banks will require some
minimum equity participation
This Prefeasibility Study was not based on a non-profit utility
operation
Even though JEA is a non-profit organization its service
contributors are profit making groups It is visualized that the
Jordan Oil Shale Co (JOSCO) will be a stand alone business
enterprise servicing JEA under long term contract To secure
funding for the proposed project JOSCO will need attractive
enough contract terms to attract both equity and debt capital
110 Additional work is needed to develop the requested information
This work can be preformed as part of the Phase II program
111 Bechtel includes contingency in all of its estimates to cover
error emissions and unforeseen items within the defined scope of
the project The level of contingency is dependent upon the
amount of scope definition For a prefeasible study such as this
15 contingency is lower than normal
32389
Page 5
112 Tables 89 through 816 include a present value calculation to
establish the relative benefit for a shale project vs coal and
oil
113 The variable maintenance cost of 1 millsKWH has been adjusted for CFB plants with an additional $200000 per year or 06 millsKWH
This yields the following
Variable Maintenance - 10 millsKWH
CFB Adjustment - 06
Fixed Maintenance Cost - 40
Total Cost 56 MillsKWH
114 Page 4-29
The royalty costs are included in the weighted average oil shale
costs for the 50 megawatt plant
Page 4-8
Shale fuel costs include return on equity and royalty These are
two separate cost items Royalty is the last item mentioned in
the sentence and it therefore reads as royalty and not return on
royalty
Page 4-31 gives rates used by Bechtel based on our calculations
using the referenced procedures
DebtEquity Capital Charge Rate
5050 153
8020 139
Table 69 displays the calculation of the 153 capital charge
rate (Line 7 of Table 69 is not used in the calculation and
should be deleted)
32389
Page 6
116 No water purchase charge from the Water Authority was added to the
operating expense based on the statement that no resource costs
will be charged
$020 per 1000 gallons is rule of thumb for USA installations in
absence of client data
Boiler make up water (p4-17) is treated in a demineralizer
train If deemed necessary comparison with reverse osmosis
process can be performed in Phase II
Water requirements were estimated to be
Cubic Metres Per Year
20 MW 50 MW 400 MW
Mine amp Shale Processing 455000 761000 773000
Power Block 3000 6000 42000
Infrastructure 80000 140000 448000
Total 538000 907000 1263000
117 Annual average operating costs shown on Table 6-1 are in error
Financing Option 5050 8020
Cost Shown 56606 48945
Corrected Cost 60396 53236
Average mining and shale processing costs are developed year by
year in the Mining Report Appendix 5 Table 12-10
32389
Page 7
118 We would be interested in receiving the breakdown of these current
power cost figures (ie capital charges fuel cost number of
operators etc) Further economic analysis employing these
figures can be developed in Phase II
119 Manpower requirements for the three case studies were estimated as
fol lows
Mining amp Shale Processing
Power Block
Operations
Maintenance
Management
20 MW 50 MW 400 MW
75 163 396
54 78 175
46 73 455
10 10 10
185 324 1036
Page 14-4 of the Mine Report is for mine and shale processing
only It should be noted that most of these manpower requirements
involved new jobs for Jordanian people
120 At the April 1988 Amman Meeting it was agreed that the following
costs would be omitted
o Permits and Licenses
o Local Taxes
o Import Taxes
If necessary such costs can be developed and added into a revised
economic analysis as part of the Phase II program
121 6 average inflation rate is the figure recommended by Bechtel
based on USA conditions for use in long term economic analyses of
new power ventures
32389
Page 8
122 This matter is referred to ORNL who prepared a rate of return
analysis
Bechtels conclusion is based on computed busbar costscumulative
benefits compared to alternate fuels in the timeframe 1995 to 2000
Relative Busbar Power Cost Net 25 Year
Mills per KWH Benefits - Million US$
Sultani Oil Shale 71-83 Base Cost
Imported Coal
$50tonne 68-88 778
$70tonne 78-107 2531
Imported Oil
$17Bbl 56-76 (18) $24Bbl 61-96 1810
The above results are based on a capacity factor of 75 which is
considered to be a reasonable target for a new plant over its 25 year
life The average selling price of 6 cents per KWH cited in the
questionnaire is based on existing plant costs which may not include
all cost elements of new capacity evaluated in this study
32389
Page 9
TECHNICAL COMMENTS
21 See answer to Item 116
Total power plant raw wate consumption rates and annual
consumptions including the water requirements for wetting ash at the truck loading p int within the power plant are given in Tables 43 and 44 for 50 MW unit and Tables 53 and 54 for 20 MW unit
The raw water requirements for 4x0 MW plant were factored
excepting the mine where a revised mine pldn is employed to reduce water request The quantities shown on these tables exclude raw
water requirements for housing complex mine and ash wetting if
required at the ash disposal site
Total power plant requirements shown in the above referred tables
are
50 MW 20 MW
Rate gpm 207 102 (See Drawing M004)
Annual Use
Gallons 1400000 675000
Cooling tower blowndown supplemented with raw water is used for
wetting ash at the truck loading point within the power plant Raw water quantities attributable for ash wetting at the power
truck loading point are
50 MW 20 MW
Rate gpm 75 325
Annual Use
Gallons 500000 215000
These quantities are included in the quantities shown in
the above referred tables
32389
Page 10
22 We recognize the POTENTIAL for leaching toxic compounds from the
spent ash However this matter is not yet defined well enough to
recommend specific action steps The Prefeasibility Study page
7-12 recommends creation of a ground water dispersion model to
determine whether more specific contaminated water mitigation
plans are needed It is anticipated that the leachate rate will
be low and that aquifer dispersion will keep problem compounds
bel3w health standards thresholds
23 Noted
We have not received up to date resource study material which
defines 50 billion tons resource base Please furnish
The resource base at Sultani alone is adequate to support two 400
MW power projects capacity subject water availability The
2-million cubic metre per year water allowance for oilshale will
limit development to about 600 MW
24 Selection of a combustion temperature is a balance between carbon
combustion efficiency and heat loss due carbonate decomposition
For purposes of the Prefeasibility Study we have opted for high
combustion efficiency At lower efficiency larger shale
mineprocessing plants will be needed
25 Bottom ash is cooled by water exchange before discharge
Cooling water is supplied to the ash screw coolers as specified by
Pyropower See Drawing MOO5 2140 gpm flow for 50 MW and 860 gpm
flow for 20 MW Heat removed by the cooling water from the ash
screw coolers is dissipated to atmosphere via a wet cooling
tower Pyropower should indicate the temperature of the ash
discharged to be 5OOF
32389
Page 11
Initially we had considered using a heat exchanger to cool the ash
and improve the cycle efficiency Considering low cost of fuel
the additional capital costs and the system complexities it was
decided not to employ such heat recovery systems for this project
26 The suggested alternates were looked at briefly and the potential
for wind blown air pollution from the ash disposal areas are too
great to warrant dry disposal unless GO(] and World Bank are
willing to accept such a potential problem Wetting the ash is
tne only practical solution Hopefully some cementation will
occur helping to reduce future leaching potential
27 JEA requirements are noted This is a conceptual study not a
final design Optimal design analysis can be performed during
Phase II
2829
JEA requirements are noted and can be incorporated into the Phase
II design
210 The transformer size is adequate for base load operation A
higher capacity can be considered at the final design stage if the
Client prefers
211 From our experience it does not appear to be economical to
provide additional dry cooling towers to take care of maximum
ambient temperatures which may prevail only for a short period of
time in a year To study this an annual dry bulb temperature
duration curve is required Also adding additional dry cooling
towers will change the plant performance It should also be noted
that the dry cooling towers are very expensive and the size should
be selected carefly considering performance and cost and not on the basis of maximum ambient temperatures This can be studied
during Phase II
32389
Page 12
212 The plant gross output varies with condenser pressure
Condenser
Pressure Design 55 in HgA Annual Ave 35 in HgA
Unit Size MW 20 50 4xlO0 20 50 4xlO0
Gross Output MW 234 593 496 2415 607 TBD
Net Output MW 1975 501 400 205 515 TBD
To be developed in Phase II
Output for 4x100 MW is estimated by others
213 The fan power consumption of the CFB boiler is about 30 to 35 of
the total auxiliary power The fan power consumption of the dry
cooling tower is about 20 to 25 of the total auxiliary power
214 Table 1-1 does not include plant net output Therefore do not
understand the comment
215 Commercial operating experience with coal fueled CFBC units in LISA
and Europe has been uniformly good showing high on stream
availability in early years (See Table 2-6 which reports on
Pyropower experience)
We expect operations with high ash content fuel like oilshale will
have unique scale up problems such as
o Solid handling in and out
o Internal solids circulation
o Erosioncorrosion steam generator intervals
o Heat recovery from bottom ash
Consequently we are recommending these items be worked out in a
single 50 MW prototype
32389
Page 13
216 Maximum dry cooling is used in this study A small wet cooling
tower is used on circulating service water system
217 Horizontal condensate pump is adequate with dry cooling tower and it is cheaper Vertical condensate pumps with cans can be
considered in the final design if required
218 A concrete shell brick lined flue stack will be larger in diameter and costs more than a steel lined stack Brick lined stack can be
considered in the final design
219 Demineralized water tank capacity for 50 MW is 76 cu meters or 20000 gallons not 1000 cu meters For 20 MW plant it is 38 cu
meters or 10000 gallons
220 It is US practice to use an average continuous blowdown rate of
1 and maximum biowdown rate of 3 for this type of plants
221 This can be studied during Phase II
222 Same as 221
223 Same as 221
224 The recommended action plan calls for continuing support studies covering the referenced items Additional effort is needed to
further define these matters and confirm the conceptual plan
The next step is to develop an outline for a project plan including
o Work Scope
o Schedule
o Budget
accommodate the increase in the number of employees and
equipment Truck bays to accommodate the 136 tonne trucks
will be added The truck bays used for the 77 tonne
trucks will be used for the maintenance of other
equipment The warehouse change house training room
offices and cafeteria will be expanded accordingly
6025 Mining and Processing Economics
Details of the oil shale mining and processing plant
economics for the 400 MW plant are included in the Mining
Report (Appendix 5) These details are of the same
magnitude as prepared for the 20 MW and 50 MW plants
The summary of the cash flow analysis for the mine and
shale processing plant is presented in Table 6-1
Table 6-1
SUMMARY OF 400 MW PLANT OIL SHALE MINING AND PROCESSING COSTS
5050 Debt-Equity 8020 Debt-Equity
US $1000 US $1000
Capital Cost
Mine Development 30915 30915
Mine Equipment 66012 66012
Process Plant Facilities 50889 50889
Spare Parts 5000 5000
Working Capital 10000 10000
Capi tal ized Interest
During Construction 24423 39075
TOTAL 187239 201891
Operating Costs and Other Costs
Annual Cost 60386 53236
Product Mined and Processed
Annual Tonnes x 1000 7783 7783
Unit Cost
US $Tonne (weighted average)
US $l06Btu (weighted average) 776
156
684
138
Year 12 costs taken as 25 year average
6-6
-Au
Table 610 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
- FCC plant sizes equivalent to proposed power application
Prefeasibility Study Oil Shale Fueled Power Generation
VOO94GEampJRI26
i
PYROFLOW UNITS IN THE US
COLORADOUTE IOYA STATE UNIV UNIV OFNUCLA CO NORTHERNAMES IA BF GOODRICH110 1o0MW(a) 2x170000 Ibhr HENRYILCEDAR FALLS IA 120000 Ibhr GENERALGULF OILu EiN P MOTORSSbtUpStart-UIL 1987 O A 1I N000 TC
NORT10 PONTIACH B MIRANCHWV00000 lbhr
CORN PRODUCTSSM NORTH-CAROLINA STOCKTOD CA
400000 lbbhl t
RUMF RD ME
CEMENT CO CALIF PORTLAND-COLTON CA
190000 Iblhr Start-Up 1985 TRUMTFTWN NYU
3I75ERTOWN N
etar t-Up loss ACE COGENERATIONCABI
TRONA CA Oper t~on l -Start-UP 1990 ~ rt upz 091Start-up loss Start-up PNeLAI 1991
MTKESFICOENERATIO-N1
BASFIELDp Start-uStar-Up WESTCA9 199otgoUp 1 MAHONEV PA|00000 Ibhr A Oz 2X365000 Ibhr
SETtr-Ups 188B CHAT TANOOGA TN
G ULF OIL EXPLORATION 8ta-rt-u) 1085BAKERSFIELD NORTH BRANCHCA SPRING GROVE PANORTH BRANCH WV 400000 IbhtOperational 19835 5 0 0 I b h 9 0 0 0 Iblh r- tart-Upi 1991 S t r - U p s l e s s
SOUTHEAST PAPER MFG CO UNIVOF NORTH CAROLINArDUBLIN GA UHAPEL HILL NO400000 IbhrStart-Ups logo Start-Ups2X250O000 1loseIbhr B
- Withdrawing ash from combustor - Withdrawing fly ash
a Internal solids circulation of the steam generator
m Erosioncorrosion of steam generatorinternals
Heat recovery from bottom ash
U Operation with low calorific-value fuel
Prefeasblity Study O Shari Fueled Power Generation
VOO7AI 27
Impact of Scale-Up
Project Size
20 MW
50 MW
100 MW
50 MW boiler in 100 MW plant
Potential Risk
Design Scale-upOperation of to 100 MW Initial Plant Plant
Low Significant
Modest Modest
High Low for duplicate units
Modest Low for duplicate units
Prefeasibility Study Oil Shaje Fueled Power Generation
VOO71-4GEAL4n2
i
Conclusions
Defined risk of CFBC boiler is acceptable
U Operating experience with commercial CFBC boilers built and under construction will strengthen confidencelevel and minimize risk for a plant built in 1995
SPrefeasibility Study Oil Shale Fueled Power Generation
V007GHAAE29
ENVIRONMENTAL ASSESSMENT
a Mine and shale processing
- Fugitive dust emissions
- Noise levels
- Leachability of disposal piles
Power plant
- Fugitive dust emissions
- Gaseous emissions
- Noise levels
- Water effluents
U Conclusions
Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel
Prefeasibility Study Oil Shale Fueled Power Generalon
- Coaloil prices will be at least 15 greater after 1995
- Discovery of indigenous conventional fuel resources is inadequate for power plant purposes
Prefeasibility Study
Oil Shale Fueled Power Generation
VOO) IDWFO
Feasibility(Contd)
N Suitable financing will be available
- For $200 million 50 MW prototypeproject
- For $1000 million 400 MW commercial project
Government of Jordan will make basic commitments
- Long-term power purchase agreement
- Long-term access to Sultani shale deposit
Adequate water and manpower resources
- Attractive tax incentives
Prefeasibility Study
Oil Shale Fueled Power Generaion
VO bull1DUJJRO 6
Timeliness
U Timely development of Jordan oil shale needs prompt action to create - Additional definitive information
- Suitable business plan
Prefeasibility Study
Oil Shale Fueled Power Generation
VooI DUJo 7
i
Expansion Conditions
U Continued expansion of powergeneration from oil shale in Jordan depends on water availability
Prospects for power export or importand domestic load growth will affect size of the needed shale-to-power program
Prefeasibility Sudy
Oil Shale Fueled Power Generation
yOWl lVuJO
Environmental Impacts
N Environmental impacts of shale development will be minimal
Prefeasibility Study Oi Shale Fueled Power Generation
i
Development Advantages
Will create significant new jobopportunities in Jordan
Will avoidreduce foreign exchangelosses for expanding alternate fuel imports
Prefeasibility Study
Oil Shale Fueled Power Generation
VOOIIULL tO
Recommended Action Plan
N Basic recommendation
N Conceptual development schedule
U Project development plan
Key plan elements
N Funding requirements
Prefeasibility Study Oil Shale Fueled Power Generation
VOO4II )U OII
i
Basic Recommendation
N Expand efforts to develop an oil shaleshyfueled power generation program at the Sultani deposit
- Conduct required supporting studies
- Define facilities costs and business plans
- Obtain project funding
Prefeasibility Study
Oil Shale Fueled Power Generation
VON I II)ILL 12
C
Conceptual DevelopmentSchedule
1989-1990
- Conduct supporting studies - Define costsbusiness plans for 50
MW prototype and 400 MW commercial projects
- Develop project financing
N 1990-1993 - Build and operate the prototype project
N 1994-1996 - Expand the 50 MW prototype to 100 MW scale
U 1996-2000 - Expand the project to 400 MW scale
N 2000-2005 - Build a second 400 MW commercial project if needed
i 1 Prefeasiblity Study
dOil Shale Fueled Power Generation
VW IMLITO 13
Conceptual Development Plan
Months
1 Project development plan - Define project
costs1busness plans
-24 -12 0 12 24 36 48 60 72 84 96 108 120
2 Secure funding
3 Build and operate 50 MW prototype
Dergn and procurement
Mine development
Plant construction
Startup and testing
Operations
L- -
4 Expand prototype to 100 MW
Design and procurement
bullConstruction
Startup
5 Expand project to 400 MW
2nd 100 MW unit
3rd100 MW unit
i 44
4th 100 MW unit -
O Project dacision point
i Prefeasib~ity Study Oil Shale Fueled Power Generation
17958562aJocdanV 3-14-89 rsO
18
Phase I - ProjectDevelopment Plan
n Program development
Seminar workshop on prefeasibilitystudy Oate project development plan woek scope schedule arid budget
U Carry out project planning program
- Conduct continuing support studies - Test Sultani shale in existing FBC
- Firm up designs and specifications
- Update costs and economic analysis
- Develop business plans and requirements
Explore project funding alternatives
i Prefeasibility Study
Oil Shale Fueled Power Generation
VO MItUOR 14 -0
Key Plan Elements
N Project feasibility analysis
- Firm up designs and equipmentspecifications for all facilities
- Update cost estimates based on preliminary designs and specifications
Explore arrangements for contract mining and mine development
Update forecasts for demand growthand for retirements of older generating capacity
- Create updated economic analysis
Preleasibility StudyO1 Shae Fueled Power Generation
VOO1IOLWRI
Key Plan Elements (Contd)
Business entity requirement
- Explore optionsconditions for a new company to managebuildoperate the project
- Explore optionsconditions for obtaining a concession agreement for Sultani development
Explore optionsconditions for water rights commitment
Prefeasibility Study Oil Shale Fueled Power Generation
VMIOIA)lj 16S
i
Key Plan Elements (Contd)
U Continuing supporting studies
- Combustion tests (additional pilot tests for design and warranty purposes contract for large-scale burn operations in existing plants if appropriate)
- Additional core drilling and core analysis
- Oil shale crushing tests
- Spent ash leaching tests
- Geotechnical data base including soils analysis
- Environmental baseline data
Prefeasibility Study O Shae Fueled Power Generation
VMMMUldMOA
Steps Required to Develop an Oil Shale-to-Power Project
Create a development business plan - Schedule - Decision tree
Develop a work scope and budget for the development plan program including - Firming up designsspecificationscosts
- Developing business entity requirements - Continuing support studies
Carry out development plan program
Assemble all planning results in a report for discussion with financial institutions
Explore project finance opportunities
Finalize business arrangements
Implement prototype project
i Prefeasibility Study
Oil Shale Fueled Power Generation
VM1-11UJROLI
MARCH 15 JEA QUESTIONS (M S ARAFAH) ON PREFEASIBILITY
STUDY DRAFT REPORT
Rt
DIR EScBSULIVAN PHD OFJCEop~BUREAU FOR SCIENCE AND~TECHNOLOGYAGENCY - --FOR INTERNATIONAL DEVELOPMhINTSWASHINGON DC x20523---------4
4 -
-SUBJ E CT - -C O H~ E T 4N l
Dr Mr sullivan ------shy
c-rommnents We ~efr-preaereorPla -tobYou lete dted Jan 91989 regardn~i4po4t P ea e1 f i nd y ubel ow our -e ot r XcOrcerned Jordanian deipartments
- --A ar o~nnYu Y o turjlt~ lt K
4 C~mments
~1 N i gFIN I~fANDECONOMIC1COIMEN S -
It sidicaed that Beohtel and US AIDWash ingtonj~4- re ojy nen ing that E 2hould und ertake the n e tshyihaisAre ~our c leometprogram n order shye-t im~ ate d f n t v design and budget cost
4Al1so Lthe study ncal--ttsutnilndcaei~ A-1 A thas ~ l 1 be eeded idb~~~~~ rn o ei t n i la itheMWa~-~5s~ 4
hrPro hehgemetTh trOfT ses~fnr4 BOT)Vmanu- a n-mnf~cure 4 r~j or contra c4-or ivoIlveiintijn I 4 4investmnt ude smi ~w 2 Zha tev e r --~4~prce e ec r it v p4~ f JA gertiy geeated-at 4 JEA 3 a l b u y ~the same average~~ A
~jithia oncot in4 ordrtan ecpoemic asess thespePower generatjoon J ordan3 oi sha I eroic c inr~etJordan 4
2P ge i1- 1 Aj iit eu that OPin he atocontr~ct 4with owner4 ofext3ing (oconstriiction r(FB rml-t
qu i of S 11 t to test large tonnagen j es StaniUti n d ajIe -for se veralIQf 31 hi
evrEAPreferpilot qr the dP 1prt7n -that the4mPIt
andi to(7 he instalI 1e 2 310 A
_
JODN ELECTRICITYAUTHORIT LL
Dac
operated in Jordan i n or~der~~t ~n nuex~on mnining crushing and haidi igQhre~ and sash Maeia nd aSootoget enough olr ndaita needed for einolre
CEBbole~ -i s~
ccordance with Jordaian oil shale
large to~ bfig
1 3 le 1-2 Page 1-7 Cost Of Pwer~i It i S menti-oned that the conmecial oil hle~ lt~project (4 X1OOmw) 1is ninacompetative roqt~range-~while table 12 indicates thattcost of-pow Ais~mill
q kwiihcii r 1
average wih i ii -much higher ihantheshy-ost of ~Power gnrtofomJEA therimaPower s ta tions Please~ indicate on what basi o ~~ shave-~made your-statement
PK
14 Pae 2 Sction 4-0sIt 1nlkly that theChousing and off- -site infrastructur-ommnity fakilitieR) to be onsidered for both the demo and prototyp prjcs oeoverwe~4 hnk that their~c_6t is raterojects Mo
iwcv~- age -1 1 Mine O(perationIIt is indicate~d that mining cot eevdfoMine contractor~ are ficomiplee h
r and iyudi-t~con qidder contract mnn opio fr4 the min4 cmflt2ng are reIanddrepres~ent the real costs derived from Phspat miin contractors in
lestfor the eo rPooypuat in order tlt7
P I eadenote tha detthe new exchangerate ofthJraian~ Di~nner you may add 20j6 Kto the quoted
1 6 P Ias e consider the followin ecn hage_
171- The new exchange ra teof tUSD=54o0 fils1 72-W2 The new~ aerage tariff for selIn~electricityhas decrreased to 120 8 f ilIsicwh
17- Page 1-7 TbIe 1-2 W bev th tthe cap ita1 cot for the pwhokand forthe min n d ash hMnd1ing equipen
P B~2Anaor a -Tl 8156152 8176 1Q MYf -t -Now 520 t 1U
JDNEECRICIT AU-RA L14lLiL
2 ~are very high We suggest~ thta You rerconsie (- telowerus e~+d accuracy est a rangethan +30
Page4-22 Table 4-5weno0ti ced( that- PyroPowe ha ddeta(IiacCst fori the bo1ilerlocation and terha dutdetlease isxtr fo~ l C~ io~ s~ e~~ 1a~ a if and indicate theonldjusted ~percentagefor construction foin Jordan
19 Page-7 Table 11-2 -Yo aeue ihrinterest rate on Equity thatn on1DehI~laseinclude~ adetaied explanation of thisrr -tni kepin in miUndie JEA is1thaIt a non profit~ shyorgaiztion unik oher private UJSA utility~in ktation
~-~110- Regarding shy
the ra4ital Rt fthe project it is~requesed tobre k it intdo foreignMeanwhile cthe nd lorcal c-osfoeigptario i nt-re3t~shol becnierdo-h
rr n ontiondonnotopdbon the 9 cnieelocal portion~onth
1-1- 237~Pa
oningeny 9tooi s high~~ a lower 4value -should be~
4~ gt ~112- -Tbles t1-1 -8-8~ inclu~de t~he c~alculationscuultie nt enefits for of Th shyunttypes l i4s difeen geeatnmrer likely tocluae
-~ Q~ J7present vk1u for tenet tthe~benefits in feralterntives -t-oa s the
49
ehliyoi shale
Wea gree with you9 tha t th e percentage used ~ an for thenua~l 0 ~amp-M rahr CFBo ndsomewha~t highervrate be n ededma y for a C B l n Me n h l ~ a e r
indir e ta~ts the -estimatedma i variablec st i ddition t he fi-xed-9i 1 mislkih We --
thinktttiis too lowK -5
shy
1-14- e 4-29
opprza tion-o to The o i1s h1 costs-nc I deAbo 1h
Pa10 mman ormTSI62 a
IB I
JORD N EtECTICI1~ 4 E~)~Is-s
Date ib-_
~ ~riii~g~nd~o9~ru~hng h~tnlin cot~u~tv yo
i Dae Jnryit
1ts c 7 4-
i smiig iniand fh co I eY
susendi ca tI t icag th t1 ~an~approximate 15 ~pita L tYII I (-~a~ge or he owe bl ockj f aniitjes isof +the capthe)t~ial7cpi~lrharge Uoratelformny SI~Uj(uiity installa~tions~ whle page 6-1T9 talJshyit is mentioned that~ the Capital rate pe-r JEA isshyi5~PeaseJustify this~matter since~w o
i16- Pae 6-1 6
1 I4~t is mentioned that the costs of 4process Water are ~ 4 ~0 2$1 000 gallons
r~j~lt IHave~You considered additionalvalue ofbying waterfrom~ the Wa ters Aito i ~or ditoa cost~f o revrseoqoesplant if ground water is used
~~ I1 7- Table 6-1 Page 6-6 Please explain how did You come ou ihteoil~ shale miniing and proces~sing uit~Icost
ltII~I~ 8- Please note 1 t hatj the average JEA~productinr ot frmthermal I power stationsr (Istationbus-barCOSt)i sbewen 6 3-17 3 fils 4kwh You may use this~
l4~ 19-i For ~4 X 100~AMW Plat iti etindo pag e14-4 VolI 11 that4 at tota I of W42 14 epoye W II eemplo~yer] And on page 69yo1Iiti mentioned that a~ tot 1 f1 ~p yeI iNbe enp1oyed a
is~ high asrmetitexeds100personorthe ~41X100~MWh~~j nsatnpPrlae
I 1 The 4 following iftemns are a sumed to1 be excluded from theraPi ta 1 cot xoI
120-1 Perits I icen es 7
1_207~3 Imprt ~xe on s7pare par ts -and c(7orfmurab -ma~teria Is
04f4 4
~4 R j4 4
D4
~ ~ ~ AIf eS taxesq in acrac ihteJraand regulations should be considered aw
21- p1ea4s e indic ate Your Ju t f c io r us ga 6
44122- Table 977App 5Page4 9-1 4L IK Car1Yiniae that the hIRR of the 4 Otplantis rather unattractive (66)most
-( Cns1er4 ngthe logical base 4csek c pwhen cii 6OL
average sell~ing prc CkhampDEratio L801~2O~Aoreover4M the ne siellin prcwh o JEA ati theamptime~ Abeing os4ltp n~ot exceed 4 Ckwh~-However Ipage 1shy~ and 14 0 T indicate that ecnms for a commeri
S4A4scale joil 4 shale projc ~
appear Piomisig-nug o4Ywarrant continued dee fgfluht 4 feaibiit 4tudy wihil cost sevea~lili
do ar~sf Plas lear wether the ~x step jqs~$j~~lt 4
gtt 9o be considered arCcording4to jthe 4unattractiveresul to mentioned in IRR7 Table 97 gt4
a C4 44fET2 4 144-4444 P a g 1 T b6 l
htte~We ~ ~ ae~ rqieetfrteX ~ noie ~~ ~ 444 MW un t44 r te4l w w e o p r d i th e w t r n rre u f4m or4444~ the4444 54M4rto y e Pg~A~44EHiveL det ile an l A44
s o awa er c n um t a4r f rofsho in P6Io erT
e ch 2 50 M W aPln wa e d 41004 MW4 1 consumption_____________
ma4~2 k e u p houin~44 p A44 4444444 C O 4ltI4
a nd a sh et in etc 4 2 4 1 -24 P a g e4 2 - 1 A P P 5
4Yo 4_ j1 4 4~h444 N44 44
1gro nd tce t hir fthe w bern coqir mna t efora4e 4X10A M 444444 4 r i n to 4 4 4lo w w ehA 7 n 2 cinCie h rh4 n ttthh1eb -e 4 44t Of3 E4O
ea h n~ ffl 4 4Jl44 4 4444 4giv
6 ig re sofrat4 de in cl ar f w w at5 c hrw pe o
s h b 444 o t h e g nd L 44 h u i n C
r 4ne a4 t44 e L(704 2 4 p ae) 2 - o Au P dn 5ai 7~e r 44 I Y (1t 44a
ve7 rn e qu 1saharvthe y
and n~~~o speci~~~l4 p n l nh i n t x
r ~rA M e d r o t eu n 8 1 wTtl t t h
- c re e N I wo6
~ n n a i n a t d h l7 A PP6 gt
J
S2~3- Page 2-4 ~ ~ It ~is i
that oil eindicated the- sha le r our~ Cesin Jordan are 10 billion tons -The anulp e reere maiy exeed 50 4 billion tons ~
~ 24- 4Page~2 -l1 iujntr We beiv thtCBcmuto~ep i s high and~alSo
~~ ~ -2 ~~ Page 4-1~6 j - shy
Please~~ indicates your procedure to cool the omn ashand atwa icagd-eprtr
A Have you~ considered~ additional he~at exchanger topcool th ash and to imrve h cycleef ficiency
-~2~6 Page 4-16 It s~ indicated that ash from each silo i Amixed19 ~with~fabout 20 waterKb weight to minimize generation of dust~during trnprtto to mine and disposalHave you~ coniidered other 4lternativeto
~ ~eliminate dustiiig -and avoid use ofwat r uring it ransportationi such as~ using closed trucks or closed
of ~fans conUMnPo wihrlaintthe total plant auiir poe osupin 1~21- Table 5_-3 and I ~
Th~~ is- somneere c6ntradiction regardingplnneotpu~t in both am tables 21-~ Tabl~e 1-33
We noticed tha~t yourall9 cacacapac t fatro75 tion ae asdnWe thilt ~that 7capacityshyfacto is tobo high for- an oil shale fired plant duketo lack of existing simila~r ~plants handl~~~firing oil adshale ~K
216~ The study iniae thtawet~coigtower wi11~used Actually a b
dry cooling should be consideda5ini ~HTP S inZ atomnmz so water rnumption4the cycle~ efficiency willbe reducedHenre YO33~reconsider calculating the cyclefficiy
U~~~~~ codnt umconsidered ofhorizontal -aretypethe~ the vertical cian type can alsobeh considered
shy ~ ~ ~ I~~
2~2 Kconcrete shy
shjell stepl fltstack is onidereconcrete shell brick flue Rt c ~s beCaconsidered3V
2-19~- Deminiraized water~ tank3 capacity~ is -76 ui(meterThe recommnended tank cameter- ui tyi 00cbc
220Designconditions Pa~ge (4-74)te5 hat bow 3down percentage splusmn ~fomrpra til re i hou I be 3~)~
PoD Z 2 m a ad~ - e 5 1 2 iJS~ ~ p A f amp ~ ~ y1
4
JO R ECTICITY AUTHORTIT 4L
~ 4
Date~
t etats ttthe quantityof s i S ~1 000Tons ra Sthis tuntity 11- be transporited for severIy --to tu ofI pit a~te torg P KM ra~erm Spower plIatS about 12 midilidoni CUIA(- met ryea
h e ndd mp e he (d u p in i n L
area wil evric power plant6t Please zn1 a te~tiv s tudY for dumping th r~ a enoug
-from the power plantr~~h~
S 2- Please provide deald-ifrat ao etbaaiedrawing hwn TH11 R thaU and~pV ra~te takcing illto o 6it v- consumptionn _uig themrining equipment
alternate~ study 0o Jine operation for 1 shiftday Vand twoshifts day -lt
224- Conceptua~l pflR 1 for mi ing anusdtransportation of oil- shale a 0 dmj of hs f u r therV examinedh iV~sdpatI ho u1d be
orderj to poe~ehicalq and~eoomca1 fesblt of t his operation
SYour are requested te) study and consider all- above - iPoin s at your earliest in rder -to be peete y oiAnimain on March 29-301989 peetdb~o 4 n
S9incerly-You S
WDIRECTORGENERAL -
I~ CCMR WLINTON ~vs
5N
Pa D~t~IoAmmn -Jordtn -Tel 815615 20 Bl76 15 -19j A VINO- AFf TY
MARCH 21 RESPONSE TO JEA QUESTIONS
Bechtel Power Corporation Engineers - Constructors
Fifty Beale Street San Francisco California Mail Address P 0 Box 3965 San Franclco CA 94119
March 21 1989
Mr M S Arafah Director General Jordan Electricity Authority PO Box 2310 Amman Jordan
Subject Jordan Oil Shale Prefeasibility Study
Dear Mr Arafah
Your letter of 15 March 1989 with comments on the Oil Shale to Power Prefeasibility Study draft report has been referred to me for reply
The attached responses to each item in the reference letter follows the order submitted
Also attached are three revised pages for the draft report - Volume I
Page 6-1 Page 6-21 Page 6-23
Please copy these revised pages into the report previously sent to you
We plan to review this material with JEA during the March 2930 and April 1 meetings in Amman
rsuVertrul yours
W Linton Project Manager
WHLdc
Attachments Questionnaire Response Three revised pages
cc C J Aulisio R R Buta G D Gould T J Wilbanks
32389
Page 1
RESPONSE TO MARCH 15 1989 QUESTIONAIRE
OIL SHALE TO POWER PREFEASIBILITY STUDY
This study examines economic prospects in terms of a 1995-2000 timeframe
FIRANCIAL AND ECONOMIC COMMENTS
11 It is likely that a BOT deal can be structured at present JEA
generation costs for either 20 MW or 50 MW size units if GOJ is
willing to subsidize the incremental power generation cost
Furthermore these incremental costs can be recovered during the 25
year operation of a Commercial Scale Project
12 A 3rd Party Test was proposed as an alternate means to raising
$100+ for an independent JEA sponsored 20 MW Demonstration
program
13 71 millsKWH for Shale Power
VS
JEA 1987 costs
Purchased Power 17 filsKWH = 51 mills
Produced Power 1360 filsKWH = 41 mills
19952000 Costs - Expected to be 30 to 40 higher and in line
with the cost estimate presented in this study
It also is important to recognize that the busbar cost of power
generated by any new power source can not be compared directly
with the cost of existing older installed capacity because of the
lower capital cost component of the latter (See enclosed Figure
1-1 which demonstrates how total capital carrying costs decline as
the investment is paid off) Any new capacity whether coal oil
or oil shale will be an unreasonable disadvantage compared with
costs for existing older capacity
l
024
o2
0De return
E 016Total carrying charge
012 qu return
S -008
ety taxes and n rcw vshy000 X 0 5 10 15 20 25
Figure 1-1 Year-by-year Carrying Charge Components for 15-yearTax Recovery Period
1-7
30
32389
Page 2
14 Infrastructure Cost
Total People
OperatorFamilies Installed Cost
20 MW $10000000 185700 $54000Operator
50 MW 15000000 3241200 46000Operator
400 MW 45000000 10364000 43000Operator
Factored allowance for grass roots desert installation
including housing and community facilities was developed as
follows for the 50 MW case study
Infrastructure
50 MW
Family Housing 200 30K = $ 6 Million
Bachelor Housing 100 20K = 2 M
HospitalClinic (8 Beds) 11 M
SchoolMosque I1 M
Stores Services amp Recreation = 2 M
Facilities
Roads Electricity Water Sewage = 3 M
$15 Million
Infrastructure costs for the 20 MW and 400 MW cases was ratioed
from this breakdown
At this conceptual level costs are order-of-magnitude In a Phase
II program these infrastructure costs can be developed in detail
32389
Page 3
15 Contract Mining Alternatives
Page 4-11 Mine Operation
Based on Bechtels evaluation of the mine contractors price as found in Section 15 of the Mining Report it was concluded that
the mine contractors price does not include costs for such things
as developing the mine with a box-cut ramp haul roads
developing an area for the waste material maintaining the
haulroads constructing the mine services facilities diversion
ditches sedimentation ponds water well crushing the oil shale
pre-mixing the oil shale at the mine and other items associated
with operating a mine to support a power plant If it is proven
that the mine contractors price includes cost for the above
mentioned scope of work in additi-n to drill blast load and
haul then the contractors price can be used but in the meantime
the all inclusive cost developed by Bechtel should be used
Contract Mining appears to be attractive for the smaller size
plants but not for the larger commercial scale operation Some
third party must provide the necessary capital for trucks
loading mining machines etc under a contract arrangement
16 Reassessment due to Dinar value change needs further study and can
not be evaluated given present budget limitations If average
labor rate of $300hr still valid then little change involve with
study
If deemed necessary reexamination of project economics can be
done in Phase IIwhen funded
17 Costs in this study are based on recent similar Bechtel experience
on Mount Poso project and on Montana I project The Mount Poso
project is a 50 MW unit firing coal in a Pyropower boiler The
Montana I project is a 35 MW unit firing coal in a Keeler Dorr
Oliver FBC boiler utilizing dry cooling
32389
Page 4
18 The Pyropower quote of $186000000 to futnish and erect the steam
generator stack and baghouse has been adjusted to include
engineering construction indirect cost etc to be consistant
with the rest of the costs shown in Table 65 p 6-10 No
further adjustment for location was made
19 Equity funding has the lowest priority of payoff in case of a
liquidation and carries greater risk Hence a higher rate of
return is needed to attract these funds Debt funding is a first
mortgage and has first priority for payoff in case of liquidation
and carries less risk Hence it requires lower rate of return
than equity funding
The risk taking equity owner will ask for greater interest rate
to make funds available The only way to minimize this expense is
to find a loaning agency willing to provide 90 or perhaps 95 of
the investment cost It is likely that banks will require some
minimum equity participation
This Prefeasibility Study was not based on a non-profit utility
operation
Even though JEA is a non-profit organization its service
contributors are profit making groups It is visualized that the
Jordan Oil Shale Co (JOSCO) will be a stand alone business
enterprise servicing JEA under long term contract To secure
funding for the proposed project JOSCO will need attractive
enough contract terms to attract both equity and debt capital
110 Additional work is needed to develop the requested information
This work can be preformed as part of the Phase II program
111 Bechtel includes contingency in all of its estimates to cover
error emissions and unforeseen items within the defined scope of
the project The level of contingency is dependent upon the
amount of scope definition For a prefeasible study such as this
15 contingency is lower than normal
32389
Page 5
112 Tables 89 through 816 include a present value calculation to
establish the relative benefit for a shale project vs coal and
oil
113 The variable maintenance cost of 1 millsKWH has been adjusted for CFB plants with an additional $200000 per year or 06 millsKWH
This yields the following
Variable Maintenance - 10 millsKWH
CFB Adjustment - 06
Fixed Maintenance Cost - 40
Total Cost 56 MillsKWH
114 Page 4-29
The royalty costs are included in the weighted average oil shale
costs for the 50 megawatt plant
Page 4-8
Shale fuel costs include return on equity and royalty These are
two separate cost items Royalty is the last item mentioned in
the sentence and it therefore reads as royalty and not return on
royalty
Page 4-31 gives rates used by Bechtel based on our calculations
using the referenced procedures
DebtEquity Capital Charge Rate
5050 153
8020 139
Table 69 displays the calculation of the 153 capital charge
rate (Line 7 of Table 69 is not used in the calculation and
should be deleted)
32389
Page 6
116 No water purchase charge from the Water Authority was added to the
operating expense based on the statement that no resource costs
will be charged
$020 per 1000 gallons is rule of thumb for USA installations in
absence of client data
Boiler make up water (p4-17) is treated in a demineralizer
train If deemed necessary comparison with reverse osmosis
process can be performed in Phase II
Water requirements were estimated to be
Cubic Metres Per Year
20 MW 50 MW 400 MW
Mine amp Shale Processing 455000 761000 773000
Power Block 3000 6000 42000
Infrastructure 80000 140000 448000
Total 538000 907000 1263000
117 Annual average operating costs shown on Table 6-1 are in error
Financing Option 5050 8020
Cost Shown 56606 48945
Corrected Cost 60396 53236
Average mining and shale processing costs are developed year by
year in the Mining Report Appendix 5 Table 12-10
32389
Page 7
118 We would be interested in receiving the breakdown of these current
power cost figures (ie capital charges fuel cost number of
operators etc) Further economic analysis employing these
figures can be developed in Phase II
119 Manpower requirements for the three case studies were estimated as
fol lows
Mining amp Shale Processing
Power Block
Operations
Maintenance
Management
20 MW 50 MW 400 MW
75 163 396
54 78 175
46 73 455
10 10 10
185 324 1036
Page 14-4 of the Mine Report is for mine and shale processing
only It should be noted that most of these manpower requirements
involved new jobs for Jordanian people
120 At the April 1988 Amman Meeting it was agreed that the following
costs would be omitted
o Permits and Licenses
o Local Taxes
o Import Taxes
If necessary such costs can be developed and added into a revised
economic analysis as part of the Phase II program
121 6 average inflation rate is the figure recommended by Bechtel
based on USA conditions for use in long term economic analyses of
new power ventures
32389
Page 8
122 This matter is referred to ORNL who prepared a rate of return
analysis
Bechtels conclusion is based on computed busbar costscumulative
benefits compared to alternate fuels in the timeframe 1995 to 2000
Relative Busbar Power Cost Net 25 Year
Mills per KWH Benefits - Million US$
Sultani Oil Shale 71-83 Base Cost
Imported Coal
$50tonne 68-88 778
$70tonne 78-107 2531
Imported Oil
$17Bbl 56-76 (18) $24Bbl 61-96 1810
The above results are based on a capacity factor of 75 which is
considered to be a reasonable target for a new plant over its 25 year
life The average selling price of 6 cents per KWH cited in the
questionnaire is based on existing plant costs which may not include
all cost elements of new capacity evaluated in this study
32389
Page 9
TECHNICAL COMMENTS
21 See answer to Item 116
Total power plant raw wate consumption rates and annual
consumptions including the water requirements for wetting ash at the truck loading p int within the power plant are given in Tables 43 and 44 for 50 MW unit and Tables 53 and 54 for 20 MW unit
The raw water requirements for 4x0 MW plant were factored
excepting the mine where a revised mine pldn is employed to reduce water request The quantities shown on these tables exclude raw
water requirements for housing complex mine and ash wetting if
required at the ash disposal site
Total power plant requirements shown in the above referred tables
are
50 MW 20 MW
Rate gpm 207 102 (See Drawing M004)
Annual Use
Gallons 1400000 675000
Cooling tower blowndown supplemented with raw water is used for
wetting ash at the truck loading point within the power plant Raw water quantities attributable for ash wetting at the power
truck loading point are
50 MW 20 MW
Rate gpm 75 325
Annual Use
Gallons 500000 215000
These quantities are included in the quantities shown in
the above referred tables
32389
Page 10
22 We recognize the POTENTIAL for leaching toxic compounds from the
spent ash However this matter is not yet defined well enough to
recommend specific action steps The Prefeasibility Study page
7-12 recommends creation of a ground water dispersion model to
determine whether more specific contaminated water mitigation
plans are needed It is anticipated that the leachate rate will
be low and that aquifer dispersion will keep problem compounds
bel3w health standards thresholds
23 Noted
We have not received up to date resource study material which
defines 50 billion tons resource base Please furnish
The resource base at Sultani alone is adequate to support two 400
MW power projects capacity subject water availability The
2-million cubic metre per year water allowance for oilshale will
limit development to about 600 MW
24 Selection of a combustion temperature is a balance between carbon
combustion efficiency and heat loss due carbonate decomposition
For purposes of the Prefeasibility Study we have opted for high
combustion efficiency At lower efficiency larger shale
mineprocessing plants will be needed
25 Bottom ash is cooled by water exchange before discharge
Cooling water is supplied to the ash screw coolers as specified by
Pyropower See Drawing MOO5 2140 gpm flow for 50 MW and 860 gpm
flow for 20 MW Heat removed by the cooling water from the ash
screw coolers is dissipated to atmosphere via a wet cooling
tower Pyropower should indicate the temperature of the ash
discharged to be 5OOF
32389
Page 11
Initially we had considered using a heat exchanger to cool the ash
and improve the cycle efficiency Considering low cost of fuel
the additional capital costs and the system complexities it was
decided not to employ such heat recovery systems for this project
26 The suggested alternates were looked at briefly and the potential
for wind blown air pollution from the ash disposal areas are too
great to warrant dry disposal unless GO(] and World Bank are
willing to accept such a potential problem Wetting the ash is
tne only practical solution Hopefully some cementation will
occur helping to reduce future leaching potential
27 JEA requirements are noted This is a conceptual study not a
final design Optimal design analysis can be performed during
Phase II
2829
JEA requirements are noted and can be incorporated into the Phase
II design
210 The transformer size is adequate for base load operation A
higher capacity can be considered at the final design stage if the
Client prefers
211 From our experience it does not appear to be economical to
provide additional dry cooling towers to take care of maximum
ambient temperatures which may prevail only for a short period of
time in a year To study this an annual dry bulb temperature
duration curve is required Also adding additional dry cooling
towers will change the plant performance It should also be noted
that the dry cooling towers are very expensive and the size should
be selected carefly considering performance and cost and not on the basis of maximum ambient temperatures This can be studied
during Phase II
32389
Page 12
212 The plant gross output varies with condenser pressure
Condenser
Pressure Design 55 in HgA Annual Ave 35 in HgA
Unit Size MW 20 50 4xlO0 20 50 4xlO0
Gross Output MW 234 593 496 2415 607 TBD
Net Output MW 1975 501 400 205 515 TBD
To be developed in Phase II
Output for 4x100 MW is estimated by others
213 The fan power consumption of the CFB boiler is about 30 to 35 of
the total auxiliary power The fan power consumption of the dry
cooling tower is about 20 to 25 of the total auxiliary power
214 Table 1-1 does not include plant net output Therefore do not
understand the comment
215 Commercial operating experience with coal fueled CFBC units in LISA
and Europe has been uniformly good showing high on stream
availability in early years (See Table 2-6 which reports on
Pyropower experience)
We expect operations with high ash content fuel like oilshale will
have unique scale up problems such as
o Solid handling in and out
o Internal solids circulation
o Erosioncorrosion steam generator intervals
o Heat recovery from bottom ash
Consequently we are recommending these items be worked out in a
single 50 MW prototype
32389
Page 13
216 Maximum dry cooling is used in this study A small wet cooling
tower is used on circulating service water system
217 Horizontal condensate pump is adequate with dry cooling tower and it is cheaper Vertical condensate pumps with cans can be
considered in the final design if required
218 A concrete shell brick lined flue stack will be larger in diameter and costs more than a steel lined stack Brick lined stack can be
considered in the final design
219 Demineralized water tank capacity for 50 MW is 76 cu meters or 20000 gallons not 1000 cu meters For 20 MW plant it is 38 cu
meters or 10000 gallons
220 It is US practice to use an average continuous blowdown rate of
1 and maximum biowdown rate of 3 for this type of plants
221 This can be studied during Phase II
222 Same as 221
223 Same as 221
224 The recommended action plan calls for continuing support studies covering the referenced items Additional effort is needed to
further define these matters and confirm the conceptual plan
The next step is to develop an outline for a project plan including
o Work Scope
o Schedule
o Budget
accommodate the increase in the number of employees and
equipment Truck bays to accommodate the 136 tonne trucks
will be added The truck bays used for the 77 tonne
trucks will be used for the maintenance of other
equipment The warehouse change house training room
offices and cafeteria will be expanded accordingly
6025 Mining and Processing Economics
Details of the oil shale mining and processing plant
economics for the 400 MW plant are included in the Mining
Report (Appendix 5) These details are of the same
magnitude as prepared for the 20 MW and 50 MW plants
The summary of the cash flow analysis for the mine and
shale processing plant is presented in Table 6-1
Table 6-1
SUMMARY OF 400 MW PLANT OIL SHALE MINING AND PROCESSING COSTS
5050 Debt-Equity 8020 Debt-Equity
US $1000 US $1000
Capital Cost
Mine Development 30915 30915
Mine Equipment 66012 66012
Process Plant Facilities 50889 50889
Spare Parts 5000 5000
Working Capital 10000 10000
Capi tal ized Interest
During Construction 24423 39075
TOTAL 187239 201891
Operating Costs and Other Costs
Annual Cost 60386 53236
Product Mined and Processed
Annual Tonnes x 1000 7783 7783
Unit Cost
US $Tonne (weighted average)
US $l06Btu (weighted average) 776
156
684
138
Year 12 costs taken as 25 year average
6-6
-Au
Table 610 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
- FCC plant sizes equivalent to proposed power application
Prefeasibility Study Oil Shale Fueled Power Generation
VOO94GEampJRI26
i
PYROFLOW UNITS IN THE US
COLORADOUTE IOYA STATE UNIV UNIV OFNUCLA CO NORTHERNAMES IA BF GOODRICH110 1o0MW(a) 2x170000 Ibhr HENRYILCEDAR FALLS IA 120000 Ibhr GENERALGULF OILu EiN P MOTORSSbtUpStart-UIL 1987 O A 1I N000 TC
NORT10 PONTIACH B MIRANCHWV00000 lbhr
CORN PRODUCTSSM NORTH-CAROLINA STOCKTOD CA
400000 lbbhl t
RUMF RD ME
CEMENT CO CALIF PORTLAND-COLTON CA
190000 Iblhr Start-Up 1985 TRUMTFTWN NYU
3I75ERTOWN N
etar t-Up loss ACE COGENERATIONCABI
TRONA CA Oper t~on l -Start-UP 1990 ~ rt upz 091Start-up loss Start-up PNeLAI 1991
MTKESFICOENERATIO-N1
BASFIELDp Start-uStar-Up WESTCA9 199otgoUp 1 MAHONEV PA|00000 Ibhr A Oz 2X365000 Ibhr
SETtr-Ups 188B CHAT TANOOGA TN
G ULF OIL EXPLORATION 8ta-rt-u) 1085BAKERSFIELD NORTH BRANCHCA SPRING GROVE PANORTH BRANCH WV 400000 IbhtOperational 19835 5 0 0 I b h 9 0 0 0 Iblh r- tart-Upi 1991 S t r - U p s l e s s
SOUTHEAST PAPER MFG CO UNIVOF NORTH CAROLINArDUBLIN GA UHAPEL HILL NO400000 IbhrStart-Ups logo Start-Ups2X250O000 1loseIbhr B
- Withdrawing ash from combustor - Withdrawing fly ash
a Internal solids circulation of the steam generator
m Erosioncorrosion of steam generatorinternals
Heat recovery from bottom ash
U Operation with low calorific-value fuel
Prefeasblity Study O Shari Fueled Power Generation
VOO7AI 27
Impact of Scale-Up
Project Size
20 MW
50 MW
100 MW
50 MW boiler in 100 MW plant
Potential Risk
Design Scale-upOperation of to 100 MW Initial Plant Plant
Low Significant
Modest Modest
High Low for duplicate units
Modest Low for duplicate units
Prefeasibility Study Oil Shaje Fueled Power Generation
VOO71-4GEAL4n2
i
Conclusions
Defined risk of CFBC boiler is acceptable
U Operating experience with commercial CFBC boilers built and under construction will strengthen confidencelevel and minimize risk for a plant built in 1995
SPrefeasibility Study Oil Shale Fueled Power Generation
V007GHAAE29
ENVIRONMENTAL ASSESSMENT
a Mine and shale processing
- Fugitive dust emissions
- Noise levels
- Leachability of disposal piles
Power plant
- Fugitive dust emissions
- Gaseous emissions
- Noise levels
- Water effluents
U Conclusions
Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel
Prefeasibility Study Oil Shale Fueled Power Generalon
- Coaloil prices will be at least 15 greater after 1995
- Discovery of indigenous conventional fuel resources is inadequate for power plant purposes
Prefeasibility Study
Oil Shale Fueled Power Generation
VOO) IDWFO
Feasibility(Contd)
N Suitable financing will be available
- For $200 million 50 MW prototypeproject
- For $1000 million 400 MW commercial project
Government of Jordan will make basic commitments
- Long-term power purchase agreement
- Long-term access to Sultani shale deposit
Adequate water and manpower resources
- Attractive tax incentives
Prefeasibility Study
Oil Shale Fueled Power Generaion
VO bull1DUJJRO 6
Timeliness
U Timely development of Jordan oil shale needs prompt action to create - Additional definitive information
- Suitable business plan
Prefeasibility Study
Oil Shale Fueled Power Generation
VooI DUJo 7
i
Expansion Conditions
U Continued expansion of powergeneration from oil shale in Jordan depends on water availability
Prospects for power export or importand domestic load growth will affect size of the needed shale-to-power program
Prefeasibility Sudy
Oil Shale Fueled Power Generation
yOWl lVuJO
Environmental Impacts
N Environmental impacts of shale development will be minimal
Prefeasibility Study Oi Shale Fueled Power Generation
i
Development Advantages
Will create significant new jobopportunities in Jordan
Will avoidreduce foreign exchangelosses for expanding alternate fuel imports
Prefeasibility Study
Oil Shale Fueled Power Generation
VOOIIULL tO
Recommended Action Plan
N Basic recommendation
N Conceptual development schedule
U Project development plan
Key plan elements
N Funding requirements
Prefeasibility Study Oil Shale Fueled Power Generation
VOO4II )U OII
i
Basic Recommendation
N Expand efforts to develop an oil shaleshyfueled power generation program at the Sultani deposit
- Conduct required supporting studies
- Define facilities costs and business plans
- Obtain project funding
Prefeasibility Study
Oil Shale Fueled Power Generation
VON I II)ILL 12
C
Conceptual DevelopmentSchedule
1989-1990
- Conduct supporting studies - Define costsbusiness plans for 50
MW prototype and 400 MW commercial projects
- Develop project financing
N 1990-1993 - Build and operate the prototype project
N 1994-1996 - Expand the 50 MW prototype to 100 MW scale
U 1996-2000 - Expand the project to 400 MW scale
N 2000-2005 - Build a second 400 MW commercial project if needed
i 1 Prefeasiblity Study
dOil Shale Fueled Power Generation
VW IMLITO 13
Conceptual Development Plan
Months
1 Project development plan - Define project
costs1busness plans
-24 -12 0 12 24 36 48 60 72 84 96 108 120
2 Secure funding
3 Build and operate 50 MW prototype
Dergn and procurement
Mine development
Plant construction
Startup and testing
Operations
L- -
4 Expand prototype to 100 MW
Design and procurement
bullConstruction
Startup
5 Expand project to 400 MW
2nd 100 MW unit
3rd100 MW unit
i 44
4th 100 MW unit -
O Project dacision point
i Prefeasib~ity Study Oil Shale Fueled Power Generation
17958562aJocdanV 3-14-89 rsO
18
Phase I - ProjectDevelopment Plan
n Program development
Seminar workshop on prefeasibilitystudy Oate project development plan woek scope schedule arid budget
U Carry out project planning program
- Conduct continuing support studies - Test Sultani shale in existing FBC
- Firm up designs and specifications
- Update costs and economic analysis
- Develop business plans and requirements
Explore project funding alternatives
i Prefeasibility Study
Oil Shale Fueled Power Generation
VO MItUOR 14 -0
Key Plan Elements
N Project feasibility analysis
- Firm up designs and equipmentspecifications for all facilities
- Update cost estimates based on preliminary designs and specifications
Explore arrangements for contract mining and mine development
Update forecasts for demand growthand for retirements of older generating capacity
- Create updated economic analysis
Preleasibility StudyO1 Shae Fueled Power Generation
VOO1IOLWRI
Key Plan Elements (Contd)
Business entity requirement
- Explore optionsconditions for a new company to managebuildoperate the project
- Explore optionsconditions for obtaining a concession agreement for Sultani development
Explore optionsconditions for water rights commitment
Prefeasibility Study Oil Shale Fueled Power Generation
VMIOIA)lj 16S
i
Key Plan Elements (Contd)
U Continuing supporting studies
- Combustion tests (additional pilot tests for design and warranty purposes contract for large-scale burn operations in existing plants if appropriate)
- Additional core drilling and core analysis
- Oil shale crushing tests
- Spent ash leaching tests
- Geotechnical data base including soils analysis
- Environmental baseline data
Prefeasibility Study O Shae Fueled Power Generation
VMMMUldMOA
Steps Required to Develop an Oil Shale-to-Power Project
Create a development business plan - Schedule - Decision tree
Develop a work scope and budget for the development plan program including - Firming up designsspecificationscosts
- Developing business entity requirements - Continuing support studies
Carry out development plan program
Assemble all planning results in a report for discussion with financial institutions
Explore project finance opportunities
Finalize business arrangements
Implement prototype project
i Prefeasibility Study
Oil Shale Fueled Power Generation
VM1-11UJROLI
MARCH 15 JEA QUESTIONS (M S ARAFAH) ON PREFEASIBILITY
STUDY DRAFT REPORT
Rt
DIR EScBSULIVAN PHD OFJCEop~BUREAU FOR SCIENCE AND~TECHNOLOGYAGENCY - --FOR INTERNATIONAL DEVELOPMhINTSWASHINGON DC x20523---------4
4 -
-SUBJ E CT - -C O H~ E T 4N l
Dr Mr sullivan ------shy
c-rommnents We ~efr-preaereorPla -tobYou lete dted Jan 91989 regardn~i4po4t P ea e1 f i nd y ubel ow our -e ot r XcOrcerned Jordanian deipartments
- --A ar o~nnYu Y o turjlt~ lt K
4 C~mments
~1 N i gFIN I~fANDECONOMIC1COIMEN S -
It sidicaed that Beohtel and US AIDWash ingtonj~4- re ojy nen ing that E 2hould und ertake the n e tshyihaisAre ~our c leometprogram n order shye-t im~ ate d f n t v design and budget cost
4Al1so Lthe study ncal--ttsutnilndcaei~ A-1 A thas ~ l 1 be eeded idb~~~~~ rn o ei t n i la itheMWa~-~5s~ 4
hrPro hehgemetTh trOfT ses~fnr4 BOT)Vmanu- a n-mnf~cure 4 r~j or contra c4-or ivoIlveiintijn I 4 4investmnt ude smi ~w 2 Zha tev e r --~4~prce e ec r it v p4~ f JA gertiy geeated-at 4 JEA 3 a l b u y ~the same average~~ A
~jithia oncot in4 ordrtan ecpoemic asess thespePower generatjoon J ordan3 oi sha I eroic c inr~etJordan 4
2P ge i1- 1 Aj iit eu that OPin he atocontr~ct 4with owner4 ofext3ing (oconstriiction r(FB rml-t
qu i of S 11 t to test large tonnagen j es StaniUti n d ajIe -for se veralIQf 31 hi
evrEAPreferpilot qr the dP 1prt7n -that the4mPIt
andi to(7 he instalI 1e 2 310 A
_
JODN ELECTRICITYAUTHORIT LL
Dac
operated in Jordan i n or~der~~t ~n nuex~on mnining crushing and haidi igQhre~ and sash Maeia nd aSootoget enough olr ndaita needed for einolre
CEBbole~ -i s~
ccordance with Jordaian oil shale
large to~ bfig
1 3 le 1-2 Page 1-7 Cost Of Pwer~i It i S menti-oned that the conmecial oil hle~ lt~project (4 X1OOmw) 1is ninacompetative roqt~range-~while table 12 indicates thattcost of-pow Ais~mill
q kwiihcii r 1
average wih i ii -much higher ihantheshy-ost of ~Power gnrtofomJEA therimaPower s ta tions Please~ indicate on what basi o ~~ shave-~made your-statement
PK
14 Pae 2 Sction 4-0sIt 1nlkly that theChousing and off- -site infrastructur-ommnity fakilitieR) to be onsidered for both the demo and prototyp prjcs oeoverwe~4 hnk that their~c_6t is raterojects Mo
iwcv~- age -1 1 Mine O(perationIIt is indicate~d that mining cot eevdfoMine contractor~ are ficomiplee h
r and iyudi-t~con qidder contract mnn opio fr4 the min4 cmflt2ng are reIanddrepres~ent the real costs derived from Phspat miin contractors in
lestfor the eo rPooypuat in order tlt7
P I eadenote tha detthe new exchangerate ofthJraian~ Di~nner you may add 20j6 Kto the quoted
1 6 P Ias e consider the followin ecn hage_
171- The new exchange ra teof tUSD=54o0 fils1 72-W2 The new~ aerage tariff for selIn~electricityhas decrreased to 120 8 f ilIsicwh
17- Page 1-7 TbIe 1-2 W bev th tthe cap ita1 cot for the pwhokand forthe min n d ash hMnd1ing equipen
P B~2Anaor a -Tl 8156152 8176 1Q MYf -t -Now 520 t 1U
JDNEECRICIT AU-RA L14lLiL
2 ~are very high We suggest~ thta You rerconsie (- telowerus e~+d accuracy est a rangethan +30
Page4-22 Table 4-5weno0ti ced( that- PyroPowe ha ddeta(IiacCst fori the bo1ilerlocation and terha dutdetlease isxtr fo~ l C~ io~ s~ e~~ 1a~ a if and indicate theonldjusted ~percentagefor construction foin Jordan
19 Page-7 Table 11-2 -Yo aeue ihrinterest rate on Equity thatn on1DehI~laseinclude~ adetaied explanation of thisrr -tni kepin in miUndie JEA is1thaIt a non profit~ shyorgaiztion unik oher private UJSA utility~in ktation
~-~110- Regarding shy
the ra4ital Rt fthe project it is~requesed tobre k it intdo foreignMeanwhile cthe nd lorcal c-osfoeigptario i nt-re3t~shol becnierdo-h
rr n ontiondonnotopdbon the 9 cnieelocal portion~onth
1-1- 237~Pa
oningeny 9tooi s high~~ a lower 4value -should be~
4~ gt ~112- -Tbles t1-1 -8-8~ inclu~de t~he c~alculationscuultie nt enefits for of Th shyunttypes l i4s difeen geeatnmrer likely tocluae
-~ Q~ J7present vk1u for tenet tthe~benefits in feralterntives -t-oa s the
49
ehliyoi shale
Wea gree with you9 tha t th e percentage used ~ an for thenua~l 0 ~amp-M rahr CFBo ndsomewha~t highervrate be n ededma y for a C B l n Me n h l ~ a e r
indir e ta~ts the -estimatedma i variablec st i ddition t he fi-xed-9i 1 mislkih We --
thinktttiis too lowK -5
shy
1-14- e 4-29
opprza tion-o to The o i1s h1 costs-nc I deAbo 1h
Pa10 mman ormTSI62 a
IB I
JORD N EtECTICI1~ 4 E~)~Is-s
Date ib-_
~ ~riii~g~nd~o9~ru~hng h~tnlin cot~u~tv yo
i Dae Jnryit
1ts c 7 4-
i smiig iniand fh co I eY
susendi ca tI t icag th t1 ~an~approximate 15 ~pita L tYII I (-~a~ge or he owe bl ockj f aniitjes isof +the capthe)t~ial7cpi~lrharge Uoratelformny SI~Uj(uiity installa~tions~ whle page 6-1T9 talJshyit is mentioned that~ the Capital rate pe-r JEA isshyi5~PeaseJustify this~matter since~w o
i16- Pae 6-1 6
1 I4~t is mentioned that the costs of 4process Water are ~ 4 ~0 2$1 000 gallons
r~j~lt IHave~You considered additionalvalue ofbying waterfrom~ the Wa ters Aito i ~or ditoa cost~f o revrseoqoesplant if ground water is used
~~ I1 7- Table 6-1 Page 6-6 Please explain how did You come ou ihteoil~ shale miniing and proces~sing uit~Icost
ltII~I~ 8- Please note 1 t hatj the average JEA~productinr ot frmthermal I power stationsr (Istationbus-barCOSt)i sbewen 6 3-17 3 fils 4kwh You may use this~
l4~ 19-i For ~4 X 100~AMW Plat iti etindo pag e14-4 VolI 11 that4 at tota I of W42 14 epoye W II eemplo~yer] And on page 69yo1Iiti mentioned that a~ tot 1 f1 ~p yeI iNbe enp1oyed a
is~ high asrmetitexeds100personorthe ~41X100~MWh~~j nsatnpPrlae
I 1 The 4 following iftemns are a sumed to1 be excluded from theraPi ta 1 cot xoI
120-1 Perits I icen es 7
1_207~3 Imprt ~xe on s7pare par ts -and c(7orfmurab -ma~teria Is
04f4 4
~4 R j4 4
D4
~ ~ ~ AIf eS taxesq in acrac ihteJraand regulations should be considered aw
21- p1ea4s e indic ate Your Ju t f c io r us ga 6
44122- Table 977App 5Page4 9-1 4L IK Car1Yiniae that the hIRR of the 4 Otplantis rather unattractive (66)most
-( Cns1er4 ngthe logical base 4csek c pwhen cii 6OL
average sell~ing prc CkhampDEratio L801~2O~Aoreover4M the ne siellin prcwh o JEA ati theamptime~ Abeing os4ltp n~ot exceed 4 Ckwh~-However Ipage 1shy~ and 14 0 T indicate that ecnms for a commeri
S4A4scale joil 4 shale projc ~
appear Piomisig-nug o4Ywarrant continued dee fgfluht 4 feaibiit 4tudy wihil cost sevea~lili
do ar~sf Plas lear wether the ~x step jqs~$j~~lt 4
gtt 9o be considered arCcording4to jthe 4unattractiveresul to mentioned in IRR7 Table 97 gt4
a C4 44fET2 4 144-4444 P a g 1 T b6 l
htte~We ~ ~ ae~ rqieetfrteX ~ noie ~~ ~ 444 MW un t44 r te4l w w e o p r d i th e w t r n rre u f4m or4444~ the4444 54M4rto y e Pg~A~44EHiveL det ile an l A44
s o awa er c n um t a4r f rofsho in P6Io erT
e ch 2 50 M W aPln wa e d 41004 MW4 1 consumption_____________
ma4~2 k e u p houin~44 p A44 4444444 C O 4ltI4
a nd a sh et in etc 4 2 4 1 -24 P a g e4 2 - 1 A P P 5
4Yo 4_ j1 4 4~h444 N44 44
1gro nd tce t hir fthe w bern coqir mna t efora4e 4X10A M 444444 4 r i n to 4 4 4lo w w ehA 7 n 2 cinCie h rh4 n ttthh1eb -e 4 44t Of3 E4O
ea h n~ ffl 4 4Jl44 4 4444 4giv
6 ig re sofrat4 de in cl ar f w w at5 c hrw pe o
s h b 444 o t h e g nd L 44 h u i n C
r 4ne a4 t44 e L(704 2 4 p ae) 2 - o Au P dn 5ai 7~e r 44 I Y (1t 44a
ve7 rn e qu 1saharvthe y
and n~~~o speci~~~l4 p n l nh i n t x
r ~rA M e d r o t eu n 8 1 wTtl t t h
- c re e N I wo6
~ n n a i n a t d h l7 A PP6 gt
J
S2~3- Page 2-4 ~ ~ It ~is i
that oil eindicated the- sha le r our~ Cesin Jordan are 10 billion tons -The anulp e reere maiy exeed 50 4 billion tons ~
~ 24- 4Page~2 -l1 iujntr We beiv thtCBcmuto~ep i s high and~alSo
~~ ~ -2 ~~ Page 4-1~6 j - shy
Please~~ indicates your procedure to cool the omn ashand atwa icagd-eprtr
A Have you~ considered~ additional he~at exchanger topcool th ash and to imrve h cycleef ficiency
-~2~6 Page 4-16 It s~ indicated that ash from each silo i Amixed19 ~with~fabout 20 waterKb weight to minimize generation of dust~during trnprtto to mine and disposalHave you~ coniidered other 4lternativeto
~ ~eliminate dustiiig -and avoid use ofwat r uring it ransportationi such as~ using closed trucks or closed
of ~fans conUMnPo wihrlaintthe total plant auiir poe osupin 1~21- Table 5_-3 and I ~
Th~~ is- somneere c6ntradiction regardingplnneotpu~t in both am tables 21-~ Tabl~e 1-33
We noticed tha~t yourall9 cacacapac t fatro75 tion ae asdnWe thilt ~that 7capacityshyfacto is tobo high for- an oil shale fired plant duketo lack of existing simila~r ~plants handl~~~firing oil adshale ~K
216~ The study iniae thtawet~coigtower wi11~used Actually a b
dry cooling should be consideda5ini ~HTP S inZ atomnmz so water rnumption4the cycle~ efficiency willbe reducedHenre YO33~reconsider calculating the cyclefficiy
U~~~~~ codnt umconsidered ofhorizontal -aretypethe~ the vertical cian type can alsobeh considered
shy ~ ~ ~ I~~
2~2 Kconcrete shy
shjell stepl fltstack is onidereconcrete shell brick flue Rt c ~s beCaconsidered3V
2-19~- Deminiraized water~ tank3 capacity~ is -76 ui(meterThe recommnended tank cameter- ui tyi 00cbc
220Designconditions Pa~ge (4-74)te5 hat bow 3down percentage splusmn ~fomrpra til re i hou I be 3~)~
PoD Z 2 m a ad~ - e 5 1 2 iJS~ ~ p A f amp ~ ~ y1
4
JO R ECTICITY AUTHORTIT 4L
~ 4
Date~
t etats ttthe quantityof s i S ~1 000Tons ra Sthis tuntity 11- be transporited for severIy --to tu ofI pit a~te torg P KM ra~erm Spower plIatS about 12 midilidoni CUIA(- met ryea
h e ndd mp e he (d u p in i n L
area wil evric power plant6t Please zn1 a te~tiv s tudY for dumping th r~ a enoug
-from the power plantr~~h~
S 2- Please provide deald-ifrat ao etbaaiedrawing hwn TH11 R thaU and~pV ra~te takcing illto o 6it v- consumptionn _uig themrining equipment
alternate~ study 0o Jine operation for 1 shiftday Vand twoshifts day -lt
224- Conceptua~l pflR 1 for mi ing anusdtransportation of oil- shale a 0 dmj of hs f u r therV examinedh iV~sdpatI ho u1d be
orderj to poe~ehicalq and~eoomca1 fesblt of t his operation
SYour are requested te) study and consider all- above - iPoin s at your earliest in rder -to be peete y oiAnimain on March 29-301989 peetdb~o 4 n
S9incerly-You S
WDIRECTORGENERAL -
I~ CCMR WLINTON ~vs
5N
Pa D~t~IoAmmn -Jordtn -Tel 815615 20 Bl76 15 -19j A VINO- AFf TY
MARCH 21 RESPONSE TO JEA QUESTIONS
Bechtel Power Corporation Engineers - Constructors
Fifty Beale Street San Francisco California Mail Address P 0 Box 3965 San Franclco CA 94119
March 21 1989
Mr M S Arafah Director General Jordan Electricity Authority PO Box 2310 Amman Jordan
Subject Jordan Oil Shale Prefeasibility Study
Dear Mr Arafah
Your letter of 15 March 1989 with comments on the Oil Shale to Power Prefeasibility Study draft report has been referred to me for reply
The attached responses to each item in the reference letter follows the order submitted
Also attached are three revised pages for the draft report - Volume I
Page 6-1 Page 6-21 Page 6-23
Please copy these revised pages into the report previously sent to you
We plan to review this material with JEA during the March 2930 and April 1 meetings in Amman
rsuVertrul yours
W Linton Project Manager
WHLdc
Attachments Questionnaire Response Three revised pages
cc C J Aulisio R R Buta G D Gould T J Wilbanks
32389
Page 1
RESPONSE TO MARCH 15 1989 QUESTIONAIRE
OIL SHALE TO POWER PREFEASIBILITY STUDY
This study examines economic prospects in terms of a 1995-2000 timeframe
FIRANCIAL AND ECONOMIC COMMENTS
11 It is likely that a BOT deal can be structured at present JEA
generation costs for either 20 MW or 50 MW size units if GOJ is
willing to subsidize the incremental power generation cost
Furthermore these incremental costs can be recovered during the 25
year operation of a Commercial Scale Project
12 A 3rd Party Test was proposed as an alternate means to raising
$100+ for an independent JEA sponsored 20 MW Demonstration
program
13 71 millsKWH for Shale Power
VS
JEA 1987 costs
Purchased Power 17 filsKWH = 51 mills
Produced Power 1360 filsKWH = 41 mills
19952000 Costs - Expected to be 30 to 40 higher and in line
with the cost estimate presented in this study
It also is important to recognize that the busbar cost of power
generated by any new power source can not be compared directly
with the cost of existing older installed capacity because of the
lower capital cost component of the latter (See enclosed Figure
1-1 which demonstrates how total capital carrying costs decline as
the investment is paid off) Any new capacity whether coal oil
or oil shale will be an unreasonable disadvantage compared with
costs for existing older capacity
l
024
o2
0De return
E 016Total carrying charge
012 qu return
S -008
ety taxes and n rcw vshy000 X 0 5 10 15 20 25
Figure 1-1 Year-by-year Carrying Charge Components for 15-yearTax Recovery Period
1-7
30
32389
Page 2
14 Infrastructure Cost
Total People
OperatorFamilies Installed Cost
20 MW $10000000 185700 $54000Operator
50 MW 15000000 3241200 46000Operator
400 MW 45000000 10364000 43000Operator
Factored allowance for grass roots desert installation
including housing and community facilities was developed as
follows for the 50 MW case study
Infrastructure
50 MW
Family Housing 200 30K = $ 6 Million
Bachelor Housing 100 20K = 2 M
HospitalClinic (8 Beds) 11 M
SchoolMosque I1 M
Stores Services amp Recreation = 2 M
Facilities
Roads Electricity Water Sewage = 3 M
$15 Million
Infrastructure costs for the 20 MW and 400 MW cases was ratioed
from this breakdown
At this conceptual level costs are order-of-magnitude In a Phase
II program these infrastructure costs can be developed in detail
32389
Page 3
15 Contract Mining Alternatives
Page 4-11 Mine Operation
Based on Bechtels evaluation of the mine contractors price as found in Section 15 of the Mining Report it was concluded that
the mine contractors price does not include costs for such things
as developing the mine with a box-cut ramp haul roads
developing an area for the waste material maintaining the
haulroads constructing the mine services facilities diversion
ditches sedimentation ponds water well crushing the oil shale
pre-mixing the oil shale at the mine and other items associated
with operating a mine to support a power plant If it is proven
that the mine contractors price includes cost for the above
mentioned scope of work in additi-n to drill blast load and
haul then the contractors price can be used but in the meantime
the all inclusive cost developed by Bechtel should be used
Contract Mining appears to be attractive for the smaller size
plants but not for the larger commercial scale operation Some
third party must provide the necessary capital for trucks
loading mining machines etc under a contract arrangement
16 Reassessment due to Dinar value change needs further study and can
not be evaluated given present budget limitations If average
labor rate of $300hr still valid then little change involve with
study
If deemed necessary reexamination of project economics can be
done in Phase IIwhen funded
17 Costs in this study are based on recent similar Bechtel experience
on Mount Poso project and on Montana I project The Mount Poso
project is a 50 MW unit firing coal in a Pyropower boiler The
Montana I project is a 35 MW unit firing coal in a Keeler Dorr
Oliver FBC boiler utilizing dry cooling
32389
Page 4
18 The Pyropower quote of $186000000 to futnish and erect the steam
generator stack and baghouse has been adjusted to include
engineering construction indirect cost etc to be consistant
with the rest of the costs shown in Table 65 p 6-10 No
further adjustment for location was made
19 Equity funding has the lowest priority of payoff in case of a
liquidation and carries greater risk Hence a higher rate of
return is needed to attract these funds Debt funding is a first
mortgage and has first priority for payoff in case of liquidation
and carries less risk Hence it requires lower rate of return
than equity funding
The risk taking equity owner will ask for greater interest rate
to make funds available The only way to minimize this expense is
to find a loaning agency willing to provide 90 or perhaps 95 of
the investment cost It is likely that banks will require some
minimum equity participation
This Prefeasibility Study was not based on a non-profit utility
operation
Even though JEA is a non-profit organization its service
contributors are profit making groups It is visualized that the
Jordan Oil Shale Co (JOSCO) will be a stand alone business
enterprise servicing JEA under long term contract To secure
funding for the proposed project JOSCO will need attractive
enough contract terms to attract both equity and debt capital
110 Additional work is needed to develop the requested information
This work can be preformed as part of the Phase II program
111 Bechtel includes contingency in all of its estimates to cover
error emissions and unforeseen items within the defined scope of
the project The level of contingency is dependent upon the
amount of scope definition For a prefeasible study such as this
15 contingency is lower than normal
32389
Page 5
112 Tables 89 through 816 include a present value calculation to
establish the relative benefit for a shale project vs coal and
oil
113 The variable maintenance cost of 1 millsKWH has been adjusted for CFB plants with an additional $200000 per year or 06 millsKWH
This yields the following
Variable Maintenance - 10 millsKWH
CFB Adjustment - 06
Fixed Maintenance Cost - 40
Total Cost 56 MillsKWH
114 Page 4-29
The royalty costs are included in the weighted average oil shale
costs for the 50 megawatt plant
Page 4-8
Shale fuel costs include return on equity and royalty These are
two separate cost items Royalty is the last item mentioned in
the sentence and it therefore reads as royalty and not return on
royalty
Page 4-31 gives rates used by Bechtel based on our calculations
using the referenced procedures
DebtEquity Capital Charge Rate
5050 153
8020 139
Table 69 displays the calculation of the 153 capital charge
rate (Line 7 of Table 69 is not used in the calculation and
should be deleted)
32389
Page 6
116 No water purchase charge from the Water Authority was added to the
operating expense based on the statement that no resource costs
will be charged
$020 per 1000 gallons is rule of thumb for USA installations in
absence of client data
Boiler make up water (p4-17) is treated in a demineralizer
train If deemed necessary comparison with reverse osmosis
process can be performed in Phase II
Water requirements were estimated to be
Cubic Metres Per Year
20 MW 50 MW 400 MW
Mine amp Shale Processing 455000 761000 773000
Power Block 3000 6000 42000
Infrastructure 80000 140000 448000
Total 538000 907000 1263000
117 Annual average operating costs shown on Table 6-1 are in error
Financing Option 5050 8020
Cost Shown 56606 48945
Corrected Cost 60396 53236
Average mining and shale processing costs are developed year by
year in the Mining Report Appendix 5 Table 12-10
32389
Page 7
118 We would be interested in receiving the breakdown of these current
power cost figures (ie capital charges fuel cost number of
operators etc) Further economic analysis employing these
figures can be developed in Phase II
119 Manpower requirements for the three case studies were estimated as
fol lows
Mining amp Shale Processing
Power Block
Operations
Maintenance
Management
20 MW 50 MW 400 MW
75 163 396
54 78 175
46 73 455
10 10 10
185 324 1036
Page 14-4 of the Mine Report is for mine and shale processing
only It should be noted that most of these manpower requirements
involved new jobs for Jordanian people
120 At the April 1988 Amman Meeting it was agreed that the following
costs would be omitted
o Permits and Licenses
o Local Taxes
o Import Taxes
If necessary such costs can be developed and added into a revised
economic analysis as part of the Phase II program
121 6 average inflation rate is the figure recommended by Bechtel
based on USA conditions for use in long term economic analyses of
new power ventures
32389
Page 8
122 This matter is referred to ORNL who prepared a rate of return
analysis
Bechtels conclusion is based on computed busbar costscumulative
benefits compared to alternate fuels in the timeframe 1995 to 2000
Relative Busbar Power Cost Net 25 Year
Mills per KWH Benefits - Million US$
Sultani Oil Shale 71-83 Base Cost
Imported Coal
$50tonne 68-88 778
$70tonne 78-107 2531
Imported Oil
$17Bbl 56-76 (18) $24Bbl 61-96 1810
The above results are based on a capacity factor of 75 which is
considered to be a reasonable target for a new plant over its 25 year
life The average selling price of 6 cents per KWH cited in the
questionnaire is based on existing plant costs which may not include
all cost elements of new capacity evaluated in this study
32389
Page 9
TECHNICAL COMMENTS
21 See answer to Item 116
Total power plant raw wate consumption rates and annual
consumptions including the water requirements for wetting ash at the truck loading p int within the power plant are given in Tables 43 and 44 for 50 MW unit and Tables 53 and 54 for 20 MW unit
The raw water requirements for 4x0 MW plant were factored
excepting the mine where a revised mine pldn is employed to reduce water request The quantities shown on these tables exclude raw
water requirements for housing complex mine and ash wetting if
required at the ash disposal site
Total power plant requirements shown in the above referred tables
are
50 MW 20 MW
Rate gpm 207 102 (See Drawing M004)
Annual Use
Gallons 1400000 675000
Cooling tower blowndown supplemented with raw water is used for
wetting ash at the truck loading point within the power plant Raw water quantities attributable for ash wetting at the power
truck loading point are
50 MW 20 MW
Rate gpm 75 325
Annual Use
Gallons 500000 215000
These quantities are included in the quantities shown in
the above referred tables
32389
Page 10
22 We recognize the POTENTIAL for leaching toxic compounds from the
spent ash However this matter is not yet defined well enough to
recommend specific action steps The Prefeasibility Study page
7-12 recommends creation of a ground water dispersion model to
determine whether more specific contaminated water mitigation
plans are needed It is anticipated that the leachate rate will
be low and that aquifer dispersion will keep problem compounds
bel3w health standards thresholds
23 Noted
We have not received up to date resource study material which
defines 50 billion tons resource base Please furnish
The resource base at Sultani alone is adequate to support two 400
MW power projects capacity subject water availability The
2-million cubic metre per year water allowance for oilshale will
limit development to about 600 MW
24 Selection of a combustion temperature is a balance between carbon
combustion efficiency and heat loss due carbonate decomposition
For purposes of the Prefeasibility Study we have opted for high
combustion efficiency At lower efficiency larger shale
mineprocessing plants will be needed
25 Bottom ash is cooled by water exchange before discharge
Cooling water is supplied to the ash screw coolers as specified by
Pyropower See Drawing MOO5 2140 gpm flow for 50 MW and 860 gpm
flow for 20 MW Heat removed by the cooling water from the ash
screw coolers is dissipated to atmosphere via a wet cooling
tower Pyropower should indicate the temperature of the ash
discharged to be 5OOF
32389
Page 11
Initially we had considered using a heat exchanger to cool the ash
and improve the cycle efficiency Considering low cost of fuel
the additional capital costs and the system complexities it was
decided not to employ such heat recovery systems for this project
26 The suggested alternates were looked at briefly and the potential
for wind blown air pollution from the ash disposal areas are too
great to warrant dry disposal unless GO(] and World Bank are
willing to accept such a potential problem Wetting the ash is
tne only practical solution Hopefully some cementation will
occur helping to reduce future leaching potential
27 JEA requirements are noted This is a conceptual study not a
final design Optimal design analysis can be performed during
Phase II
2829
JEA requirements are noted and can be incorporated into the Phase
II design
210 The transformer size is adequate for base load operation A
higher capacity can be considered at the final design stage if the
Client prefers
211 From our experience it does not appear to be economical to
provide additional dry cooling towers to take care of maximum
ambient temperatures which may prevail only for a short period of
time in a year To study this an annual dry bulb temperature
duration curve is required Also adding additional dry cooling
towers will change the plant performance It should also be noted
that the dry cooling towers are very expensive and the size should
be selected carefly considering performance and cost and not on the basis of maximum ambient temperatures This can be studied
during Phase II
32389
Page 12
212 The plant gross output varies with condenser pressure
Condenser
Pressure Design 55 in HgA Annual Ave 35 in HgA
Unit Size MW 20 50 4xlO0 20 50 4xlO0
Gross Output MW 234 593 496 2415 607 TBD
Net Output MW 1975 501 400 205 515 TBD
To be developed in Phase II
Output for 4x100 MW is estimated by others
213 The fan power consumption of the CFB boiler is about 30 to 35 of
the total auxiliary power The fan power consumption of the dry
cooling tower is about 20 to 25 of the total auxiliary power
214 Table 1-1 does not include plant net output Therefore do not
understand the comment
215 Commercial operating experience with coal fueled CFBC units in LISA
and Europe has been uniformly good showing high on stream
availability in early years (See Table 2-6 which reports on
Pyropower experience)
We expect operations with high ash content fuel like oilshale will
have unique scale up problems such as
o Solid handling in and out
o Internal solids circulation
o Erosioncorrosion steam generator intervals
o Heat recovery from bottom ash
Consequently we are recommending these items be worked out in a
single 50 MW prototype
32389
Page 13
216 Maximum dry cooling is used in this study A small wet cooling
tower is used on circulating service water system
217 Horizontal condensate pump is adequate with dry cooling tower and it is cheaper Vertical condensate pumps with cans can be
considered in the final design if required
218 A concrete shell brick lined flue stack will be larger in diameter and costs more than a steel lined stack Brick lined stack can be
considered in the final design
219 Demineralized water tank capacity for 50 MW is 76 cu meters or 20000 gallons not 1000 cu meters For 20 MW plant it is 38 cu
meters or 10000 gallons
220 It is US practice to use an average continuous blowdown rate of
1 and maximum biowdown rate of 3 for this type of plants
221 This can be studied during Phase II
222 Same as 221
223 Same as 221
224 The recommended action plan calls for continuing support studies covering the referenced items Additional effort is needed to
further define these matters and confirm the conceptual plan
The next step is to develop an outline for a project plan including
o Work Scope
o Schedule
o Budget
accommodate the increase in the number of employees and
equipment Truck bays to accommodate the 136 tonne trucks
will be added The truck bays used for the 77 tonne
trucks will be used for the maintenance of other
equipment The warehouse change house training room
offices and cafeteria will be expanded accordingly
6025 Mining and Processing Economics
Details of the oil shale mining and processing plant
economics for the 400 MW plant are included in the Mining
Report (Appendix 5) These details are of the same
magnitude as prepared for the 20 MW and 50 MW plants
The summary of the cash flow analysis for the mine and
shale processing plant is presented in Table 6-1
Table 6-1
SUMMARY OF 400 MW PLANT OIL SHALE MINING AND PROCESSING COSTS
5050 Debt-Equity 8020 Debt-Equity
US $1000 US $1000
Capital Cost
Mine Development 30915 30915
Mine Equipment 66012 66012
Process Plant Facilities 50889 50889
Spare Parts 5000 5000
Working Capital 10000 10000
Capi tal ized Interest
During Construction 24423 39075
TOTAL 187239 201891
Operating Costs and Other Costs
Annual Cost 60386 53236
Product Mined and Processed
Annual Tonnes x 1000 7783 7783
Unit Cost
US $Tonne (weighted average)
US $l06Btu (weighted average) 776
156
684
138
Year 12 costs taken as 25 year average
6-6
-Au
Table 610 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
- FCC plant sizes equivalent to proposed power application
Prefeasibility Study Oil Shale Fueled Power Generation
VOO94GEampJRI26
i
PYROFLOW UNITS IN THE US
COLORADOUTE IOYA STATE UNIV UNIV OFNUCLA CO NORTHERNAMES IA BF GOODRICH110 1o0MW(a) 2x170000 Ibhr HENRYILCEDAR FALLS IA 120000 Ibhr GENERALGULF OILu EiN P MOTORSSbtUpStart-UIL 1987 O A 1I N000 TC
NORT10 PONTIACH B MIRANCHWV00000 lbhr
CORN PRODUCTSSM NORTH-CAROLINA STOCKTOD CA
400000 lbbhl t
RUMF RD ME
CEMENT CO CALIF PORTLAND-COLTON CA
190000 Iblhr Start-Up 1985 TRUMTFTWN NYU
3I75ERTOWN N
etar t-Up loss ACE COGENERATIONCABI
TRONA CA Oper t~on l -Start-UP 1990 ~ rt upz 091Start-up loss Start-up PNeLAI 1991
MTKESFICOENERATIO-N1
BASFIELDp Start-uStar-Up WESTCA9 199otgoUp 1 MAHONEV PA|00000 Ibhr A Oz 2X365000 Ibhr
SETtr-Ups 188B CHAT TANOOGA TN
G ULF OIL EXPLORATION 8ta-rt-u) 1085BAKERSFIELD NORTH BRANCHCA SPRING GROVE PANORTH BRANCH WV 400000 IbhtOperational 19835 5 0 0 I b h 9 0 0 0 Iblh r- tart-Upi 1991 S t r - U p s l e s s
SOUTHEAST PAPER MFG CO UNIVOF NORTH CAROLINArDUBLIN GA UHAPEL HILL NO400000 IbhrStart-Ups logo Start-Ups2X250O000 1loseIbhr B
- Withdrawing ash from combustor - Withdrawing fly ash
a Internal solids circulation of the steam generator
m Erosioncorrosion of steam generatorinternals
Heat recovery from bottom ash
U Operation with low calorific-value fuel
Prefeasblity Study O Shari Fueled Power Generation
VOO7AI 27
Impact of Scale-Up
Project Size
20 MW
50 MW
100 MW
50 MW boiler in 100 MW plant
Potential Risk
Design Scale-upOperation of to 100 MW Initial Plant Plant
Low Significant
Modest Modest
High Low for duplicate units
Modest Low for duplicate units
Prefeasibility Study Oil Shaje Fueled Power Generation
VOO71-4GEAL4n2
i
Conclusions
Defined risk of CFBC boiler is acceptable
U Operating experience with commercial CFBC boilers built and under construction will strengthen confidencelevel and minimize risk for a plant built in 1995
SPrefeasibility Study Oil Shale Fueled Power Generation
V007GHAAE29
ENVIRONMENTAL ASSESSMENT
a Mine and shale processing
- Fugitive dust emissions
- Noise levels
- Leachability of disposal piles
Power plant
- Fugitive dust emissions
- Gaseous emissions
- Noise levels
- Water effluents
U Conclusions
Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel
Prefeasibility Study Oil Shale Fueled Power Generalon
- Coaloil prices will be at least 15 greater after 1995
- Discovery of indigenous conventional fuel resources is inadequate for power plant purposes
Prefeasibility Study
Oil Shale Fueled Power Generation
VOO) IDWFO
Feasibility(Contd)
N Suitable financing will be available
- For $200 million 50 MW prototypeproject
- For $1000 million 400 MW commercial project
Government of Jordan will make basic commitments
- Long-term power purchase agreement
- Long-term access to Sultani shale deposit
Adequate water and manpower resources
- Attractive tax incentives
Prefeasibility Study
Oil Shale Fueled Power Generaion
VO bull1DUJJRO 6
Timeliness
U Timely development of Jordan oil shale needs prompt action to create - Additional definitive information
- Suitable business plan
Prefeasibility Study
Oil Shale Fueled Power Generation
VooI DUJo 7
i
Expansion Conditions
U Continued expansion of powergeneration from oil shale in Jordan depends on water availability
Prospects for power export or importand domestic load growth will affect size of the needed shale-to-power program
Prefeasibility Sudy
Oil Shale Fueled Power Generation
yOWl lVuJO
Environmental Impacts
N Environmental impacts of shale development will be minimal
Prefeasibility Study Oi Shale Fueled Power Generation
i
Development Advantages
Will create significant new jobopportunities in Jordan
Will avoidreduce foreign exchangelosses for expanding alternate fuel imports
Prefeasibility Study
Oil Shale Fueled Power Generation
VOOIIULL tO
Recommended Action Plan
N Basic recommendation
N Conceptual development schedule
U Project development plan
Key plan elements
N Funding requirements
Prefeasibility Study Oil Shale Fueled Power Generation
VOO4II )U OII
i
Basic Recommendation
N Expand efforts to develop an oil shaleshyfueled power generation program at the Sultani deposit
- Conduct required supporting studies
- Define facilities costs and business plans
- Obtain project funding
Prefeasibility Study
Oil Shale Fueled Power Generation
VON I II)ILL 12
C
Conceptual DevelopmentSchedule
1989-1990
- Conduct supporting studies - Define costsbusiness plans for 50
MW prototype and 400 MW commercial projects
- Develop project financing
N 1990-1993 - Build and operate the prototype project
N 1994-1996 - Expand the 50 MW prototype to 100 MW scale
U 1996-2000 - Expand the project to 400 MW scale
N 2000-2005 - Build a second 400 MW commercial project if needed
i 1 Prefeasiblity Study
dOil Shale Fueled Power Generation
VW IMLITO 13
Conceptual Development Plan
Months
1 Project development plan - Define project
costs1busness plans
-24 -12 0 12 24 36 48 60 72 84 96 108 120
2 Secure funding
3 Build and operate 50 MW prototype
Dergn and procurement
Mine development
Plant construction
Startup and testing
Operations
L- -
4 Expand prototype to 100 MW
Design and procurement
bullConstruction
Startup
5 Expand project to 400 MW
2nd 100 MW unit
3rd100 MW unit
i 44
4th 100 MW unit -
O Project dacision point
i Prefeasib~ity Study Oil Shale Fueled Power Generation
17958562aJocdanV 3-14-89 rsO
18
Phase I - ProjectDevelopment Plan
n Program development
Seminar workshop on prefeasibilitystudy Oate project development plan woek scope schedule arid budget
U Carry out project planning program
- Conduct continuing support studies - Test Sultani shale in existing FBC
- Firm up designs and specifications
- Update costs and economic analysis
- Develop business plans and requirements
Explore project funding alternatives
i Prefeasibility Study
Oil Shale Fueled Power Generation
VO MItUOR 14 -0
Key Plan Elements
N Project feasibility analysis
- Firm up designs and equipmentspecifications for all facilities
- Update cost estimates based on preliminary designs and specifications
Explore arrangements for contract mining and mine development
Update forecasts for demand growthand for retirements of older generating capacity
- Create updated economic analysis
Preleasibility StudyO1 Shae Fueled Power Generation
VOO1IOLWRI
Key Plan Elements (Contd)
Business entity requirement
- Explore optionsconditions for a new company to managebuildoperate the project
- Explore optionsconditions for obtaining a concession agreement for Sultani development
Explore optionsconditions for water rights commitment
Prefeasibility Study Oil Shale Fueled Power Generation
VMIOIA)lj 16S
i
Key Plan Elements (Contd)
U Continuing supporting studies
- Combustion tests (additional pilot tests for design and warranty purposes contract for large-scale burn operations in existing plants if appropriate)
- Additional core drilling and core analysis
- Oil shale crushing tests
- Spent ash leaching tests
- Geotechnical data base including soils analysis
- Environmental baseline data
Prefeasibility Study O Shae Fueled Power Generation
VMMMUldMOA
Steps Required to Develop an Oil Shale-to-Power Project
Create a development business plan - Schedule - Decision tree
Develop a work scope and budget for the development plan program including - Firming up designsspecificationscosts
- Developing business entity requirements - Continuing support studies
Carry out development plan program
Assemble all planning results in a report for discussion with financial institutions
Explore project finance opportunities
Finalize business arrangements
Implement prototype project
i Prefeasibility Study
Oil Shale Fueled Power Generation
VM1-11UJROLI
MARCH 15 JEA QUESTIONS (M S ARAFAH) ON PREFEASIBILITY
STUDY DRAFT REPORT
Rt
DIR EScBSULIVAN PHD OFJCEop~BUREAU FOR SCIENCE AND~TECHNOLOGYAGENCY - --FOR INTERNATIONAL DEVELOPMhINTSWASHINGON DC x20523---------4
4 -
-SUBJ E CT - -C O H~ E T 4N l
Dr Mr sullivan ------shy
c-rommnents We ~efr-preaereorPla -tobYou lete dted Jan 91989 regardn~i4po4t P ea e1 f i nd y ubel ow our -e ot r XcOrcerned Jordanian deipartments
- --A ar o~nnYu Y o turjlt~ lt K
4 C~mments
~1 N i gFIN I~fANDECONOMIC1COIMEN S -
It sidicaed that Beohtel and US AIDWash ingtonj~4- re ojy nen ing that E 2hould und ertake the n e tshyihaisAre ~our c leometprogram n order shye-t im~ ate d f n t v design and budget cost
4Al1so Lthe study ncal--ttsutnilndcaei~ A-1 A thas ~ l 1 be eeded idb~~~~~ rn o ei t n i la itheMWa~-~5s~ 4
hrPro hehgemetTh trOfT ses~fnr4 BOT)Vmanu- a n-mnf~cure 4 r~j or contra c4-or ivoIlveiintijn I 4 4investmnt ude smi ~w 2 Zha tev e r --~4~prce e ec r it v p4~ f JA gertiy geeated-at 4 JEA 3 a l b u y ~the same average~~ A
~jithia oncot in4 ordrtan ecpoemic asess thespePower generatjoon J ordan3 oi sha I eroic c inr~etJordan 4
2P ge i1- 1 Aj iit eu that OPin he atocontr~ct 4with owner4 ofext3ing (oconstriiction r(FB rml-t
qu i of S 11 t to test large tonnagen j es StaniUti n d ajIe -for se veralIQf 31 hi
evrEAPreferpilot qr the dP 1prt7n -that the4mPIt
andi to(7 he instalI 1e 2 310 A
_
JODN ELECTRICITYAUTHORIT LL
Dac
operated in Jordan i n or~der~~t ~n nuex~on mnining crushing and haidi igQhre~ and sash Maeia nd aSootoget enough olr ndaita needed for einolre
CEBbole~ -i s~
ccordance with Jordaian oil shale
large to~ bfig
1 3 le 1-2 Page 1-7 Cost Of Pwer~i It i S menti-oned that the conmecial oil hle~ lt~project (4 X1OOmw) 1is ninacompetative roqt~range-~while table 12 indicates thattcost of-pow Ais~mill
q kwiihcii r 1
average wih i ii -much higher ihantheshy-ost of ~Power gnrtofomJEA therimaPower s ta tions Please~ indicate on what basi o ~~ shave-~made your-statement
PK
14 Pae 2 Sction 4-0sIt 1nlkly that theChousing and off- -site infrastructur-ommnity fakilitieR) to be onsidered for both the demo and prototyp prjcs oeoverwe~4 hnk that their~c_6t is raterojects Mo
iwcv~- age -1 1 Mine O(perationIIt is indicate~d that mining cot eevdfoMine contractor~ are ficomiplee h
r and iyudi-t~con qidder contract mnn opio fr4 the min4 cmflt2ng are reIanddrepres~ent the real costs derived from Phspat miin contractors in
lestfor the eo rPooypuat in order tlt7
P I eadenote tha detthe new exchangerate ofthJraian~ Di~nner you may add 20j6 Kto the quoted
1 6 P Ias e consider the followin ecn hage_
171- The new exchange ra teof tUSD=54o0 fils1 72-W2 The new~ aerage tariff for selIn~electricityhas decrreased to 120 8 f ilIsicwh
17- Page 1-7 TbIe 1-2 W bev th tthe cap ita1 cot for the pwhokand forthe min n d ash hMnd1ing equipen
P B~2Anaor a -Tl 8156152 8176 1Q MYf -t -Now 520 t 1U
JDNEECRICIT AU-RA L14lLiL
2 ~are very high We suggest~ thta You rerconsie (- telowerus e~+d accuracy est a rangethan +30
Page4-22 Table 4-5weno0ti ced( that- PyroPowe ha ddeta(IiacCst fori the bo1ilerlocation and terha dutdetlease isxtr fo~ l C~ io~ s~ e~~ 1a~ a if and indicate theonldjusted ~percentagefor construction foin Jordan
19 Page-7 Table 11-2 -Yo aeue ihrinterest rate on Equity thatn on1DehI~laseinclude~ adetaied explanation of thisrr -tni kepin in miUndie JEA is1thaIt a non profit~ shyorgaiztion unik oher private UJSA utility~in ktation
~-~110- Regarding shy
the ra4ital Rt fthe project it is~requesed tobre k it intdo foreignMeanwhile cthe nd lorcal c-osfoeigptario i nt-re3t~shol becnierdo-h
rr n ontiondonnotopdbon the 9 cnieelocal portion~onth
1-1- 237~Pa
oningeny 9tooi s high~~ a lower 4value -should be~
4~ gt ~112- -Tbles t1-1 -8-8~ inclu~de t~he c~alculationscuultie nt enefits for of Th shyunttypes l i4s difeen geeatnmrer likely tocluae
-~ Q~ J7present vk1u for tenet tthe~benefits in feralterntives -t-oa s the
49
ehliyoi shale
Wea gree with you9 tha t th e percentage used ~ an for thenua~l 0 ~amp-M rahr CFBo ndsomewha~t highervrate be n ededma y for a C B l n Me n h l ~ a e r
indir e ta~ts the -estimatedma i variablec st i ddition t he fi-xed-9i 1 mislkih We --
thinktttiis too lowK -5
shy
1-14- e 4-29
opprza tion-o to The o i1s h1 costs-nc I deAbo 1h
Pa10 mman ormTSI62 a
IB I
JORD N EtECTICI1~ 4 E~)~Is-s
Date ib-_
~ ~riii~g~nd~o9~ru~hng h~tnlin cot~u~tv yo
i Dae Jnryit
1ts c 7 4-
i smiig iniand fh co I eY
susendi ca tI t icag th t1 ~an~approximate 15 ~pita L tYII I (-~a~ge or he owe bl ockj f aniitjes isof +the capthe)t~ial7cpi~lrharge Uoratelformny SI~Uj(uiity installa~tions~ whle page 6-1T9 talJshyit is mentioned that~ the Capital rate pe-r JEA isshyi5~PeaseJustify this~matter since~w o
i16- Pae 6-1 6
1 I4~t is mentioned that the costs of 4process Water are ~ 4 ~0 2$1 000 gallons
r~j~lt IHave~You considered additionalvalue ofbying waterfrom~ the Wa ters Aito i ~or ditoa cost~f o revrseoqoesplant if ground water is used
~~ I1 7- Table 6-1 Page 6-6 Please explain how did You come ou ihteoil~ shale miniing and proces~sing uit~Icost
ltII~I~ 8- Please note 1 t hatj the average JEA~productinr ot frmthermal I power stationsr (Istationbus-barCOSt)i sbewen 6 3-17 3 fils 4kwh You may use this~
l4~ 19-i For ~4 X 100~AMW Plat iti etindo pag e14-4 VolI 11 that4 at tota I of W42 14 epoye W II eemplo~yer] And on page 69yo1Iiti mentioned that a~ tot 1 f1 ~p yeI iNbe enp1oyed a
is~ high asrmetitexeds100personorthe ~41X100~MWh~~j nsatnpPrlae
I 1 The 4 following iftemns are a sumed to1 be excluded from theraPi ta 1 cot xoI
120-1 Perits I icen es 7
1_207~3 Imprt ~xe on s7pare par ts -and c(7orfmurab -ma~teria Is
04f4 4
~4 R j4 4
D4
~ ~ ~ AIf eS taxesq in acrac ihteJraand regulations should be considered aw
21- p1ea4s e indic ate Your Ju t f c io r us ga 6
44122- Table 977App 5Page4 9-1 4L IK Car1Yiniae that the hIRR of the 4 Otplantis rather unattractive (66)most
-( Cns1er4 ngthe logical base 4csek c pwhen cii 6OL
average sell~ing prc CkhampDEratio L801~2O~Aoreover4M the ne siellin prcwh o JEA ati theamptime~ Abeing os4ltp n~ot exceed 4 Ckwh~-However Ipage 1shy~ and 14 0 T indicate that ecnms for a commeri
S4A4scale joil 4 shale projc ~
appear Piomisig-nug o4Ywarrant continued dee fgfluht 4 feaibiit 4tudy wihil cost sevea~lili
do ar~sf Plas lear wether the ~x step jqs~$j~~lt 4
gtt 9o be considered arCcording4to jthe 4unattractiveresul to mentioned in IRR7 Table 97 gt4
a C4 44fET2 4 144-4444 P a g 1 T b6 l
htte~We ~ ~ ae~ rqieetfrteX ~ noie ~~ ~ 444 MW un t44 r te4l w w e o p r d i th e w t r n rre u f4m or4444~ the4444 54M4rto y e Pg~A~44EHiveL det ile an l A44
s o awa er c n um t a4r f rofsho in P6Io erT
e ch 2 50 M W aPln wa e d 41004 MW4 1 consumption_____________
ma4~2 k e u p houin~44 p A44 4444444 C O 4ltI4
a nd a sh et in etc 4 2 4 1 -24 P a g e4 2 - 1 A P P 5
4Yo 4_ j1 4 4~h444 N44 44
1gro nd tce t hir fthe w bern coqir mna t efora4e 4X10A M 444444 4 r i n to 4 4 4lo w w ehA 7 n 2 cinCie h rh4 n ttthh1eb -e 4 44t Of3 E4O
ea h n~ ffl 4 4Jl44 4 4444 4giv
6 ig re sofrat4 de in cl ar f w w at5 c hrw pe o
s h b 444 o t h e g nd L 44 h u i n C
r 4ne a4 t44 e L(704 2 4 p ae) 2 - o Au P dn 5ai 7~e r 44 I Y (1t 44a
ve7 rn e qu 1saharvthe y
and n~~~o speci~~~l4 p n l nh i n t x
r ~rA M e d r o t eu n 8 1 wTtl t t h
- c re e N I wo6
~ n n a i n a t d h l7 A PP6 gt
J
S2~3- Page 2-4 ~ ~ It ~is i
that oil eindicated the- sha le r our~ Cesin Jordan are 10 billion tons -The anulp e reere maiy exeed 50 4 billion tons ~
~ 24- 4Page~2 -l1 iujntr We beiv thtCBcmuto~ep i s high and~alSo
~~ ~ -2 ~~ Page 4-1~6 j - shy
Please~~ indicates your procedure to cool the omn ashand atwa icagd-eprtr
A Have you~ considered~ additional he~at exchanger topcool th ash and to imrve h cycleef ficiency
-~2~6 Page 4-16 It s~ indicated that ash from each silo i Amixed19 ~with~fabout 20 waterKb weight to minimize generation of dust~during trnprtto to mine and disposalHave you~ coniidered other 4lternativeto
~ ~eliminate dustiiig -and avoid use ofwat r uring it ransportationi such as~ using closed trucks or closed
of ~fans conUMnPo wihrlaintthe total plant auiir poe osupin 1~21- Table 5_-3 and I ~
Th~~ is- somneere c6ntradiction regardingplnneotpu~t in both am tables 21-~ Tabl~e 1-33
We noticed tha~t yourall9 cacacapac t fatro75 tion ae asdnWe thilt ~that 7capacityshyfacto is tobo high for- an oil shale fired plant duketo lack of existing simila~r ~plants handl~~~firing oil adshale ~K
216~ The study iniae thtawet~coigtower wi11~used Actually a b
dry cooling should be consideda5ini ~HTP S inZ atomnmz so water rnumption4the cycle~ efficiency willbe reducedHenre YO33~reconsider calculating the cyclefficiy
U~~~~~ codnt umconsidered ofhorizontal -aretypethe~ the vertical cian type can alsobeh considered
shy ~ ~ ~ I~~
2~2 Kconcrete shy
shjell stepl fltstack is onidereconcrete shell brick flue Rt c ~s beCaconsidered3V
2-19~- Deminiraized water~ tank3 capacity~ is -76 ui(meterThe recommnended tank cameter- ui tyi 00cbc
220Designconditions Pa~ge (4-74)te5 hat bow 3down percentage splusmn ~fomrpra til re i hou I be 3~)~
PoD Z 2 m a ad~ - e 5 1 2 iJS~ ~ p A f amp ~ ~ y1
4
JO R ECTICITY AUTHORTIT 4L
~ 4
Date~
t etats ttthe quantityof s i S ~1 000Tons ra Sthis tuntity 11- be transporited for severIy --to tu ofI pit a~te torg P KM ra~erm Spower plIatS about 12 midilidoni CUIA(- met ryea
h e ndd mp e he (d u p in i n L
area wil evric power plant6t Please zn1 a te~tiv s tudY for dumping th r~ a enoug
-from the power plantr~~h~
S 2- Please provide deald-ifrat ao etbaaiedrawing hwn TH11 R thaU and~pV ra~te takcing illto o 6it v- consumptionn _uig themrining equipment
alternate~ study 0o Jine operation for 1 shiftday Vand twoshifts day -lt
224- Conceptua~l pflR 1 for mi ing anusdtransportation of oil- shale a 0 dmj of hs f u r therV examinedh iV~sdpatI ho u1d be
orderj to poe~ehicalq and~eoomca1 fesblt of t his operation
SYour are requested te) study and consider all- above - iPoin s at your earliest in rder -to be peete y oiAnimain on March 29-301989 peetdb~o 4 n
S9incerly-You S
WDIRECTORGENERAL -
I~ CCMR WLINTON ~vs
5N
Pa D~t~IoAmmn -Jordtn -Tel 815615 20 Bl76 15 -19j A VINO- AFf TY
MARCH 21 RESPONSE TO JEA QUESTIONS
Bechtel Power Corporation Engineers - Constructors
Fifty Beale Street San Francisco California Mail Address P 0 Box 3965 San Franclco CA 94119
March 21 1989
Mr M S Arafah Director General Jordan Electricity Authority PO Box 2310 Amman Jordan
Subject Jordan Oil Shale Prefeasibility Study
Dear Mr Arafah
Your letter of 15 March 1989 with comments on the Oil Shale to Power Prefeasibility Study draft report has been referred to me for reply
The attached responses to each item in the reference letter follows the order submitted
Also attached are three revised pages for the draft report - Volume I
Page 6-1 Page 6-21 Page 6-23
Please copy these revised pages into the report previously sent to you
We plan to review this material with JEA during the March 2930 and April 1 meetings in Amman
rsuVertrul yours
W Linton Project Manager
WHLdc
Attachments Questionnaire Response Three revised pages
cc C J Aulisio R R Buta G D Gould T J Wilbanks
32389
Page 1
RESPONSE TO MARCH 15 1989 QUESTIONAIRE
OIL SHALE TO POWER PREFEASIBILITY STUDY
This study examines economic prospects in terms of a 1995-2000 timeframe
FIRANCIAL AND ECONOMIC COMMENTS
11 It is likely that a BOT deal can be structured at present JEA
generation costs for either 20 MW or 50 MW size units if GOJ is
willing to subsidize the incremental power generation cost
Furthermore these incremental costs can be recovered during the 25
year operation of a Commercial Scale Project
12 A 3rd Party Test was proposed as an alternate means to raising
$100+ for an independent JEA sponsored 20 MW Demonstration
program
13 71 millsKWH for Shale Power
VS
JEA 1987 costs
Purchased Power 17 filsKWH = 51 mills
Produced Power 1360 filsKWH = 41 mills
19952000 Costs - Expected to be 30 to 40 higher and in line
with the cost estimate presented in this study
It also is important to recognize that the busbar cost of power
generated by any new power source can not be compared directly
with the cost of existing older installed capacity because of the
lower capital cost component of the latter (See enclosed Figure
1-1 which demonstrates how total capital carrying costs decline as
the investment is paid off) Any new capacity whether coal oil
or oil shale will be an unreasonable disadvantage compared with
costs for existing older capacity
l
024
o2
0De return
E 016Total carrying charge
012 qu return
S -008
ety taxes and n rcw vshy000 X 0 5 10 15 20 25
Figure 1-1 Year-by-year Carrying Charge Components for 15-yearTax Recovery Period
1-7
30
32389
Page 2
14 Infrastructure Cost
Total People
OperatorFamilies Installed Cost
20 MW $10000000 185700 $54000Operator
50 MW 15000000 3241200 46000Operator
400 MW 45000000 10364000 43000Operator
Factored allowance for grass roots desert installation
including housing and community facilities was developed as
follows for the 50 MW case study
Infrastructure
50 MW
Family Housing 200 30K = $ 6 Million
Bachelor Housing 100 20K = 2 M
HospitalClinic (8 Beds) 11 M
SchoolMosque I1 M
Stores Services amp Recreation = 2 M
Facilities
Roads Electricity Water Sewage = 3 M
$15 Million
Infrastructure costs for the 20 MW and 400 MW cases was ratioed
from this breakdown
At this conceptual level costs are order-of-magnitude In a Phase
II program these infrastructure costs can be developed in detail
32389
Page 3
15 Contract Mining Alternatives
Page 4-11 Mine Operation
Based on Bechtels evaluation of the mine contractors price as found in Section 15 of the Mining Report it was concluded that
the mine contractors price does not include costs for such things
as developing the mine with a box-cut ramp haul roads
developing an area for the waste material maintaining the
haulroads constructing the mine services facilities diversion
ditches sedimentation ponds water well crushing the oil shale
pre-mixing the oil shale at the mine and other items associated
with operating a mine to support a power plant If it is proven
that the mine contractors price includes cost for the above
mentioned scope of work in additi-n to drill blast load and
haul then the contractors price can be used but in the meantime
the all inclusive cost developed by Bechtel should be used
Contract Mining appears to be attractive for the smaller size
plants but not for the larger commercial scale operation Some
third party must provide the necessary capital for trucks
loading mining machines etc under a contract arrangement
16 Reassessment due to Dinar value change needs further study and can
not be evaluated given present budget limitations If average
labor rate of $300hr still valid then little change involve with
study
If deemed necessary reexamination of project economics can be
done in Phase IIwhen funded
17 Costs in this study are based on recent similar Bechtel experience
on Mount Poso project and on Montana I project The Mount Poso
project is a 50 MW unit firing coal in a Pyropower boiler The
Montana I project is a 35 MW unit firing coal in a Keeler Dorr
Oliver FBC boiler utilizing dry cooling
32389
Page 4
18 The Pyropower quote of $186000000 to futnish and erect the steam
generator stack and baghouse has been adjusted to include
engineering construction indirect cost etc to be consistant
with the rest of the costs shown in Table 65 p 6-10 No
further adjustment for location was made
19 Equity funding has the lowest priority of payoff in case of a
liquidation and carries greater risk Hence a higher rate of
return is needed to attract these funds Debt funding is a first
mortgage and has first priority for payoff in case of liquidation
and carries less risk Hence it requires lower rate of return
than equity funding
The risk taking equity owner will ask for greater interest rate
to make funds available The only way to minimize this expense is
to find a loaning agency willing to provide 90 or perhaps 95 of
the investment cost It is likely that banks will require some
minimum equity participation
This Prefeasibility Study was not based on a non-profit utility
operation
Even though JEA is a non-profit organization its service
contributors are profit making groups It is visualized that the
Jordan Oil Shale Co (JOSCO) will be a stand alone business
enterprise servicing JEA under long term contract To secure
funding for the proposed project JOSCO will need attractive
enough contract terms to attract both equity and debt capital
110 Additional work is needed to develop the requested information
This work can be preformed as part of the Phase II program
111 Bechtel includes contingency in all of its estimates to cover
error emissions and unforeseen items within the defined scope of
the project The level of contingency is dependent upon the
amount of scope definition For a prefeasible study such as this
15 contingency is lower than normal
32389
Page 5
112 Tables 89 through 816 include a present value calculation to
establish the relative benefit for a shale project vs coal and
oil
113 The variable maintenance cost of 1 millsKWH has been adjusted for CFB plants with an additional $200000 per year or 06 millsKWH
This yields the following
Variable Maintenance - 10 millsKWH
CFB Adjustment - 06
Fixed Maintenance Cost - 40
Total Cost 56 MillsKWH
114 Page 4-29
The royalty costs are included in the weighted average oil shale
costs for the 50 megawatt plant
Page 4-8
Shale fuel costs include return on equity and royalty These are
two separate cost items Royalty is the last item mentioned in
the sentence and it therefore reads as royalty and not return on
royalty
Page 4-31 gives rates used by Bechtel based on our calculations
using the referenced procedures
DebtEquity Capital Charge Rate
5050 153
8020 139
Table 69 displays the calculation of the 153 capital charge
rate (Line 7 of Table 69 is not used in the calculation and
should be deleted)
32389
Page 6
116 No water purchase charge from the Water Authority was added to the
operating expense based on the statement that no resource costs
will be charged
$020 per 1000 gallons is rule of thumb for USA installations in
absence of client data
Boiler make up water (p4-17) is treated in a demineralizer
train If deemed necessary comparison with reverse osmosis
process can be performed in Phase II
Water requirements were estimated to be
Cubic Metres Per Year
20 MW 50 MW 400 MW
Mine amp Shale Processing 455000 761000 773000
Power Block 3000 6000 42000
Infrastructure 80000 140000 448000
Total 538000 907000 1263000
117 Annual average operating costs shown on Table 6-1 are in error
Financing Option 5050 8020
Cost Shown 56606 48945
Corrected Cost 60396 53236
Average mining and shale processing costs are developed year by
year in the Mining Report Appendix 5 Table 12-10
32389
Page 7
118 We would be interested in receiving the breakdown of these current
power cost figures (ie capital charges fuel cost number of
operators etc) Further economic analysis employing these
figures can be developed in Phase II
119 Manpower requirements for the three case studies were estimated as
fol lows
Mining amp Shale Processing
Power Block
Operations
Maintenance
Management
20 MW 50 MW 400 MW
75 163 396
54 78 175
46 73 455
10 10 10
185 324 1036
Page 14-4 of the Mine Report is for mine and shale processing
only It should be noted that most of these manpower requirements
involved new jobs for Jordanian people
120 At the April 1988 Amman Meeting it was agreed that the following
costs would be omitted
o Permits and Licenses
o Local Taxes
o Import Taxes
If necessary such costs can be developed and added into a revised
economic analysis as part of the Phase II program
121 6 average inflation rate is the figure recommended by Bechtel
based on USA conditions for use in long term economic analyses of
new power ventures
32389
Page 8
122 This matter is referred to ORNL who prepared a rate of return
analysis
Bechtels conclusion is based on computed busbar costscumulative
benefits compared to alternate fuels in the timeframe 1995 to 2000
Relative Busbar Power Cost Net 25 Year
Mills per KWH Benefits - Million US$
Sultani Oil Shale 71-83 Base Cost
Imported Coal
$50tonne 68-88 778
$70tonne 78-107 2531
Imported Oil
$17Bbl 56-76 (18) $24Bbl 61-96 1810
The above results are based on a capacity factor of 75 which is
considered to be a reasonable target for a new plant over its 25 year
life The average selling price of 6 cents per KWH cited in the
questionnaire is based on existing plant costs which may not include
all cost elements of new capacity evaluated in this study
32389
Page 9
TECHNICAL COMMENTS
21 See answer to Item 116
Total power plant raw wate consumption rates and annual
consumptions including the water requirements for wetting ash at the truck loading p int within the power plant are given in Tables 43 and 44 for 50 MW unit and Tables 53 and 54 for 20 MW unit
The raw water requirements for 4x0 MW plant were factored
excepting the mine where a revised mine pldn is employed to reduce water request The quantities shown on these tables exclude raw
water requirements for housing complex mine and ash wetting if
required at the ash disposal site
Total power plant requirements shown in the above referred tables
are
50 MW 20 MW
Rate gpm 207 102 (See Drawing M004)
Annual Use
Gallons 1400000 675000
Cooling tower blowndown supplemented with raw water is used for
wetting ash at the truck loading point within the power plant Raw water quantities attributable for ash wetting at the power
truck loading point are
50 MW 20 MW
Rate gpm 75 325
Annual Use
Gallons 500000 215000
These quantities are included in the quantities shown in
the above referred tables
32389
Page 10
22 We recognize the POTENTIAL for leaching toxic compounds from the
spent ash However this matter is not yet defined well enough to
recommend specific action steps The Prefeasibility Study page
7-12 recommends creation of a ground water dispersion model to
determine whether more specific contaminated water mitigation
plans are needed It is anticipated that the leachate rate will
be low and that aquifer dispersion will keep problem compounds
bel3w health standards thresholds
23 Noted
We have not received up to date resource study material which
defines 50 billion tons resource base Please furnish
The resource base at Sultani alone is adequate to support two 400
MW power projects capacity subject water availability The
2-million cubic metre per year water allowance for oilshale will
limit development to about 600 MW
24 Selection of a combustion temperature is a balance between carbon
combustion efficiency and heat loss due carbonate decomposition
For purposes of the Prefeasibility Study we have opted for high
combustion efficiency At lower efficiency larger shale
mineprocessing plants will be needed
25 Bottom ash is cooled by water exchange before discharge
Cooling water is supplied to the ash screw coolers as specified by
Pyropower See Drawing MOO5 2140 gpm flow for 50 MW and 860 gpm
flow for 20 MW Heat removed by the cooling water from the ash
screw coolers is dissipated to atmosphere via a wet cooling
tower Pyropower should indicate the temperature of the ash
discharged to be 5OOF
32389
Page 11
Initially we had considered using a heat exchanger to cool the ash
and improve the cycle efficiency Considering low cost of fuel
the additional capital costs and the system complexities it was
decided not to employ such heat recovery systems for this project
26 The suggested alternates were looked at briefly and the potential
for wind blown air pollution from the ash disposal areas are too
great to warrant dry disposal unless GO(] and World Bank are
willing to accept such a potential problem Wetting the ash is
tne only practical solution Hopefully some cementation will
occur helping to reduce future leaching potential
27 JEA requirements are noted This is a conceptual study not a
final design Optimal design analysis can be performed during
Phase II
2829
JEA requirements are noted and can be incorporated into the Phase
II design
210 The transformer size is adequate for base load operation A
higher capacity can be considered at the final design stage if the
Client prefers
211 From our experience it does not appear to be economical to
provide additional dry cooling towers to take care of maximum
ambient temperatures which may prevail only for a short period of
time in a year To study this an annual dry bulb temperature
duration curve is required Also adding additional dry cooling
towers will change the plant performance It should also be noted
that the dry cooling towers are very expensive and the size should
be selected carefly considering performance and cost and not on the basis of maximum ambient temperatures This can be studied
during Phase II
32389
Page 12
212 The plant gross output varies with condenser pressure
Condenser
Pressure Design 55 in HgA Annual Ave 35 in HgA
Unit Size MW 20 50 4xlO0 20 50 4xlO0
Gross Output MW 234 593 496 2415 607 TBD
Net Output MW 1975 501 400 205 515 TBD
To be developed in Phase II
Output for 4x100 MW is estimated by others
213 The fan power consumption of the CFB boiler is about 30 to 35 of
the total auxiliary power The fan power consumption of the dry
cooling tower is about 20 to 25 of the total auxiliary power
214 Table 1-1 does not include plant net output Therefore do not
understand the comment
215 Commercial operating experience with coal fueled CFBC units in LISA
and Europe has been uniformly good showing high on stream
availability in early years (See Table 2-6 which reports on
Pyropower experience)
We expect operations with high ash content fuel like oilshale will
have unique scale up problems such as
o Solid handling in and out
o Internal solids circulation
o Erosioncorrosion steam generator intervals
o Heat recovery from bottom ash
Consequently we are recommending these items be worked out in a
single 50 MW prototype
32389
Page 13
216 Maximum dry cooling is used in this study A small wet cooling
tower is used on circulating service water system
217 Horizontal condensate pump is adequate with dry cooling tower and it is cheaper Vertical condensate pumps with cans can be
considered in the final design if required
218 A concrete shell brick lined flue stack will be larger in diameter and costs more than a steel lined stack Brick lined stack can be
considered in the final design
219 Demineralized water tank capacity for 50 MW is 76 cu meters or 20000 gallons not 1000 cu meters For 20 MW plant it is 38 cu
meters or 10000 gallons
220 It is US practice to use an average continuous blowdown rate of
1 and maximum biowdown rate of 3 for this type of plants
221 This can be studied during Phase II
222 Same as 221
223 Same as 221
224 The recommended action plan calls for continuing support studies covering the referenced items Additional effort is needed to
further define these matters and confirm the conceptual plan
The next step is to develop an outline for a project plan including
o Work Scope
o Schedule
o Budget
accommodate the increase in the number of employees and
equipment Truck bays to accommodate the 136 tonne trucks
will be added The truck bays used for the 77 tonne
trucks will be used for the maintenance of other
equipment The warehouse change house training room
offices and cafeteria will be expanded accordingly
6025 Mining and Processing Economics
Details of the oil shale mining and processing plant
economics for the 400 MW plant are included in the Mining
Report (Appendix 5) These details are of the same
magnitude as prepared for the 20 MW and 50 MW plants
The summary of the cash flow analysis for the mine and
shale processing plant is presented in Table 6-1
Table 6-1
SUMMARY OF 400 MW PLANT OIL SHALE MINING AND PROCESSING COSTS
5050 Debt-Equity 8020 Debt-Equity
US $1000 US $1000
Capital Cost
Mine Development 30915 30915
Mine Equipment 66012 66012
Process Plant Facilities 50889 50889
Spare Parts 5000 5000
Working Capital 10000 10000
Capi tal ized Interest
During Construction 24423 39075
TOTAL 187239 201891
Operating Costs and Other Costs
Annual Cost 60386 53236
Product Mined and Processed
Annual Tonnes x 1000 7783 7783
Unit Cost
US $Tonne (weighted average)
US $l06Btu (weighted average) 776
156
684
138
Year 12 costs taken as 25 year average
6-6
-Au
Table 610 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
- FCC plant sizes equivalent to proposed power application
Prefeasibility Study Oil Shale Fueled Power Generation
VOO94GEampJRI26
i
PYROFLOW UNITS IN THE US
COLORADOUTE IOYA STATE UNIV UNIV OFNUCLA CO NORTHERNAMES IA BF GOODRICH110 1o0MW(a) 2x170000 Ibhr HENRYILCEDAR FALLS IA 120000 Ibhr GENERALGULF OILu EiN P MOTORSSbtUpStart-UIL 1987 O A 1I N000 TC
NORT10 PONTIACH B MIRANCHWV00000 lbhr
CORN PRODUCTSSM NORTH-CAROLINA STOCKTOD CA
400000 lbbhl t
RUMF RD ME
CEMENT CO CALIF PORTLAND-COLTON CA
190000 Iblhr Start-Up 1985 TRUMTFTWN NYU
3I75ERTOWN N
etar t-Up loss ACE COGENERATIONCABI
TRONA CA Oper t~on l -Start-UP 1990 ~ rt upz 091Start-up loss Start-up PNeLAI 1991
MTKESFICOENERATIO-N1
BASFIELDp Start-uStar-Up WESTCA9 199otgoUp 1 MAHONEV PA|00000 Ibhr A Oz 2X365000 Ibhr
SETtr-Ups 188B CHAT TANOOGA TN
G ULF OIL EXPLORATION 8ta-rt-u) 1085BAKERSFIELD NORTH BRANCHCA SPRING GROVE PANORTH BRANCH WV 400000 IbhtOperational 19835 5 0 0 I b h 9 0 0 0 Iblh r- tart-Upi 1991 S t r - U p s l e s s
SOUTHEAST PAPER MFG CO UNIVOF NORTH CAROLINArDUBLIN GA UHAPEL HILL NO400000 IbhrStart-Ups logo Start-Ups2X250O000 1loseIbhr B
- Withdrawing ash from combustor - Withdrawing fly ash
a Internal solids circulation of the steam generator
m Erosioncorrosion of steam generatorinternals
Heat recovery from bottom ash
U Operation with low calorific-value fuel
Prefeasblity Study O Shari Fueled Power Generation
VOO7AI 27
Impact of Scale-Up
Project Size
20 MW
50 MW
100 MW
50 MW boiler in 100 MW plant
Potential Risk
Design Scale-upOperation of to 100 MW Initial Plant Plant
Low Significant
Modest Modest
High Low for duplicate units
Modest Low for duplicate units
Prefeasibility Study Oil Shaje Fueled Power Generation
VOO71-4GEAL4n2
i
Conclusions
Defined risk of CFBC boiler is acceptable
U Operating experience with commercial CFBC boilers built and under construction will strengthen confidencelevel and minimize risk for a plant built in 1995
SPrefeasibility Study Oil Shale Fueled Power Generation
V007GHAAE29
ENVIRONMENTAL ASSESSMENT
a Mine and shale processing
- Fugitive dust emissions
- Noise levels
- Leachability of disposal piles
Power plant
- Fugitive dust emissions
- Gaseous emissions
- Noise levels
- Water effluents
U Conclusions
Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel
Prefeasibility Study Oil Shale Fueled Power Generalon
- Coaloil prices will be at least 15 greater after 1995
- Discovery of indigenous conventional fuel resources is inadequate for power plant purposes
Prefeasibility Study
Oil Shale Fueled Power Generation
VOO) IDWFO
Feasibility(Contd)
N Suitable financing will be available
- For $200 million 50 MW prototypeproject
- For $1000 million 400 MW commercial project
Government of Jordan will make basic commitments
- Long-term power purchase agreement
- Long-term access to Sultani shale deposit
Adequate water and manpower resources
- Attractive tax incentives
Prefeasibility Study
Oil Shale Fueled Power Generaion
VO bull1DUJJRO 6
Timeliness
U Timely development of Jordan oil shale needs prompt action to create - Additional definitive information
- Suitable business plan
Prefeasibility Study
Oil Shale Fueled Power Generation
VooI DUJo 7
i
Expansion Conditions
U Continued expansion of powergeneration from oil shale in Jordan depends on water availability
Prospects for power export or importand domestic load growth will affect size of the needed shale-to-power program
Prefeasibility Sudy
Oil Shale Fueled Power Generation
yOWl lVuJO
Environmental Impacts
N Environmental impacts of shale development will be minimal
Prefeasibility Study Oi Shale Fueled Power Generation
i
Development Advantages
Will create significant new jobopportunities in Jordan
Will avoidreduce foreign exchangelosses for expanding alternate fuel imports
Prefeasibility Study
Oil Shale Fueled Power Generation
VOOIIULL tO
Recommended Action Plan
N Basic recommendation
N Conceptual development schedule
U Project development plan
Key plan elements
N Funding requirements
Prefeasibility Study Oil Shale Fueled Power Generation
VOO4II )U OII
i
Basic Recommendation
N Expand efforts to develop an oil shaleshyfueled power generation program at the Sultani deposit
- Conduct required supporting studies
- Define facilities costs and business plans
- Obtain project funding
Prefeasibility Study
Oil Shale Fueled Power Generation
VON I II)ILL 12
C
Conceptual DevelopmentSchedule
1989-1990
- Conduct supporting studies - Define costsbusiness plans for 50
MW prototype and 400 MW commercial projects
- Develop project financing
N 1990-1993 - Build and operate the prototype project
N 1994-1996 - Expand the 50 MW prototype to 100 MW scale
U 1996-2000 - Expand the project to 400 MW scale
N 2000-2005 - Build a second 400 MW commercial project if needed
i 1 Prefeasiblity Study
dOil Shale Fueled Power Generation
VW IMLITO 13
Conceptual Development Plan
Months
1 Project development plan - Define project
costs1busness plans
-24 -12 0 12 24 36 48 60 72 84 96 108 120
2 Secure funding
3 Build and operate 50 MW prototype
Dergn and procurement
Mine development
Plant construction
Startup and testing
Operations
L- -
4 Expand prototype to 100 MW
Design and procurement
bullConstruction
Startup
5 Expand project to 400 MW
2nd 100 MW unit
3rd100 MW unit
i 44
4th 100 MW unit -
O Project dacision point
i Prefeasib~ity Study Oil Shale Fueled Power Generation
17958562aJocdanV 3-14-89 rsO
18
Phase I - ProjectDevelopment Plan
n Program development
Seminar workshop on prefeasibilitystudy Oate project development plan woek scope schedule arid budget
U Carry out project planning program
- Conduct continuing support studies - Test Sultani shale in existing FBC
- Firm up designs and specifications
- Update costs and economic analysis
- Develop business plans and requirements
Explore project funding alternatives
i Prefeasibility Study
Oil Shale Fueled Power Generation
VO MItUOR 14 -0
Key Plan Elements
N Project feasibility analysis
- Firm up designs and equipmentspecifications for all facilities
- Update cost estimates based on preliminary designs and specifications
Explore arrangements for contract mining and mine development
Update forecasts for demand growthand for retirements of older generating capacity
- Create updated economic analysis
Preleasibility StudyO1 Shae Fueled Power Generation
VOO1IOLWRI
Key Plan Elements (Contd)
Business entity requirement
- Explore optionsconditions for a new company to managebuildoperate the project
- Explore optionsconditions for obtaining a concession agreement for Sultani development
Explore optionsconditions for water rights commitment
Prefeasibility Study Oil Shale Fueled Power Generation
VMIOIA)lj 16S
i
Key Plan Elements (Contd)
U Continuing supporting studies
- Combustion tests (additional pilot tests for design and warranty purposes contract for large-scale burn operations in existing plants if appropriate)
- Additional core drilling and core analysis
- Oil shale crushing tests
- Spent ash leaching tests
- Geotechnical data base including soils analysis
- Environmental baseline data
Prefeasibility Study O Shae Fueled Power Generation
VMMMUldMOA
Steps Required to Develop an Oil Shale-to-Power Project
Create a development business plan - Schedule - Decision tree
Develop a work scope and budget for the development plan program including - Firming up designsspecificationscosts
- Developing business entity requirements - Continuing support studies
Carry out development plan program
Assemble all planning results in a report for discussion with financial institutions
Explore project finance opportunities
Finalize business arrangements
Implement prototype project
i Prefeasibility Study
Oil Shale Fueled Power Generation
VM1-11UJROLI
MARCH 15 JEA QUESTIONS (M S ARAFAH) ON PREFEASIBILITY
STUDY DRAFT REPORT
Rt
DIR EScBSULIVAN PHD OFJCEop~BUREAU FOR SCIENCE AND~TECHNOLOGYAGENCY - --FOR INTERNATIONAL DEVELOPMhINTSWASHINGON DC x20523---------4
4 -
-SUBJ E CT - -C O H~ E T 4N l
Dr Mr sullivan ------shy
c-rommnents We ~efr-preaereorPla -tobYou lete dted Jan 91989 regardn~i4po4t P ea e1 f i nd y ubel ow our -e ot r XcOrcerned Jordanian deipartments
- --A ar o~nnYu Y o turjlt~ lt K
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It sidicaed that Beohtel and US AIDWash ingtonj~4- re ojy nen ing that E 2hould und ertake the n e tshyihaisAre ~our c leometprogram n order shye-t im~ ate d f n t v design and budget cost
4Al1so Lthe study ncal--ttsutnilndcaei~ A-1 A thas ~ l 1 be eeded idb~~~~~ rn o ei t n i la itheMWa~-~5s~ 4
hrPro hehgemetTh trOfT ses~fnr4 BOT)Vmanu- a n-mnf~cure 4 r~j or contra c4-or ivoIlveiintijn I 4 4investmnt ude smi ~w 2 Zha tev e r --~4~prce e ec r it v p4~ f JA gertiy geeated-at 4 JEA 3 a l b u y ~the same average~~ A
~jithia oncot in4 ordrtan ecpoemic asess thespePower generatjoon J ordan3 oi sha I eroic c inr~etJordan 4
2P ge i1- 1 Aj iit eu that OPin he atocontr~ct 4with owner4 ofext3ing (oconstriiction r(FB rml-t
qu i of S 11 t to test large tonnagen j es StaniUti n d ajIe -for se veralIQf 31 hi
evrEAPreferpilot qr the dP 1prt7n -that the4mPIt
andi to(7 he instalI 1e 2 310 A
_
JODN ELECTRICITYAUTHORIT LL
Dac
operated in Jordan i n or~der~~t ~n nuex~on mnining crushing and haidi igQhre~ and sash Maeia nd aSootoget enough olr ndaita needed for einolre
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ccordance with Jordaian oil shale
large to~ bfig
1 3 le 1-2 Page 1-7 Cost Of Pwer~i It i S menti-oned that the conmecial oil hle~ lt~project (4 X1OOmw) 1is ninacompetative roqt~range-~while table 12 indicates thattcost of-pow Ais~mill
q kwiihcii r 1
average wih i ii -much higher ihantheshy-ost of ~Power gnrtofomJEA therimaPower s ta tions Please~ indicate on what basi o ~~ shave-~made your-statement
PK
14 Pae 2 Sction 4-0sIt 1nlkly that theChousing and off- -site infrastructur-ommnity fakilitieR) to be onsidered for both the demo and prototyp prjcs oeoverwe~4 hnk that their~c_6t is raterojects Mo
iwcv~- age -1 1 Mine O(perationIIt is indicate~d that mining cot eevdfoMine contractor~ are ficomiplee h
r and iyudi-t~con qidder contract mnn opio fr4 the min4 cmflt2ng are reIanddrepres~ent the real costs derived from Phspat miin contractors in
lestfor the eo rPooypuat in order tlt7
P I eadenote tha detthe new exchangerate ofthJraian~ Di~nner you may add 20j6 Kto the quoted
1 6 P Ias e consider the followin ecn hage_
171- The new exchange ra teof tUSD=54o0 fils1 72-W2 The new~ aerage tariff for selIn~electricityhas decrreased to 120 8 f ilIsicwh
17- Page 1-7 TbIe 1-2 W bev th tthe cap ita1 cot for the pwhokand forthe min n d ash hMnd1ing equipen
P B~2Anaor a -Tl 8156152 8176 1Q MYf -t -Now 520 t 1U
JDNEECRICIT AU-RA L14lLiL
2 ~are very high We suggest~ thta You rerconsie (- telowerus e~+d accuracy est a rangethan +30
Page4-22 Table 4-5weno0ti ced( that- PyroPowe ha ddeta(IiacCst fori the bo1ilerlocation and terha dutdetlease isxtr fo~ l C~ io~ s~ e~~ 1a~ a if and indicate theonldjusted ~percentagefor construction foin Jordan
19 Page-7 Table 11-2 -Yo aeue ihrinterest rate on Equity thatn on1DehI~laseinclude~ adetaied explanation of thisrr -tni kepin in miUndie JEA is1thaIt a non profit~ shyorgaiztion unik oher private UJSA utility~in ktation
~-~110- Regarding shy
the ra4ital Rt fthe project it is~requesed tobre k it intdo foreignMeanwhile cthe nd lorcal c-osfoeigptario i nt-re3t~shol becnierdo-h
rr n ontiondonnotopdbon the 9 cnieelocal portion~onth
1-1- 237~Pa
oningeny 9tooi s high~~ a lower 4value -should be~
4~ gt ~112- -Tbles t1-1 -8-8~ inclu~de t~he c~alculationscuultie nt enefits for of Th shyunttypes l i4s difeen geeatnmrer likely tocluae
-~ Q~ J7present vk1u for tenet tthe~benefits in feralterntives -t-oa s the
49
ehliyoi shale
Wea gree with you9 tha t th e percentage used ~ an for thenua~l 0 ~amp-M rahr CFBo ndsomewha~t highervrate be n ededma y for a C B l n Me n h l ~ a e r
indir e ta~ts the -estimatedma i variablec st i ddition t he fi-xed-9i 1 mislkih We --
thinktttiis too lowK -5
shy
1-14- e 4-29
opprza tion-o to The o i1s h1 costs-nc I deAbo 1h
Pa10 mman ormTSI62 a
IB I
JORD N EtECTICI1~ 4 E~)~Is-s
Date ib-_
~ ~riii~g~nd~o9~ru~hng h~tnlin cot~u~tv yo
i Dae Jnryit
1ts c 7 4-
i smiig iniand fh co I eY
susendi ca tI t icag th t1 ~an~approximate 15 ~pita L tYII I (-~a~ge or he owe bl ockj f aniitjes isof +the capthe)t~ial7cpi~lrharge Uoratelformny SI~Uj(uiity installa~tions~ whle page 6-1T9 talJshyit is mentioned that~ the Capital rate pe-r JEA isshyi5~PeaseJustify this~matter since~w o
i16- Pae 6-1 6
1 I4~t is mentioned that the costs of 4process Water are ~ 4 ~0 2$1 000 gallons
r~j~lt IHave~You considered additionalvalue ofbying waterfrom~ the Wa ters Aito i ~or ditoa cost~f o revrseoqoesplant if ground water is used
~~ I1 7- Table 6-1 Page 6-6 Please explain how did You come ou ihteoil~ shale miniing and proces~sing uit~Icost
ltII~I~ 8- Please note 1 t hatj the average JEA~productinr ot frmthermal I power stationsr (Istationbus-barCOSt)i sbewen 6 3-17 3 fils 4kwh You may use this~
l4~ 19-i For ~4 X 100~AMW Plat iti etindo pag e14-4 VolI 11 that4 at tota I of W42 14 epoye W II eemplo~yer] And on page 69yo1Iiti mentioned that a~ tot 1 f1 ~p yeI iNbe enp1oyed a
is~ high asrmetitexeds100personorthe ~41X100~MWh~~j nsatnpPrlae
I 1 The 4 following iftemns are a sumed to1 be excluded from theraPi ta 1 cot xoI
120-1 Perits I icen es 7
1_207~3 Imprt ~xe on s7pare par ts -and c(7orfmurab -ma~teria Is
04f4 4
~4 R j4 4
D4
~ ~ ~ AIf eS taxesq in acrac ihteJraand regulations should be considered aw
21- p1ea4s e indic ate Your Ju t f c io r us ga 6
44122- Table 977App 5Page4 9-1 4L IK Car1Yiniae that the hIRR of the 4 Otplantis rather unattractive (66)most
-( Cns1er4 ngthe logical base 4csek c pwhen cii 6OL
average sell~ing prc CkhampDEratio L801~2O~Aoreover4M the ne siellin prcwh o JEA ati theamptime~ Abeing os4ltp n~ot exceed 4 Ckwh~-However Ipage 1shy~ and 14 0 T indicate that ecnms for a commeri
S4A4scale joil 4 shale projc ~
appear Piomisig-nug o4Ywarrant continued dee fgfluht 4 feaibiit 4tudy wihil cost sevea~lili
do ar~sf Plas lear wether the ~x step jqs~$j~~lt 4
gtt 9o be considered arCcording4to jthe 4unattractiveresul to mentioned in IRR7 Table 97 gt4
a C4 44fET2 4 144-4444 P a g 1 T b6 l
htte~We ~ ~ ae~ rqieetfrteX ~ noie ~~ ~ 444 MW un t44 r te4l w w e o p r d i th e w t r n rre u f4m or4444~ the4444 54M4rto y e Pg~A~44EHiveL det ile an l A44
s o awa er c n um t a4r f rofsho in P6Io erT
e ch 2 50 M W aPln wa e d 41004 MW4 1 consumption_____________
ma4~2 k e u p houin~44 p A44 4444444 C O 4ltI4
a nd a sh et in etc 4 2 4 1 -24 P a g e4 2 - 1 A P P 5
4Yo 4_ j1 4 4~h444 N44 44
1gro nd tce t hir fthe w bern coqir mna t efora4e 4X10A M 444444 4 r i n to 4 4 4lo w w ehA 7 n 2 cinCie h rh4 n ttthh1eb -e 4 44t Of3 E4O
ea h n~ ffl 4 4Jl44 4 4444 4giv
6 ig re sofrat4 de in cl ar f w w at5 c hrw pe o
s h b 444 o t h e g nd L 44 h u i n C
r 4ne a4 t44 e L(704 2 4 p ae) 2 - o Au P dn 5ai 7~e r 44 I Y (1t 44a
ve7 rn e qu 1saharvthe y
and n~~~o speci~~~l4 p n l nh i n t x
r ~rA M e d r o t eu n 8 1 wTtl t t h
- c re e N I wo6
~ n n a i n a t d h l7 A PP6 gt
J
S2~3- Page 2-4 ~ ~ It ~is i
that oil eindicated the- sha le r our~ Cesin Jordan are 10 billion tons -The anulp e reere maiy exeed 50 4 billion tons ~
~ 24- 4Page~2 -l1 iujntr We beiv thtCBcmuto~ep i s high and~alSo
~~ ~ -2 ~~ Page 4-1~6 j - shy
Please~~ indicates your procedure to cool the omn ashand atwa icagd-eprtr
A Have you~ considered~ additional he~at exchanger topcool th ash and to imrve h cycleef ficiency
-~2~6 Page 4-16 It s~ indicated that ash from each silo i Amixed19 ~with~fabout 20 waterKb weight to minimize generation of dust~during trnprtto to mine and disposalHave you~ coniidered other 4lternativeto
~ ~eliminate dustiiig -and avoid use ofwat r uring it ransportationi such as~ using closed trucks or closed
of ~fans conUMnPo wihrlaintthe total plant auiir poe osupin 1~21- Table 5_-3 and I ~
Th~~ is- somneere c6ntradiction regardingplnneotpu~t in both am tables 21-~ Tabl~e 1-33
We noticed tha~t yourall9 cacacapac t fatro75 tion ae asdnWe thilt ~that 7capacityshyfacto is tobo high for- an oil shale fired plant duketo lack of existing simila~r ~plants handl~~~firing oil adshale ~K
216~ The study iniae thtawet~coigtower wi11~used Actually a b
dry cooling should be consideda5ini ~HTP S inZ atomnmz so water rnumption4the cycle~ efficiency willbe reducedHenre YO33~reconsider calculating the cyclefficiy
U~~~~~ codnt umconsidered ofhorizontal -aretypethe~ the vertical cian type can alsobeh considered
shy ~ ~ ~ I~~
2~2 Kconcrete shy
shjell stepl fltstack is onidereconcrete shell brick flue Rt c ~s beCaconsidered3V
2-19~- Deminiraized water~ tank3 capacity~ is -76 ui(meterThe recommnended tank cameter- ui tyi 00cbc
220Designconditions Pa~ge (4-74)te5 hat bow 3down percentage splusmn ~fomrpra til re i hou I be 3~)~
PoD Z 2 m a ad~ - e 5 1 2 iJS~ ~ p A f amp ~ ~ y1
4
JO R ECTICITY AUTHORTIT 4L
~ 4
Date~
t etats ttthe quantityof s i S ~1 000Tons ra Sthis tuntity 11- be transporited for severIy --to tu ofI pit a~te torg P KM ra~erm Spower plIatS about 12 midilidoni CUIA(- met ryea
h e ndd mp e he (d u p in i n L
area wil evric power plant6t Please zn1 a te~tiv s tudY for dumping th r~ a enoug
-from the power plantr~~h~
S 2- Please provide deald-ifrat ao etbaaiedrawing hwn TH11 R thaU and~pV ra~te takcing illto o 6it v- consumptionn _uig themrining equipment
alternate~ study 0o Jine operation for 1 shiftday Vand twoshifts day -lt
224- Conceptua~l pflR 1 for mi ing anusdtransportation of oil- shale a 0 dmj of hs f u r therV examinedh iV~sdpatI ho u1d be
orderj to poe~ehicalq and~eoomca1 fesblt of t his operation
SYour are requested te) study and consider all- above - iPoin s at your earliest in rder -to be peete y oiAnimain on March 29-301989 peetdb~o 4 n
S9incerly-You S
WDIRECTORGENERAL -
I~ CCMR WLINTON ~vs
5N
Pa D~t~IoAmmn -Jordtn -Tel 815615 20 Bl76 15 -19j A VINO- AFf TY
MARCH 21 RESPONSE TO JEA QUESTIONS
Bechtel Power Corporation Engineers - Constructors
Fifty Beale Street San Francisco California Mail Address P 0 Box 3965 San Franclco CA 94119
March 21 1989
Mr M S Arafah Director General Jordan Electricity Authority PO Box 2310 Amman Jordan
Subject Jordan Oil Shale Prefeasibility Study
Dear Mr Arafah
Your letter of 15 March 1989 with comments on the Oil Shale to Power Prefeasibility Study draft report has been referred to me for reply
The attached responses to each item in the reference letter follows the order submitted
Also attached are three revised pages for the draft report - Volume I
Page 6-1 Page 6-21 Page 6-23
Please copy these revised pages into the report previously sent to you
We plan to review this material with JEA during the March 2930 and April 1 meetings in Amman
rsuVertrul yours
W Linton Project Manager
WHLdc
Attachments Questionnaire Response Three revised pages
cc C J Aulisio R R Buta G D Gould T J Wilbanks
32389
Page 1
RESPONSE TO MARCH 15 1989 QUESTIONAIRE
OIL SHALE TO POWER PREFEASIBILITY STUDY
This study examines economic prospects in terms of a 1995-2000 timeframe
FIRANCIAL AND ECONOMIC COMMENTS
11 It is likely that a BOT deal can be structured at present JEA
generation costs for either 20 MW or 50 MW size units if GOJ is
willing to subsidize the incremental power generation cost
Furthermore these incremental costs can be recovered during the 25
year operation of a Commercial Scale Project
12 A 3rd Party Test was proposed as an alternate means to raising
$100+ for an independent JEA sponsored 20 MW Demonstration
program
13 71 millsKWH for Shale Power
VS
JEA 1987 costs
Purchased Power 17 filsKWH = 51 mills
Produced Power 1360 filsKWH = 41 mills
19952000 Costs - Expected to be 30 to 40 higher and in line
with the cost estimate presented in this study
It also is important to recognize that the busbar cost of power
generated by any new power source can not be compared directly
with the cost of existing older installed capacity because of the
lower capital cost component of the latter (See enclosed Figure
1-1 which demonstrates how total capital carrying costs decline as
the investment is paid off) Any new capacity whether coal oil
or oil shale will be an unreasonable disadvantage compared with
costs for existing older capacity
l
024
o2
0De return
E 016Total carrying charge
012 qu return
S -008
ety taxes and n rcw vshy000 X 0 5 10 15 20 25
Figure 1-1 Year-by-year Carrying Charge Components for 15-yearTax Recovery Period
1-7
30
32389
Page 2
14 Infrastructure Cost
Total People
OperatorFamilies Installed Cost
20 MW $10000000 185700 $54000Operator
50 MW 15000000 3241200 46000Operator
400 MW 45000000 10364000 43000Operator
Factored allowance for grass roots desert installation
including housing and community facilities was developed as
follows for the 50 MW case study
Infrastructure
50 MW
Family Housing 200 30K = $ 6 Million
Bachelor Housing 100 20K = 2 M
HospitalClinic (8 Beds) 11 M
SchoolMosque I1 M
Stores Services amp Recreation = 2 M
Facilities
Roads Electricity Water Sewage = 3 M
$15 Million
Infrastructure costs for the 20 MW and 400 MW cases was ratioed
from this breakdown
At this conceptual level costs are order-of-magnitude In a Phase
II program these infrastructure costs can be developed in detail
32389
Page 3
15 Contract Mining Alternatives
Page 4-11 Mine Operation
Based on Bechtels evaluation of the mine contractors price as found in Section 15 of the Mining Report it was concluded that
the mine contractors price does not include costs for such things
as developing the mine with a box-cut ramp haul roads
developing an area for the waste material maintaining the
haulroads constructing the mine services facilities diversion
ditches sedimentation ponds water well crushing the oil shale
pre-mixing the oil shale at the mine and other items associated
with operating a mine to support a power plant If it is proven
that the mine contractors price includes cost for the above
mentioned scope of work in additi-n to drill blast load and
haul then the contractors price can be used but in the meantime
the all inclusive cost developed by Bechtel should be used
Contract Mining appears to be attractive for the smaller size
plants but not for the larger commercial scale operation Some
third party must provide the necessary capital for trucks
loading mining machines etc under a contract arrangement
16 Reassessment due to Dinar value change needs further study and can
not be evaluated given present budget limitations If average
labor rate of $300hr still valid then little change involve with
study
If deemed necessary reexamination of project economics can be
done in Phase IIwhen funded
17 Costs in this study are based on recent similar Bechtel experience
on Mount Poso project and on Montana I project The Mount Poso
project is a 50 MW unit firing coal in a Pyropower boiler The
Montana I project is a 35 MW unit firing coal in a Keeler Dorr
Oliver FBC boiler utilizing dry cooling
32389
Page 4
18 The Pyropower quote of $186000000 to futnish and erect the steam
generator stack and baghouse has been adjusted to include
engineering construction indirect cost etc to be consistant
with the rest of the costs shown in Table 65 p 6-10 No
further adjustment for location was made
19 Equity funding has the lowest priority of payoff in case of a
liquidation and carries greater risk Hence a higher rate of
return is needed to attract these funds Debt funding is a first
mortgage and has first priority for payoff in case of liquidation
and carries less risk Hence it requires lower rate of return
than equity funding
The risk taking equity owner will ask for greater interest rate
to make funds available The only way to minimize this expense is
to find a loaning agency willing to provide 90 or perhaps 95 of
the investment cost It is likely that banks will require some
minimum equity participation
This Prefeasibility Study was not based on a non-profit utility
operation
Even though JEA is a non-profit organization its service
contributors are profit making groups It is visualized that the
Jordan Oil Shale Co (JOSCO) will be a stand alone business
enterprise servicing JEA under long term contract To secure
funding for the proposed project JOSCO will need attractive
enough contract terms to attract both equity and debt capital
110 Additional work is needed to develop the requested information
This work can be preformed as part of the Phase II program
111 Bechtel includes contingency in all of its estimates to cover
error emissions and unforeseen items within the defined scope of
the project The level of contingency is dependent upon the
amount of scope definition For a prefeasible study such as this
15 contingency is lower than normal
32389
Page 5
112 Tables 89 through 816 include a present value calculation to
establish the relative benefit for a shale project vs coal and
oil
113 The variable maintenance cost of 1 millsKWH has been adjusted for CFB plants with an additional $200000 per year or 06 millsKWH
This yields the following
Variable Maintenance - 10 millsKWH
CFB Adjustment - 06
Fixed Maintenance Cost - 40
Total Cost 56 MillsKWH
114 Page 4-29
The royalty costs are included in the weighted average oil shale
costs for the 50 megawatt plant
Page 4-8
Shale fuel costs include return on equity and royalty These are
two separate cost items Royalty is the last item mentioned in
the sentence and it therefore reads as royalty and not return on
royalty
Page 4-31 gives rates used by Bechtel based on our calculations
using the referenced procedures
DebtEquity Capital Charge Rate
5050 153
8020 139
Table 69 displays the calculation of the 153 capital charge
rate (Line 7 of Table 69 is not used in the calculation and
should be deleted)
32389
Page 6
116 No water purchase charge from the Water Authority was added to the
operating expense based on the statement that no resource costs
will be charged
$020 per 1000 gallons is rule of thumb for USA installations in
absence of client data
Boiler make up water (p4-17) is treated in a demineralizer
train If deemed necessary comparison with reverse osmosis
process can be performed in Phase II
Water requirements were estimated to be
Cubic Metres Per Year
20 MW 50 MW 400 MW
Mine amp Shale Processing 455000 761000 773000
Power Block 3000 6000 42000
Infrastructure 80000 140000 448000
Total 538000 907000 1263000
117 Annual average operating costs shown on Table 6-1 are in error
Financing Option 5050 8020
Cost Shown 56606 48945
Corrected Cost 60396 53236
Average mining and shale processing costs are developed year by
year in the Mining Report Appendix 5 Table 12-10
32389
Page 7
118 We would be interested in receiving the breakdown of these current
power cost figures (ie capital charges fuel cost number of
operators etc) Further economic analysis employing these
figures can be developed in Phase II
119 Manpower requirements for the three case studies were estimated as
fol lows
Mining amp Shale Processing
Power Block
Operations
Maintenance
Management
20 MW 50 MW 400 MW
75 163 396
54 78 175
46 73 455
10 10 10
185 324 1036
Page 14-4 of the Mine Report is for mine and shale processing
only It should be noted that most of these manpower requirements
involved new jobs for Jordanian people
120 At the April 1988 Amman Meeting it was agreed that the following
costs would be omitted
o Permits and Licenses
o Local Taxes
o Import Taxes
If necessary such costs can be developed and added into a revised
economic analysis as part of the Phase II program
121 6 average inflation rate is the figure recommended by Bechtel
based on USA conditions for use in long term economic analyses of
new power ventures
32389
Page 8
122 This matter is referred to ORNL who prepared a rate of return
analysis
Bechtels conclusion is based on computed busbar costscumulative
benefits compared to alternate fuels in the timeframe 1995 to 2000
Relative Busbar Power Cost Net 25 Year
Mills per KWH Benefits - Million US$
Sultani Oil Shale 71-83 Base Cost
Imported Coal
$50tonne 68-88 778
$70tonne 78-107 2531
Imported Oil
$17Bbl 56-76 (18) $24Bbl 61-96 1810
The above results are based on a capacity factor of 75 which is
considered to be a reasonable target for a new plant over its 25 year
life The average selling price of 6 cents per KWH cited in the
questionnaire is based on existing plant costs which may not include
all cost elements of new capacity evaluated in this study
32389
Page 9
TECHNICAL COMMENTS
21 See answer to Item 116
Total power plant raw wate consumption rates and annual
consumptions including the water requirements for wetting ash at the truck loading p int within the power plant are given in Tables 43 and 44 for 50 MW unit and Tables 53 and 54 for 20 MW unit
The raw water requirements for 4x0 MW plant were factored
excepting the mine where a revised mine pldn is employed to reduce water request The quantities shown on these tables exclude raw
water requirements for housing complex mine and ash wetting if
required at the ash disposal site
Total power plant requirements shown in the above referred tables
are
50 MW 20 MW
Rate gpm 207 102 (See Drawing M004)
Annual Use
Gallons 1400000 675000
Cooling tower blowndown supplemented with raw water is used for
wetting ash at the truck loading point within the power plant Raw water quantities attributable for ash wetting at the power
truck loading point are
50 MW 20 MW
Rate gpm 75 325
Annual Use
Gallons 500000 215000
These quantities are included in the quantities shown in
the above referred tables
32389
Page 10
22 We recognize the POTENTIAL for leaching toxic compounds from the
spent ash However this matter is not yet defined well enough to
recommend specific action steps The Prefeasibility Study page
7-12 recommends creation of a ground water dispersion model to
determine whether more specific contaminated water mitigation
plans are needed It is anticipated that the leachate rate will
be low and that aquifer dispersion will keep problem compounds
bel3w health standards thresholds
23 Noted
We have not received up to date resource study material which
defines 50 billion tons resource base Please furnish
The resource base at Sultani alone is adequate to support two 400
MW power projects capacity subject water availability The
2-million cubic metre per year water allowance for oilshale will
limit development to about 600 MW
24 Selection of a combustion temperature is a balance between carbon
combustion efficiency and heat loss due carbonate decomposition
For purposes of the Prefeasibility Study we have opted for high
combustion efficiency At lower efficiency larger shale
mineprocessing plants will be needed
25 Bottom ash is cooled by water exchange before discharge
Cooling water is supplied to the ash screw coolers as specified by
Pyropower See Drawing MOO5 2140 gpm flow for 50 MW and 860 gpm
flow for 20 MW Heat removed by the cooling water from the ash
screw coolers is dissipated to atmosphere via a wet cooling
tower Pyropower should indicate the temperature of the ash
discharged to be 5OOF
32389
Page 11
Initially we had considered using a heat exchanger to cool the ash
and improve the cycle efficiency Considering low cost of fuel
the additional capital costs and the system complexities it was
decided not to employ such heat recovery systems for this project
26 The suggested alternates were looked at briefly and the potential
for wind blown air pollution from the ash disposal areas are too
great to warrant dry disposal unless GO(] and World Bank are
willing to accept such a potential problem Wetting the ash is
tne only practical solution Hopefully some cementation will
occur helping to reduce future leaching potential
27 JEA requirements are noted This is a conceptual study not a
final design Optimal design analysis can be performed during
Phase II
2829
JEA requirements are noted and can be incorporated into the Phase
II design
210 The transformer size is adequate for base load operation A
higher capacity can be considered at the final design stage if the
Client prefers
211 From our experience it does not appear to be economical to
provide additional dry cooling towers to take care of maximum
ambient temperatures which may prevail only for a short period of
time in a year To study this an annual dry bulb temperature
duration curve is required Also adding additional dry cooling
towers will change the plant performance It should also be noted
that the dry cooling towers are very expensive and the size should
be selected carefly considering performance and cost and not on the basis of maximum ambient temperatures This can be studied
during Phase II
32389
Page 12
212 The plant gross output varies with condenser pressure
Condenser
Pressure Design 55 in HgA Annual Ave 35 in HgA
Unit Size MW 20 50 4xlO0 20 50 4xlO0
Gross Output MW 234 593 496 2415 607 TBD
Net Output MW 1975 501 400 205 515 TBD
To be developed in Phase II
Output for 4x100 MW is estimated by others
213 The fan power consumption of the CFB boiler is about 30 to 35 of
the total auxiliary power The fan power consumption of the dry
cooling tower is about 20 to 25 of the total auxiliary power
214 Table 1-1 does not include plant net output Therefore do not
understand the comment
215 Commercial operating experience with coal fueled CFBC units in LISA
and Europe has been uniformly good showing high on stream
availability in early years (See Table 2-6 which reports on
Pyropower experience)
We expect operations with high ash content fuel like oilshale will
have unique scale up problems such as
o Solid handling in and out
o Internal solids circulation
o Erosioncorrosion steam generator intervals
o Heat recovery from bottom ash
Consequently we are recommending these items be worked out in a
single 50 MW prototype
32389
Page 13
216 Maximum dry cooling is used in this study A small wet cooling
tower is used on circulating service water system
217 Horizontal condensate pump is adequate with dry cooling tower and it is cheaper Vertical condensate pumps with cans can be
considered in the final design if required
218 A concrete shell brick lined flue stack will be larger in diameter and costs more than a steel lined stack Brick lined stack can be
considered in the final design
219 Demineralized water tank capacity for 50 MW is 76 cu meters or 20000 gallons not 1000 cu meters For 20 MW plant it is 38 cu
meters or 10000 gallons
220 It is US practice to use an average continuous blowdown rate of
1 and maximum biowdown rate of 3 for this type of plants
221 This can be studied during Phase II
222 Same as 221
223 Same as 221
224 The recommended action plan calls for continuing support studies covering the referenced items Additional effort is needed to
further define these matters and confirm the conceptual plan
The next step is to develop an outline for a project plan including
o Work Scope
o Schedule
o Budget
accommodate the increase in the number of employees and
equipment Truck bays to accommodate the 136 tonne trucks
will be added The truck bays used for the 77 tonne
trucks will be used for the maintenance of other
equipment The warehouse change house training room
offices and cafeteria will be expanded accordingly
6025 Mining and Processing Economics
Details of the oil shale mining and processing plant
economics for the 400 MW plant are included in the Mining
Report (Appendix 5) These details are of the same
magnitude as prepared for the 20 MW and 50 MW plants
The summary of the cash flow analysis for the mine and
shale processing plant is presented in Table 6-1
Table 6-1
SUMMARY OF 400 MW PLANT OIL SHALE MINING AND PROCESSING COSTS
5050 Debt-Equity 8020 Debt-Equity
US $1000 US $1000
Capital Cost
Mine Development 30915 30915
Mine Equipment 66012 66012
Process Plant Facilities 50889 50889
Spare Parts 5000 5000
Working Capital 10000 10000
Capi tal ized Interest
During Construction 24423 39075
TOTAL 187239 201891
Operating Costs and Other Costs
Annual Cost 60386 53236
Product Mined and Processed
Annual Tonnes x 1000 7783 7783
Unit Cost
US $Tonne (weighted average)
US $l06Btu (weighted average) 776
156
684
138
Year 12 costs taken as 25 year average
6-6
-Au
Table 610 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
- FCC plant sizes equivalent to proposed power application
Prefeasibility Study Oil Shale Fueled Power Generation
VOO94GEampJRI26
i
PYROFLOW UNITS IN THE US
COLORADOUTE IOYA STATE UNIV UNIV OFNUCLA CO NORTHERNAMES IA BF GOODRICH110 1o0MW(a) 2x170000 Ibhr HENRYILCEDAR FALLS IA 120000 Ibhr GENERALGULF OILu EiN P MOTORSSbtUpStart-UIL 1987 O A 1I N000 TC
NORT10 PONTIACH B MIRANCHWV00000 lbhr
CORN PRODUCTSSM NORTH-CAROLINA STOCKTOD CA
400000 lbbhl t
RUMF RD ME
CEMENT CO CALIF PORTLAND-COLTON CA
190000 Iblhr Start-Up 1985 TRUMTFTWN NYU
3I75ERTOWN N
etar t-Up loss ACE COGENERATIONCABI
TRONA CA Oper t~on l -Start-UP 1990 ~ rt upz 091Start-up loss Start-up PNeLAI 1991
MTKESFICOENERATIO-N1
BASFIELDp Start-uStar-Up WESTCA9 199otgoUp 1 MAHONEV PA|00000 Ibhr A Oz 2X365000 Ibhr
SETtr-Ups 188B CHAT TANOOGA TN
G ULF OIL EXPLORATION 8ta-rt-u) 1085BAKERSFIELD NORTH BRANCHCA SPRING GROVE PANORTH BRANCH WV 400000 IbhtOperational 19835 5 0 0 I b h 9 0 0 0 Iblh r- tart-Upi 1991 S t r - U p s l e s s
SOUTHEAST PAPER MFG CO UNIVOF NORTH CAROLINArDUBLIN GA UHAPEL HILL NO400000 IbhrStart-Ups logo Start-Ups2X250O000 1loseIbhr B
- Withdrawing ash from combustor - Withdrawing fly ash
a Internal solids circulation of the steam generator
m Erosioncorrosion of steam generatorinternals
Heat recovery from bottom ash
U Operation with low calorific-value fuel
Prefeasblity Study O Shari Fueled Power Generation
VOO7AI 27
Impact of Scale-Up
Project Size
20 MW
50 MW
100 MW
50 MW boiler in 100 MW plant
Potential Risk
Design Scale-upOperation of to 100 MW Initial Plant Plant
Low Significant
Modest Modest
High Low for duplicate units
Modest Low for duplicate units
Prefeasibility Study Oil Shaje Fueled Power Generation
VOO71-4GEAL4n2
i
Conclusions
Defined risk of CFBC boiler is acceptable
U Operating experience with commercial CFBC boilers built and under construction will strengthen confidencelevel and minimize risk for a plant built in 1995
SPrefeasibility Study Oil Shale Fueled Power Generation
V007GHAAE29
ENVIRONMENTAL ASSESSMENT
a Mine and shale processing
- Fugitive dust emissions
- Noise levels
- Leachability of disposal piles
Power plant
- Fugitive dust emissions
- Gaseous emissions
- Noise levels
- Water effluents
U Conclusions
Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel
Prefeasibility Study Oil Shale Fueled Power Generalon
- Coaloil prices will be at least 15 greater after 1995
- Discovery of indigenous conventional fuel resources is inadequate for power plant purposes
Prefeasibility Study
Oil Shale Fueled Power Generation
VOO) IDWFO
Feasibility(Contd)
N Suitable financing will be available
- For $200 million 50 MW prototypeproject
- For $1000 million 400 MW commercial project
Government of Jordan will make basic commitments
- Long-term power purchase agreement
- Long-term access to Sultani shale deposit
Adequate water and manpower resources
- Attractive tax incentives
Prefeasibility Study
Oil Shale Fueled Power Generaion
VO bull1DUJJRO 6
Timeliness
U Timely development of Jordan oil shale needs prompt action to create - Additional definitive information
- Suitable business plan
Prefeasibility Study
Oil Shale Fueled Power Generation
VooI DUJo 7
i
Expansion Conditions
U Continued expansion of powergeneration from oil shale in Jordan depends on water availability
Prospects for power export or importand domestic load growth will affect size of the needed shale-to-power program
Prefeasibility Sudy
Oil Shale Fueled Power Generation
yOWl lVuJO
Environmental Impacts
N Environmental impacts of shale development will be minimal
Prefeasibility Study Oi Shale Fueled Power Generation
i
Development Advantages
Will create significant new jobopportunities in Jordan
Will avoidreduce foreign exchangelosses for expanding alternate fuel imports
Prefeasibility Study
Oil Shale Fueled Power Generation
VOOIIULL tO
Recommended Action Plan
N Basic recommendation
N Conceptual development schedule
U Project development plan
Key plan elements
N Funding requirements
Prefeasibility Study Oil Shale Fueled Power Generation
VOO4II )U OII
i
Basic Recommendation
N Expand efforts to develop an oil shaleshyfueled power generation program at the Sultani deposit
- Conduct required supporting studies
- Define facilities costs and business plans
- Obtain project funding
Prefeasibility Study
Oil Shale Fueled Power Generation
VON I II)ILL 12
C
Conceptual DevelopmentSchedule
1989-1990
- Conduct supporting studies - Define costsbusiness plans for 50
MW prototype and 400 MW commercial projects
- Develop project financing
N 1990-1993 - Build and operate the prototype project
N 1994-1996 - Expand the 50 MW prototype to 100 MW scale
U 1996-2000 - Expand the project to 400 MW scale
N 2000-2005 - Build a second 400 MW commercial project if needed
i 1 Prefeasiblity Study
dOil Shale Fueled Power Generation
VW IMLITO 13
Conceptual Development Plan
Months
1 Project development plan - Define project
costs1busness plans
-24 -12 0 12 24 36 48 60 72 84 96 108 120
2 Secure funding
3 Build and operate 50 MW prototype
Dergn and procurement
Mine development
Plant construction
Startup and testing
Operations
L- -
4 Expand prototype to 100 MW
Design and procurement
bullConstruction
Startup
5 Expand project to 400 MW
2nd 100 MW unit
3rd100 MW unit
i 44
4th 100 MW unit -
O Project dacision point
i Prefeasib~ity Study Oil Shale Fueled Power Generation
17958562aJocdanV 3-14-89 rsO
18
Phase I - ProjectDevelopment Plan
n Program development
Seminar workshop on prefeasibilitystudy Oate project development plan woek scope schedule arid budget
U Carry out project planning program
- Conduct continuing support studies - Test Sultani shale in existing FBC
- Firm up designs and specifications
- Update costs and economic analysis
- Develop business plans and requirements
Explore project funding alternatives
i Prefeasibility Study
Oil Shale Fueled Power Generation
VO MItUOR 14 -0
Key Plan Elements
N Project feasibility analysis
- Firm up designs and equipmentspecifications for all facilities
- Update cost estimates based on preliminary designs and specifications
Explore arrangements for contract mining and mine development
Update forecasts for demand growthand for retirements of older generating capacity
- Create updated economic analysis
Preleasibility StudyO1 Shae Fueled Power Generation
VOO1IOLWRI
Key Plan Elements (Contd)
Business entity requirement
- Explore optionsconditions for a new company to managebuildoperate the project
- Explore optionsconditions for obtaining a concession agreement for Sultani development
Explore optionsconditions for water rights commitment
Prefeasibility Study Oil Shale Fueled Power Generation
VMIOIA)lj 16S
i
Key Plan Elements (Contd)
U Continuing supporting studies
- Combustion tests (additional pilot tests for design and warranty purposes contract for large-scale burn operations in existing plants if appropriate)
- Additional core drilling and core analysis
- Oil shale crushing tests
- Spent ash leaching tests
- Geotechnical data base including soils analysis
- Environmental baseline data
Prefeasibility Study O Shae Fueled Power Generation
VMMMUldMOA
Steps Required to Develop an Oil Shale-to-Power Project
Create a development business plan - Schedule - Decision tree
Develop a work scope and budget for the development plan program including - Firming up designsspecificationscosts
- Developing business entity requirements - Continuing support studies
Carry out development plan program
Assemble all planning results in a report for discussion with financial institutions
Explore project finance opportunities
Finalize business arrangements
Implement prototype project
i Prefeasibility Study
Oil Shale Fueled Power Generation
VM1-11UJROLI
MARCH 15 JEA QUESTIONS (M S ARAFAH) ON PREFEASIBILITY
STUDY DRAFT REPORT
Rt
DIR EScBSULIVAN PHD OFJCEop~BUREAU FOR SCIENCE AND~TECHNOLOGYAGENCY - --FOR INTERNATIONAL DEVELOPMhINTSWASHINGON DC x20523---------4
4 -
-SUBJ E CT - -C O H~ E T 4N l
Dr Mr sullivan ------shy
c-rommnents We ~efr-preaereorPla -tobYou lete dted Jan 91989 regardn~i4po4t P ea e1 f i nd y ubel ow our -e ot r XcOrcerned Jordanian deipartments
- --A ar o~nnYu Y o turjlt~ lt K
4 C~mments
~1 N i gFIN I~fANDECONOMIC1COIMEN S -
It sidicaed that Beohtel and US AIDWash ingtonj~4- re ojy nen ing that E 2hould und ertake the n e tshyihaisAre ~our c leometprogram n order shye-t im~ ate d f n t v design and budget cost
4Al1so Lthe study ncal--ttsutnilndcaei~ A-1 A thas ~ l 1 be eeded idb~~~~~ rn o ei t n i la itheMWa~-~5s~ 4
hrPro hehgemetTh trOfT ses~fnr4 BOT)Vmanu- a n-mnf~cure 4 r~j or contra c4-or ivoIlveiintijn I 4 4investmnt ude smi ~w 2 Zha tev e r --~4~prce e ec r it v p4~ f JA gertiy geeated-at 4 JEA 3 a l b u y ~the same average~~ A
~jithia oncot in4 ordrtan ecpoemic asess thespePower generatjoon J ordan3 oi sha I eroic c inr~etJordan 4
2P ge i1- 1 Aj iit eu that OPin he atocontr~ct 4with owner4 ofext3ing (oconstriiction r(FB rml-t
qu i of S 11 t to test large tonnagen j es StaniUti n d ajIe -for se veralIQf 31 hi
evrEAPreferpilot qr the dP 1prt7n -that the4mPIt
andi to(7 he instalI 1e 2 310 A
_
JODN ELECTRICITYAUTHORIT LL
Dac
operated in Jordan i n or~der~~t ~n nuex~on mnining crushing and haidi igQhre~ and sash Maeia nd aSootoget enough olr ndaita needed for einolre
CEBbole~ -i s~
ccordance with Jordaian oil shale
large to~ bfig
1 3 le 1-2 Page 1-7 Cost Of Pwer~i It i S menti-oned that the conmecial oil hle~ lt~project (4 X1OOmw) 1is ninacompetative roqt~range-~while table 12 indicates thattcost of-pow Ais~mill
q kwiihcii r 1
average wih i ii -much higher ihantheshy-ost of ~Power gnrtofomJEA therimaPower s ta tions Please~ indicate on what basi o ~~ shave-~made your-statement
PK
14 Pae 2 Sction 4-0sIt 1nlkly that theChousing and off- -site infrastructur-ommnity fakilitieR) to be onsidered for both the demo and prototyp prjcs oeoverwe~4 hnk that their~c_6t is raterojects Mo
iwcv~- age -1 1 Mine O(perationIIt is indicate~d that mining cot eevdfoMine contractor~ are ficomiplee h
r and iyudi-t~con qidder contract mnn opio fr4 the min4 cmflt2ng are reIanddrepres~ent the real costs derived from Phspat miin contractors in
lestfor the eo rPooypuat in order tlt7
P I eadenote tha detthe new exchangerate ofthJraian~ Di~nner you may add 20j6 Kto the quoted
1 6 P Ias e consider the followin ecn hage_
171- The new exchange ra teof tUSD=54o0 fils1 72-W2 The new~ aerage tariff for selIn~electricityhas decrreased to 120 8 f ilIsicwh
17- Page 1-7 TbIe 1-2 W bev th tthe cap ita1 cot for the pwhokand forthe min n d ash hMnd1ing equipen
P B~2Anaor a -Tl 8156152 8176 1Q MYf -t -Now 520 t 1U
JDNEECRICIT AU-RA L14lLiL
2 ~are very high We suggest~ thta You rerconsie (- telowerus e~+d accuracy est a rangethan +30
Page4-22 Table 4-5weno0ti ced( that- PyroPowe ha ddeta(IiacCst fori the bo1ilerlocation and terha dutdetlease isxtr fo~ l C~ io~ s~ e~~ 1a~ a if and indicate theonldjusted ~percentagefor construction foin Jordan
19 Page-7 Table 11-2 -Yo aeue ihrinterest rate on Equity thatn on1DehI~laseinclude~ adetaied explanation of thisrr -tni kepin in miUndie JEA is1thaIt a non profit~ shyorgaiztion unik oher private UJSA utility~in ktation
~-~110- Regarding shy
the ra4ital Rt fthe project it is~requesed tobre k it intdo foreignMeanwhile cthe nd lorcal c-osfoeigptario i nt-re3t~shol becnierdo-h
rr n ontiondonnotopdbon the 9 cnieelocal portion~onth
1-1- 237~Pa
oningeny 9tooi s high~~ a lower 4value -should be~
4~ gt ~112- -Tbles t1-1 -8-8~ inclu~de t~he c~alculationscuultie nt enefits for of Th shyunttypes l i4s difeen geeatnmrer likely tocluae
-~ Q~ J7present vk1u for tenet tthe~benefits in feralterntives -t-oa s the
49
ehliyoi shale
Wea gree with you9 tha t th e percentage used ~ an for thenua~l 0 ~amp-M rahr CFBo ndsomewha~t highervrate be n ededma y for a C B l n Me n h l ~ a e r
indir e ta~ts the -estimatedma i variablec st i ddition t he fi-xed-9i 1 mislkih We --
thinktttiis too lowK -5
shy
1-14- e 4-29
opprza tion-o to The o i1s h1 costs-nc I deAbo 1h
Pa10 mman ormTSI62 a
IB I
JORD N EtECTICI1~ 4 E~)~Is-s
Date ib-_
~ ~riii~g~nd~o9~ru~hng h~tnlin cot~u~tv yo
i Dae Jnryit
1ts c 7 4-
i smiig iniand fh co I eY
susendi ca tI t icag th t1 ~an~approximate 15 ~pita L tYII I (-~a~ge or he owe bl ockj f aniitjes isof +the capthe)t~ial7cpi~lrharge Uoratelformny SI~Uj(uiity installa~tions~ whle page 6-1T9 talJshyit is mentioned that~ the Capital rate pe-r JEA isshyi5~PeaseJustify this~matter since~w o
i16- Pae 6-1 6
1 I4~t is mentioned that the costs of 4process Water are ~ 4 ~0 2$1 000 gallons
r~j~lt IHave~You considered additionalvalue ofbying waterfrom~ the Wa ters Aito i ~or ditoa cost~f o revrseoqoesplant if ground water is used
~~ I1 7- Table 6-1 Page 6-6 Please explain how did You come ou ihteoil~ shale miniing and proces~sing uit~Icost
ltII~I~ 8- Please note 1 t hatj the average JEA~productinr ot frmthermal I power stationsr (Istationbus-barCOSt)i sbewen 6 3-17 3 fils 4kwh You may use this~
l4~ 19-i For ~4 X 100~AMW Plat iti etindo pag e14-4 VolI 11 that4 at tota I of W42 14 epoye W II eemplo~yer] And on page 69yo1Iiti mentioned that a~ tot 1 f1 ~p yeI iNbe enp1oyed a
is~ high asrmetitexeds100personorthe ~41X100~MWh~~j nsatnpPrlae
I 1 The 4 following iftemns are a sumed to1 be excluded from theraPi ta 1 cot xoI
120-1 Perits I icen es 7
1_207~3 Imprt ~xe on s7pare par ts -and c(7orfmurab -ma~teria Is
04f4 4
~4 R j4 4
D4
~ ~ ~ AIf eS taxesq in acrac ihteJraand regulations should be considered aw
21- p1ea4s e indic ate Your Ju t f c io r us ga 6
44122- Table 977App 5Page4 9-1 4L IK Car1Yiniae that the hIRR of the 4 Otplantis rather unattractive (66)most
-( Cns1er4 ngthe logical base 4csek c pwhen cii 6OL
average sell~ing prc CkhampDEratio L801~2O~Aoreover4M the ne siellin prcwh o JEA ati theamptime~ Abeing os4ltp n~ot exceed 4 Ckwh~-However Ipage 1shy~ and 14 0 T indicate that ecnms for a commeri
S4A4scale joil 4 shale projc ~
appear Piomisig-nug o4Ywarrant continued dee fgfluht 4 feaibiit 4tudy wihil cost sevea~lili
do ar~sf Plas lear wether the ~x step jqs~$j~~lt 4
gtt 9o be considered arCcording4to jthe 4unattractiveresul to mentioned in IRR7 Table 97 gt4
a C4 44fET2 4 144-4444 P a g 1 T b6 l
htte~We ~ ~ ae~ rqieetfrteX ~ noie ~~ ~ 444 MW un t44 r te4l w w e o p r d i th e w t r n rre u f4m or4444~ the4444 54M4rto y e Pg~A~44EHiveL det ile an l A44
s o awa er c n um t a4r f rofsho in P6Io erT
e ch 2 50 M W aPln wa e d 41004 MW4 1 consumption_____________
ma4~2 k e u p houin~44 p A44 4444444 C O 4ltI4
a nd a sh et in etc 4 2 4 1 -24 P a g e4 2 - 1 A P P 5
4Yo 4_ j1 4 4~h444 N44 44
1gro nd tce t hir fthe w bern coqir mna t efora4e 4X10A M 444444 4 r i n to 4 4 4lo w w ehA 7 n 2 cinCie h rh4 n ttthh1eb -e 4 44t Of3 E4O
ea h n~ ffl 4 4Jl44 4 4444 4giv
6 ig re sofrat4 de in cl ar f w w at5 c hrw pe o
s h b 444 o t h e g nd L 44 h u i n C
r 4ne a4 t44 e L(704 2 4 p ae) 2 - o Au P dn 5ai 7~e r 44 I Y (1t 44a
ve7 rn e qu 1saharvthe y
and n~~~o speci~~~l4 p n l nh i n t x
r ~rA M e d r o t eu n 8 1 wTtl t t h
- c re e N I wo6
~ n n a i n a t d h l7 A PP6 gt
J
S2~3- Page 2-4 ~ ~ It ~is i
that oil eindicated the- sha le r our~ Cesin Jordan are 10 billion tons -The anulp e reere maiy exeed 50 4 billion tons ~
~ 24- 4Page~2 -l1 iujntr We beiv thtCBcmuto~ep i s high and~alSo
~~ ~ -2 ~~ Page 4-1~6 j - shy
Please~~ indicates your procedure to cool the omn ashand atwa icagd-eprtr
A Have you~ considered~ additional he~at exchanger topcool th ash and to imrve h cycleef ficiency
-~2~6 Page 4-16 It s~ indicated that ash from each silo i Amixed19 ~with~fabout 20 waterKb weight to minimize generation of dust~during trnprtto to mine and disposalHave you~ coniidered other 4lternativeto
~ ~eliminate dustiiig -and avoid use ofwat r uring it ransportationi such as~ using closed trucks or closed
of ~fans conUMnPo wihrlaintthe total plant auiir poe osupin 1~21- Table 5_-3 and I ~
Th~~ is- somneere c6ntradiction regardingplnneotpu~t in both am tables 21-~ Tabl~e 1-33
We noticed tha~t yourall9 cacacapac t fatro75 tion ae asdnWe thilt ~that 7capacityshyfacto is tobo high for- an oil shale fired plant duketo lack of existing simila~r ~plants handl~~~firing oil adshale ~K
216~ The study iniae thtawet~coigtower wi11~used Actually a b
dry cooling should be consideda5ini ~HTP S inZ atomnmz so water rnumption4the cycle~ efficiency willbe reducedHenre YO33~reconsider calculating the cyclefficiy
U~~~~~ codnt umconsidered ofhorizontal -aretypethe~ the vertical cian type can alsobeh considered
shy ~ ~ ~ I~~
2~2 Kconcrete shy
shjell stepl fltstack is onidereconcrete shell brick flue Rt c ~s beCaconsidered3V
2-19~- Deminiraized water~ tank3 capacity~ is -76 ui(meterThe recommnended tank cameter- ui tyi 00cbc
220Designconditions Pa~ge (4-74)te5 hat bow 3down percentage splusmn ~fomrpra til re i hou I be 3~)~
PoD Z 2 m a ad~ - e 5 1 2 iJS~ ~ p A f amp ~ ~ y1
4
JO R ECTICITY AUTHORTIT 4L
~ 4
Date~
t etats ttthe quantityof s i S ~1 000Tons ra Sthis tuntity 11- be transporited for severIy --to tu ofI pit a~te torg P KM ra~erm Spower plIatS about 12 midilidoni CUIA(- met ryea
h e ndd mp e he (d u p in i n L
area wil evric power plant6t Please zn1 a te~tiv s tudY for dumping th r~ a enoug
-from the power plantr~~h~
S 2- Please provide deald-ifrat ao etbaaiedrawing hwn TH11 R thaU and~pV ra~te takcing illto o 6it v- consumptionn _uig themrining equipment
alternate~ study 0o Jine operation for 1 shiftday Vand twoshifts day -lt
224- Conceptua~l pflR 1 for mi ing anusdtransportation of oil- shale a 0 dmj of hs f u r therV examinedh iV~sdpatI ho u1d be
orderj to poe~ehicalq and~eoomca1 fesblt of t his operation
SYour are requested te) study and consider all- above - iPoin s at your earliest in rder -to be peete y oiAnimain on March 29-301989 peetdb~o 4 n
S9incerly-You S
WDIRECTORGENERAL -
I~ CCMR WLINTON ~vs
5N
Pa D~t~IoAmmn -Jordtn -Tel 815615 20 Bl76 15 -19j A VINO- AFf TY
MARCH 21 RESPONSE TO JEA QUESTIONS
Bechtel Power Corporation Engineers - Constructors
Fifty Beale Street San Francisco California Mail Address P 0 Box 3965 San Franclco CA 94119
March 21 1989
Mr M S Arafah Director General Jordan Electricity Authority PO Box 2310 Amman Jordan
Subject Jordan Oil Shale Prefeasibility Study
Dear Mr Arafah
Your letter of 15 March 1989 with comments on the Oil Shale to Power Prefeasibility Study draft report has been referred to me for reply
The attached responses to each item in the reference letter follows the order submitted
Also attached are three revised pages for the draft report - Volume I
Page 6-1 Page 6-21 Page 6-23
Please copy these revised pages into the report previously sent to you
We plan to review this material with JEA during the March 2930 and April 1 meetings in Amman
rsuVertrul yours
W Linton Project Manager
WHLdc
Attachments Questionnaire Response Three revised pages
cc C J Aulisio R R Buta G D Gould T J Wilbanks
32389
Page 1
RESPONSE TO MARCH 15 1989 QUESTIONAIRE
OIL SHALE TO POWER PREFEASIBILITY STUDY
This study examines economic prospects in terms of a 1995-2000 timeframe
FIRANCIAL AND ECONOMIC COMMENTS
11 It is likely that a BOT deal can be structured at present JEA
generation costs for either 20 MW or 50 MW size units if GOJ is
willing to subsidize the incremental power generation cost
Furthermore these incremental costs can be recovered during the 25
year operation of a Commercial Scale Project
12 A 3rd Party Test was proposed as an alternate means to raising
$100+ for an independent JEA sponsored 20 MW Demonstration
program
13 71 millsKWH for Shale Power
VS
JEA 1987 costs
Purchased Power 17 filsKWH = 51 mills
Produced Power 1360 filsKWH = 41 mills
19952000 Costs - Expected to be 30 to 40 higher and in line
with the cost estimate presented in this study
It also is important to recognize that the busbar cost of power
generated by any new power source can not be compared directly
with the cost of existing older installed capacity because of the
lower capital cost component of the latter (See enclosed Figure
1-1 which demonstrates how total capital carrying costs decline as
the investment is paid off) Any new capacity whether coal oil
or oil shale will be an unreasonable disadvantage compared with
costs for existing older capacity
l
024
o2
0De return
E 016Total carrying charge
012 qu return
S -008
ety taxes and n rcw vshy000 X 0 5 10 15 20 25
Figure 1-1 Year-by-year Carrying Charge Components for 15-yearTax Recovery Period
1-7
30
32389
Page 2
14 Infrastructure Cost
Total People
OperatorFamilies Installed Cost
20 MW $10000000 185700 $54000Operator
50 MW 15000000 3241200 46000Operator
400 MW 45000000 10364000 43000Operator
Factored allowance for grass roots desert installation
including housing and community facilities was developed as
follows for the 50 MW case study
Infrastructure
50 MW
Family Housing 200 30K = $ 6 Million
Bachelor Housing 100 20K = 2 M
HospitalClinic (8 Beds) 11 M
SchoolMosque I1 M
Stores Services amp Recreation = 2 M
Facilities
Roads Electricity Water Sewage = 3 M
$15 Million
Infrastructure costs for the 20 MW and 400 MW cases was ratioed
from this breakdown
At this conceptual level costs are order-of-magnitude In a Phase
II program these infrastructure costs can be developed in detail
32389
Page 3
15 Contract Mining Alternatives
Page 4-11 Mine Operation
Based on Bechtels evaluation of the mine contractors price as found in Section 15 of the Mining Report it was concluded that
the mine contractors price does not include costs for such things
as developing the mine with a box-cut ramp haul roads
developing an area for the waste material maintaining the
haulroads constructing the mine services facilities diversion
ditches sedimentation ponds water well crushing the oil shale
pre-mixing the oil shale at the mine and other items associated
with operating a mine to support a power plant If it is proven
that the mine contractors price includes cost for the above
mentioned scope of work in additi-n to drill blast load and
haul then the contractors price can be used but in the meantime
the all inclusive cost developed by Bechtel should be used
Contract Mining appears to be attractive for the smaller size
plants but not for the larger commercial scale operation Some
third party must provide the necessary capital for trucks
loading mining machines etc under a contract arrangement
16 Reassessment due to Dinar value change needs further study and can
not be evaluated given present budget limitations If average
labor rate of $300hr still valid then little change involve with
study
If deemed necessary reexamination of project economics can be
done in Phase IIwhen funded
17 Costs in this study are based on recent similar Bechtel experience
on Mount Poso project and on Montana I project The Mount Poso
project is a 50 MW unit firing coal in a Pyropower boiler The
Montana I project is a 35 MW unit firing coal in a Keeler Dorr
Oliver FBC boiler utilizing dry cooling
32389
Page 4
18 The Pyropower quote of $186000000 to futnish and erect the steam
generator stack and baghouse has been adjusted to include
engineering construction indirect cost etc to be consistant
with the rest of the costs shown in Table 65 p 6-10 No
further adjustment for location was made
19 Equity funding has the lowest priority of payoff in case of a
liquidation and carries greater risk Hence a higher rate of
return is needed to attract these funds Debt funding is a first
mortgage and has first priority for payoff in case of liquidation
and carries less risk Hence it requires lower rate of return
than equity funding
The risk taking equity owner will ask for greater interest rate
to make funds available The only way to minimize this expense is
to find a loaning agency willing to provide 90 or perhaps 95 of
the investment cost It is likely that banks will require some
minimum equity participation
This Prefeasibility Study was not based on a non-profit utility
operation
Even though JEA is a non-profit organization its service
contributors are profit making groups It is visualized that the
Jordan Oil Shale Co (JOSCO) will be a stand alone business
enterprise servicing JEA under long term contract To secure
funding for the proposed project JOSCO will need attractive
enough contract terms to attract both equity and debt capital
110 Additional work is needed to develop the requested information
This work can be preformed as part of the Phase II program
111 Bechtel includes contingency in all of its estimates to cover
error emissions and unforeseen items within the defined scope of
the project The level of contingency is dependent upon the
amount of scope definition For a prefeasible study such as this
15 contingency is lower than normal
32389
Page 5
112 Tables 89 through 816 include a present value calculation to
establish the relative benefit for a shale project vs coal and
oil
113 The variable maintenance cost of 1 millsKWH has been adjusted for CFB plants with an additional $200000 per year or 06 millsKWH
This yields the following
Variable Maintenance - 10 millsKWH
CFB Adjustment - 06
Fixed Maintenance Cost - 40
Total Cost 56 MillsKWH
114 Page 4-29
The royalty costs are included in the weighted average oil shale
costs for the 50 megawatt plant
Page 4-8
Shale fuel costs include return on equity and royalty These are
two separate cost items Royalty is the last item mentioned in
the sentence and it therefore reads as royalty and not return on
royalty
Page 4-31 gives rates used by Bechtel based on our calculations
using the referenced procedures
DebtEquity Capital Charge Rate
5050 153
8020 139
Table 69 displays the calculation of the 153 capital charge
rate (Line 7 of Table 69 is not used in the calculation and
should be deleted)
32389
Page 6
116 No water purchase charge from the Water Authority was added to the
operating expense based on the statement that no resource costs
will be charged
$020 per 1000 gallons is rule of thumb for USA installations in
absence of client data
Boiler make up water (p4-17) is treated in a demineralizer
train If deemed necessary comparison with reverse osmosis
process can be performed in Phase II
Water requirements were estimated to be
Cubic Metres Per Year
20 MW 50 MW 400 MW
Mine amp Shale Processing 455000 761000 773000
Power Block 3000 6000 42000
Infrastructure 80000 140000 448000
Total 538000 907000 1263000
117 Annual average operating costs shown on Table 6-1 are in error
Financing Option 5050 8020
Cost Shown 56606 48945
Corrected Cost 60396 53236
Average mining and shale processing costs are developed year by
year in the Mining Report Appendix 5 Table 12-10
32389
Page 7
118 We would be interested in receiving the breakdown of these current
power cost figures (ie capital charges fuel cost number of
operators etc) Further economic analysis employing these
figures can be developed in Phase II
119 Manpower requirements for the three case studies were estimated as
fol lows
Mining amp Shale Processing
Power Block
Operations
Maintenance
Management
20 MW 50 MW 400 MW
75 163 396
54 78 175
46 73 455
10 10 10
185 324 1036
Page 14-4 of the Mine Report is for mine and shale processing
only It should be noted that most of these manpower requirements
involved new jobs for Jordanian people
120 At the April 1988 Amman Meeting it was agreed that the following
costs would be omitted
o Permits and Licenses
o Local Taxes
o Import Taxes
If necessary such costs can be developed and added into a revised
economic analysis as part of the Phase II program
121 6 average inflation rate is the figure recommended by Bechtel
based on USA conditions for use in long term economic analyses of
new power ventures
32389
Page 8
122 This matter is referred to ORNL who prepared a rate of return
analysis
Bechtels conclusion is based on computed busbar costscumulative
benefits compared to alternate fuels in the timeframe 1995 to 2000
Relative Busbar Power Cost Net 25 Year
Mills per KWH Benefits - Million US$
Sultani Oil Shale 71-83 Base Cost
Imported Coal
$50tonne 68-88 778
$70tonne 78-107 2531
Imported Oil
$17Bbl 56-76 (18) $24Bbl 61-96 1810
The above results are based on a capacity factor of 75 which is
considered to be a reasonable target for a new plant over its 25 year
life The average selling price of 6 cents per KWH cited in the
questionnaire is based on existing plant costs which may not include
all cost elements of new capacity evaluated in this study
32389
Page 9
TECHNICAL COMMENTS
21 See answer to Item 116
Total power plant raw wate consumption rates and annual
consumptions including the water requirements for wetting ash at the truck loading p int within the power plant are given in Tables 43 and 44 for 50 MW unit and Tables 53 and 54 for 20 MW unit
The raw water requirements for 4x0 MW plant were factored
excepting the mine where a revised mine pldn is employed to reduce water request The quantities shown on these tables exclude raw
water requirements for housing complex mine and ash wetting if
required at the ash disposal site
Total power plant requirements shown in the above referred tables
are
50 MW 20 MW
Rate gpm 207 102 (See Drawing M004)
Annual Use
Gallons 1400000 675000
Cooling tower blowndown supplemented with raw water is used for
wetting ash at the truck loading point within the power plant Raw water quantities attributable for ash wetting at the power
truck loading point are
50 MW 20 MW
Rate gpm 75 325
Annual Use
Gallons 500000 215000
These quantities are included in the quantities shown in
the above referred tables
32389
Page 10
22 We recognize the POTENTIAL for leaching toxic compounds from the
spent ash However this matter is not yet defined well enough to
recommend specific action steps The Prefeasibility Study page
7-12 recommends creation of a ground water dispersion model to
determine whether more specific contaminated water mitigation
plans are needed It is anticipated that the leachate rate will
be low and that aquifer dispersion will keep problem compounds
bel3w health standards thresholds
23 Noted
We have not received up to date resource study material which
defines 50 billion tons resource base Please furnish
The resource base at Sultani alone is adequate to support two 400
MW power projects capacity subject water availability The
2-million cubic metre per year water allowance for oilshale will
limit development to about 600 MW
24 Selection of a combustion temperature is a balance between carbon
combustion efficiency and heat loss due carbonate decomposition
For purposes of the Prefeasibility Study we have opted for high
combustion efficiency At lower efficiency larger shale
mineprocessing plants will be needed
25 Bottom ash is cooled by water exchange before discharge
Cooling water is supplied to the ash screw coolers as specified by
Pyropower See Drawing MOO5 2140 gpm flow for 50 MW and 860 gpm
flow for 20 MW Heat removed by the cooling water from the ash
screw coolers is dissipated to atmosphere via a wet cooling
tower Pyropower should indicate the temperature of the ash
discharged to be 5OOF
32389
Page 11
Initially we had considered using a heat exchanger to cool the ash
and improve the cycle efficiency Considering low cost of fuel
the additional capital costs and the system complexities it was
decided not to employ such heat recovery systems for this project
26 The suggested alternates were looked at briefly and the potential
for wind blown air pollution from the ash disposal areas are too
great to warrant dry disposal unless GO(] and World Bank are
willing to accept such a potential problem Wetting the ash is
tne only practical solution Hopefully some cementation will
occur helping to reduce future leaching potential
27 JEA requirements are noted This is a conceptual study not a
final design Optimal design analysis can be performed during
Phase II
2829
JEA requirements are noted and can be incorporated into the Phase
II design
210 The transformer size is adequate for base load operation A
higher capacity can be considered at the final design stage if the
Client prefers
211 From our experience it does not appear to be economical to
provide additional dry cooling towers to take care of maximum
ambient temperatures which may prevail only for a short period of
time in a year To study this an annual dry bulb temperature
duration curve is required Also adding additional dry cooling
towers will change the plant performance It should also be noted
that the dry cooling towers are very expensive and the size should
be selected carefly considering performance and cost and not on the basis of maximum ambient temperatures This can be studied
during Phase II
32389
Page 12
212 The plant gross output varies with condenser pressure
Condenser
Pressure Design 55 in HgA Annual Ave 35 in HgA
Unit Size MW 20 50 4xlO0 20 50 4xlO0
Gross Output MW 234 593 496 2415 607 TBD
Net Output MW 1975 501 400 205 515 TBD
To be developed in Phase II
Output for 4x100 MW is estimated by others
213 The fan power consumption of the CFB boiler is about 30 to 35 of
the total auxiliary power The fan power consumption of the dry
cooling tower is about 20 to 25 of the total auxiliary power
214 Table 1-1 does not include plant net output Therefore do not
understand the comment
215 Commercial operating experience with coal fueled CFBC units in LISA
and Europe has been uniformly good showing high on stream
availability in early years (See Table 2-6 which reports on
Pyropower experience)
We expect operations with high ash content fuel like oilshale will
have unique scale up problems such as
o Solid handling in and out
o Internal solids circulation
o Erosioncorrosion steam generator intervals
o Heat recovery from bottom ash
Consequently we are recommending these items be worked out in a
single 50 MW prototype
32389
Page 13
216 Maximum dry cooling is used in this study A small wet cooling
tower is used on circulating service water system
217 Horizontal condensate pump is adequate with dry cooling tower and it is cheaper Vertical condensate pumps with cans can be
considered in the final design if required
218 A concrete shell brick lined flue stack will be larger in diameter and costs more than a steel lined stack Brick lined stack can be
considered in the final design
219 Demineralized water tank capacity for 50 MW is 76 cu meters or 20000 gallons not 1000 cu meters For 20 MW plant it is 38 cu
meters or 10000 gallons
220 It is US practice to use an average continuous blowdown rate of
1 and maximum biowdown rate of 3 for this type of plants
221 This can be studied during Phase II
222 Same as 221
223 Same as 221
224 The recommended action plan calls for continuing support studies covering the referenced items Additional effort is needed to
further define these matters and confirm the conceptual plan
The next step is to develop an outline for a project plan including
o Work Scope
o Schedule
o Budget
accommodate the increase in the number of employees and
equipment Truck bays to accommodate the 136 tonne trucks
will be added The truck bays used for the 77 tonne
trucks will be used for the maintenance of other
equipment The warehouse change house training room
offices and cafeteria will be expanded accordingly
6025 Mining and Processing Economics
Details of the oil shale mining and processing plant
economics for the 400 MW plant are included in the Mining
Report (Appendix 5) These details are of the same
magnitude as prepared for the 20 MW and 50 MW plants
The summary of the cash flow analysis for the mine and
shale processing plant is presented in Table 6-1
Table 6-1
SUMMARY OF 400 MW PLANT OIL SHALE MINING AND PROCESSING COSTS
5050 Debt-Equity 8020 Debt-Equity
US $1000 US $1000
Capital Cost
Mine Development 30915 30915
Mine Equipment 66012 66012
Process Plant Facilities 50889 50889
Spare Parts 5000 5000
Working Capital 10000 10000
Capi tal ized Interest
During Construction 24423 39075
TOTAL 187239 201891
Operating Costs and Other Costs
Annual Cost 60386 53236
Product Mined and Processed
Annual Tonnes x 1000 7783 7783
Unit Cost
US $Tonne (weighted average)
US $l06Btu (weighted average) 776
156
684
138
Year 12 costs taken as 25 year average
6-6
-Au
Table 610 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
- FCC plant sizes equivalent to proposed power application
Prefeasibility Study Oil Shale Fueled Power Generation
VOO94GEampJRI26
i
PYROFLOW UNITS IN THE US
COLORADOUTE IOYA STATE UNIV UNIV OFNUCLA CO NORTHERNAMES IA BF GOODRICH110 1o0MW(a) 2x170000 Ibhr HENRYILCEDAR FALLS IA 120000 Ibhr GENERALGULF OILu EiN P MOTORSSbtUpStart-UIL 1987 O A 1I N000 TC
NORT10 PONTIACH B MIRANCHWV00000 lbhr
CORN PRODUCTSSM NORTH-CAROLINA STOCKTOD CA
400000 lbbhl t
RUMF RD ME
CEMENT CO CALIF PORTLAND-COLTON CA
190000 Iblhr Start-Up 1985 TRUMTFTWN NYU
3I75ERTOWN N
etar t-Up loss ACE COGENERATIONCABI
TRONA CA Oper t~on l -Start-UP 1990 ~ rt upz 091Start-up loss Start-up PNeLAI 1991
MTKESFICOENERATIO-N1
BASFIELDp Start-uStar-Up WESTCA9 199otgoUp 1 MAHONEV PA|00000 Ibhr A Oz 2X365000 Ibhr
SETtr-Ups 188B CHAT TANOOGA TN
G ULF OIL EXPLORATION 8ta-rt-u) 1085BAKERSFIELD NORTH BRANCHCA SPRING GROVE PANORTH BRANCH WV 400000 IbhtOperational 19835 5 0 0 I b h 9 0 0 0 Iblh r- tart-Upi 1991 S t r - U p s l e s s
SOUTHEAST PAPER MFG CO UNIVOF NORTH CAROLINArDUBLIN GA UHAPEL HILL NO400000 IbhrStart-Ups logo Start-Ups2X250O000 1loseIbhr B
- Withdrawing ash from combustor - Withdrawing fly ash
a Internal solids circulation of the steam generator
m Erosioncorrosion of steam generatorinternals
Heat recovery from bottom ash
U Operation with low calorific-value fuel
Prefeasblity Study O Shari Fueled Power Generation
VOO7AI 27
Impact of Scale-Up
Project Size
20 MW
50 MW
100 MW
50 MW boiler in 100 MW plant
Potential Risk
Design Scale-upOperation of to 100 MW Initial Plant Plant
Low Significant
Modest Modest
High Low for duplicate units
Modest Low for duplicate units
Prefeasibility Study Oil Shaje Fueled Power Generation
VOO71-4GEAL4n2
i
Conclusions
Defined risk of CFBC boiler is acceptable
U Operating experience with commercial CFBC boilers built and under construction will strengthen confidencelevel and minimize risk for a plant built in 1995
SPrefeasibility Study Oil Shale Fueled Power Generation
V007GHAAE29
ENVIRONMENTAL ASSESSMENT
a Mine and shale processing
- Fugitive dust emissions
- Noise levels
- Leachability of disposal piles
Power plant
- Fugitive dust emissions
- Gaseous emissions
- Noise levels
- Water effluents
U Conclusions
Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel
Prefeasibility Study Oil Shale Fueled Power Generalon
- Coaloil prices will be at least 15 greater after 1995
- Discovery of indigenous conventional fuel resources is inadequate for power plant purposes
Prefeasibility Study
Oil Shale Fueled Power Generation
VOO) IDWFO
Feasibility(Contd)
N Suitable financing will be available
- For $200 million 50 MW prototypeproject
- For $1000 million 400 MW commercial project
Government of Jordan will make basic commitments
- Long-term power purchase agreement
- Long-term access to Sultani shale deposit
Adequate water and manpower resources
- Attractive tax incentives
Prefeasibility Study
Oil Shale Fueled Power Generaion
VO bull1DUJJRO 6
Timeliness
U Timely development of Jordan oil shale needs prompt action to create - Additional definitive information
- Suitable business plan
Prefeasibility Study
Oil Shale Fueled Power Generation
VooI DUJo 7
i
Expansion Conditions
U Continued expansion of powergeneration from oil shale in Jordan depends on water availability
Prospects for power export or importand domestic load growth will affect size of the needed shale-to-power program
Prefeasibility Sudy
Oil Shale Fueled Power Generation
yOWl lVuJO
Environmental Impacts
N Environmental impacts of shale development will be minimal
Prefeasibility Study Oi Shale Fueled Power Generation
i
Development Advantages
Will create significant new jobopportunities in Jordan
Will avoidreduce foreign exchangelosses for expanding alternate fuel imports
Prefeasibility Study
Oil Shale Fueled Power Generation
VOOIIULL tO
Recommended Action Plan
N Basic recommendation
N Conceptual development schedule
U Project development plan
Key plan elements
N Funding requirements
Prefeasibility Study Oil Shale Fueled Power Generation
VOO4II )U OII
i
Basic Recommendation
N Expand efforts to develop an oil shaleshyfueled power generation program at the Sultani deposit
- Conduct required supporting studies
- Define facilities costs and business plans
- Obtain project funding
Prefeasibility Study
Oil Shale Fueled Power Generation
VON I II)ILL 12
C
Conceptual DevelopmentSchedule
1989-1990
- Conduct supporting studies - Define costsbusiness plans for 50
MW prototype and 400 MW commercial projects
- Develop project financing
N 1990-1993 - Build and operate the prototype project
N 1994-1996 - Expand the 50 MW prototype to 100 MW scale
U 1996-2000 - Expand the project to 400 MW scale
N 2000-2005 - Build a second 400 MW commercial project if needed
i 1 Prefeasiblity Study
dOil Shale Fueled Power Generation
VW IMLITO 13
Conceptual Development Plan
Months
1 Project development plan - Define project
costs1busness plans
-24 -12 0 12 24 36 48 60 72 84 96 108 120
2 Secure funding
3 Build and operate 50 MW prototype
Dergn and procurement
Mine development
Plant construction
Startup and testing
Operations
L- -
4 Expand prototype to 100 MW
Design and procurement
bullConstruction
Startup
5 Expand project to 400 MW
2nd 100 MW unit
3rd100 MW unit
i 44
4th 100 MW unit -
O Project dacision point
i Prefeasib~ity Study Oil Shale Fueled Power Generation
17958562aJocdanV 3-14-89 rsO
18
Phase I - ProjectDevelopment Plan
n Program development
Seminar workshop on prefeasibilitystudy Oate project development plan woek scope schedule arid budget
U Carry out project planning program
- Conduct continuing support studies - Test Sultani shale in existing FBC
- Firm up designs and specifications
- Update costs and economic analysis
- Develop business plans and requirements
Explore project funding alternatives
i Prefeasibility Study
Oil Shale Fueled Power Generation
VO MItUOR 14 -0
Key Plan Elements
N Project feasibility analysis
- Firm up designs and equipmentspecifications for all facilities
- Update cost estimates based on preliminary designs and specifications
Explore arrangements for contract mining and mine development
Update forecasts for demand growthand for retirements of older generating capacity
- Create updated economic analysis
Preleasibility StudyO1 Shae Fueled Power Generation
VOO1IOLWRI
Key Plan Elements (Contd)
Business entity requirement
- Explore optionsconditions for a new company to managebuildoperate the project
- Explore optionsconditions for obtaining a concession agreement for Sultani development
Explore optionsconditions for water rights commitment
Prefeasibility Study Oil Shale Fueled Power Generation
VMIOIA)lj 16S
i
Key Plan Elements (Contd)
U Continuing supporting studies
- Combustion tests (additional pilot tests for design and warranty purposes contract for large-scale burn operations in existing plants if appropriate)
- Additional core drilling and core analysis
- Oil shale crushing tests
- Spent ash leaching tests
- Geotechnical data base including soils analysis
- Environmental baseline data
Prefeasibility Study O Shae Fueled Power Generation
VMMMUldMOA
Steps Required to Develop an Oil Shale-to-Power Project
Create a development business plan - Schedule - Decision tree
Develop a work scope and budget for the development plan program including - Firming up designsspecificationscosts
- Developing business entity requirements - Continuing support studies
Carry out development plan program
Assemble all planning results in a report for discussion with financial institutions
Explore project finance opportunities
Finalize business arrangements
Implement prototype project
i Prefeasibility Study
Oil Shale Fueled Power Generation
VM1-11UJROLI
MARCH 15 JEA QUESTIONS (M S ARAFAH) ON PREFEASIBILITY
STUDY DRAFT REPORT
Rt
DIR EScBSULIVAN PHD OFJCEop~BUREAU FOR SCIENCE AND~TECHNOLOGYAGENCY - --FOR INTERNATIONAL DEVELOPMhINTSWASHINGON DC x20523---------4
4 -
-SUBJ E CT - -C O H~ E T 4N l
Dr Mr sullivan ------shy
c-rommnents We ~efr-preaereorPla -tobYou lete dted Jan 91989 regardn~i4po4t P ea e1 f i nd y ubel ow our -e ot r XcOrcerned Jordanian deipartments
- --A ar o~nnYu Y o turjlt~ lt K
4 C~mments
~1 N i gFIN I~fANDECONOMIC1COIMEN S -
It sidicaed that Beohtel and US AIDWash ingtonj~4- re ojy nen ing that E 2hould und ertake the n e tshyihaisAre ~our c leometprogram n order shye-t im~ ate d f n t v design and budget cost
4Al1so Lthe study ncal--ttsutnilndcaei~ A-1 A thas ~ l 1 be eeded idb~~~~~ rn o ei t n i la itheMWa~-~5s~ 4
hrPro hehgemetTh trOfT ses~fnr4 BOT)Vmanu- a n-mnf~cure 4 r~j or contra c4-or ivoIlveiintijn I 4 4investmnt ude smi ~w 2 Zha tev e r --~4~prce e ec r it v p4~ f JA gertiy geeated-at 4 JEA 3 a l b u y ~the same average~~ A
~jithia oncot in4 ordrtan ecpoemic asess thespePower generatjoon J ordan3 oi sha I eroic c inr~etJordan 4
2P ge i1- 1 Aj iit eu that OPin he atocontr~ct 4with owner4 ofext3ing (oconstriiction r(FB rml-t
qu i of S 11 t to test large tonnagen j es StaniUti n d ajIe -for se veralIQf 31 hi
evrEAPreferpilot qr the dP 1prt7n -that the4mPIt
andi to(7 he instalI 1e 2 310 A
_
JODN ELECTRICITYAUTHORIT LL
Dac
operated in Jordan i n or~der~~t ~n nuex~on mnining crushing and haidi igQhre~ and sash Maeia nd aSootoget enough olr ndaita needed for einolre
CEBbole~ -i s~
ccordance with Jordaian oil shale
large to~ bfig
1 3 le 1-2 Page 1-7 Cost Of Pwer~i It i S menti-oned that the conmecial oil hle~ lt~project (4 X1OOmw) 1is ninacompetative roqt~range-~while table 12 indicates thattcost of-pow Ais~mill
q kwiihcii r 1
average wih i ii -much higher ihantheshy-ost of ~Power gnrtofomJEA therimaPower s ta tions Please~ indicate on what basi o ~~ shave-~made your-statement
PK
14 Pae 2 Sction 4-0sIt 1nlkly that theChousing and off- -site infrastructur-ommnity fakilitieR) to be onsidered for both the demo and prototyp prjcs oeoverwe~4 hnk that their~c_6t is raterojects Mo
iwcv~- age -1 1 Mine O(perationIIt is indicate~d that mining cot eevdfoMine contractor~ are ficomiplee h
r and iyudi-t~con qidder contract mnn opio fr4 the min4 cmflt2ng are reIanddrepres~ent the real costs derived from Phspat miin contractors in
lestfor the eo rPooypuat in order tlt7
P I eadenote tha detthe new exchangerate ofthJraian~ Di~nner you may add 20j6 Kto the quoted
1 6 P Ias e consider the followin ecn hage_
171- The new exchange ra teof tUSD=54o0 fils1 72-W2 The new~ aerage tariff for selIn~electricityhas decrreased to 120 8 f ilIsicwh
17- Page 1-7 TbIe 1-2 W bev th tthe cap ita1 cot for the pwhokand forthe min n d ash hMnd1ing equipen
P B~2Anaor a -Tl 8156152 8176 1Q MYf -t -Now 520 t 1U
JDNEECRICIT AU-RA L14lLiL
2 ~are very high We suggest~ thta You rerconsie (- telowerus e~+d accuracy est a rangethan +30
Page4-22 Table 4-5weno0ti ced( that- PyroPowe ha ddeta(IiacCst fori the bo1ilerlocation and terha dutdetlease isxtr fo~ l C~ io~ s~ e~~ 1a~ a if and indicate theonldjusted ~percentagefor construction foin Jordan
19 Page-7 Table 11-2 -Yo aeue ihrinterest rate on Equity thatn on1DehI~laseinclude~ adetaied explanation of thisrr -tni kepin in miUndie JEA is1thaIt a non profit~ shyorgaiztion unik oher private UJSA utility~in ktation
~-~110- Regarding shy
the ra4ital Rt fthe project it is~requesed tobre k it intdo foreignMeanwhile cthe nd lorcal c-osfoeigptario i nt-re3t~shol becnierdo-h
rr n ontiondonnotopdbon the 9 cnieelocal portion~onth
1-1- 237~Pa
oningeny 9tooi s high~~ a lower 4value -should be~
4~ gt ~112- -Tbles t1-1 -8-8~ inclu~de t~he c~alculationscuultie nt enefits for of Th shyunttypes l i4s difeen geeatnmrer likely tocluae
-~ Q~ J7present vk1u for tenet tthe~benefits in feralterntives -t-oa s the
49
ehliyoi shale
Wea gree with you9 tha t th e percentage used ~ an for thenua~l 0 ~amp-M rahr CFBo ndsomewha~t highervrate be n ededma y for a C B l n Me n h l ~ a e r
indir e ta~ts the -estimatedma i variablec st i ddition t he fi-xed-9i 1 mislkih We --
thinktttiis too lowK -5
shy
1-14- e 4-29
opprza tion-o to The o i1s h1 costs-nc I deAbo 1h
Pa10 mman ormTSI62 a
IB I
JORD N EtECTICI1~ 4 E~)~Is-s
Date ib-_
~ ~riii~g~nd~o9~ru~hng h~tnlin cot~u~tv yo
i Dae Jnryit
1ts c 7 4-
i smiig iniand fh co I eY
susendi ca tI t icag th t1 ~an~approximate 15 ~pita L tYII I (-~a~ge or he owe bl ockj f aniitjes isof +the capthe)t~ial7cpi~lrharge Uoratelformny SI~Uj(uiity installa~tions~ whle page 6-1T9 talJshyit is mentioned that~ the Capital rate pe-r JEA isshyi5~PeaseJustify this~matter since~w o
i16- Pae 6-1 6
1 I4~t is mentioned that the costs of 4process Water are ~ 4 ~0 2$1 000 gallons
r~j~lt IHave~You considered additionalvalue ofbying waterfrom~ the Wa ters Aito i ~or ditoa cost~f o revrseoqoesplant if ground water is used
~~ I1 7- Table 6-1 Page 6-6 Please explain how did You come ou ihteoil~ shale miniing and proces~sing uit~Icost
ltII~I~ 8- Please note 1 t hatj the average JEA~productinr ot frmthermal I power stationsr (Istationbus-barCOSt)i sbewen 6 3-17 3 fils 4kwh You may use this~
l4~ 19-i For ~4 X 100~AMW Plat iti etindo pag e14-4 VolI 11 that4 at tota I of W42 14 epoye W II eemplo~yer] And on page 69yo1Iiti mentioned that a~ tot 1 f1 ~p yeI iNbe enp1oyed a
is~ high asrmetitexeds100personorthe ~41X100~MWh~~j nsatnpPrlae
I 1 The 4 following iftemns are a sumed to1 be excluded from theraPi ta 1 cot xoI
120-1 Perits I icen es 7
1_207~3 Imprt ~xe on s7pare par ts -and c(7orfmurab -ma~teria Is
04f4 4
~4 R j4 4
D4
~ ~ ~ AIf eS taxesq in acrac ihteJraand regulations should be considered aw
21- p1ea4s e indic ate Your Ju t f c io r us ga 6
44122- Table 977App 5Page4 9-1 4L IK Car1Yiniae that the hIRR of the 4 Otplantis rather unattractive (66)most
-( Cns1er4 ngthe logical base 4csek c pwhen cii 6OL
average sell~ing prc CkhampDEratio L801~2O~Aoreover4M the ne siellin prcwh o JEA ati theamptime~ Abeing os4ltp n~ot exceed 4 Ckwh~-However Ipage 1shy~ and 14 0 T indicate that ecnms for a commeri
S4A4scale joil 4 shale projc ~
appear Piomisig-nug o4Ywarrant continued dee fgfluht 4 feaibiit 4tudy wihil cost sevea~lili
do ar~sf Plas lear wether the ~x step jqs~$j~~lt 4
gtt 9o be considered arCcording4to jthe 4unattractiveresul to mentioned in IRR7 Table 97 gt4
a C4 44fET2 4 144-4444 P a g 1 T b6 l
htte~We ~ ~ ae~ rqieetfrteX ~ noie ~~ ~ 444 MW un t44 r te4l w w e o p r d i th e w t r n rre u f4m or4444~ the4444 54M4rto y e Pg~A~44EHiveL det ile an l A44
s o awa er c n um t a4r f rofsho in P6Io erT
e ch 2 50 M W aPln wa e d 41004 MW4 1 consumption_____________
ma4~2 k e u p houin~44 p A44 4444444 C O 4ltI4
a nd a sh et in etc 4 2 4 1 -24 P a g e4 2 - 1 A P P 5
4Yo 4_ j1 4 4~h444 N44 44
1gro nd tce t hir fthe w bern coqir mna t efora4e 4X10A M 444444 4 r i n to 4 4 4lo w w ehA 7 n 2 cinCie h rh4 n ttthh1eb -e 4 44t Of3 E4O
ea h n~ ffl 4 4Jl44 4 4444 4giv
6 ig re sofrat4 de in cl ar f w w at5 c hrw pe o
s h b 444 o t h e g nd L 44 h u i n C
r 4ne a4 t44 e L(704 2 4 p ae) 2 - o Au P dn 5ai 7~e r 44 I Y (1t 44a
ve7 rn e qu 1saharvthe y
and n~~~o speci~~~l4 p n l nh i n t x
r ~rA M e d r o t eu n 8 1 wTtl t t h
- c re e N I wo6
~ n n a i n a t d h l7 A PP6 gt
J
S2~3- Page 2-4 ~ ~ It ~is i
that oil eindicated the- sha le r our~ Cesin Jordan are 10 billion tons -The anulp e reere maiy exeed 50 4 billion tons ~
~ 24- 4Page~2 -l1 iujntr We beiv thtCBcmuto~ep i s high and~alSo
~~ ~ -2 ~~ Page 4-1~6 j - shy
Please~~ indicates your procedure to cool the omn ashand atwa icagd-eprtr
A Have you~ considered~ additional he~at exchanger topcool th ash and to imrve h cycleef ficiency
-~2~6 Page 4-16 It s~ indicated that ash from each silo i Amixed19 ~with~fabout 20 waterKb weight to minimize generation of dust~during trnprtto to mine and disposalHave you~ coniidered other 4lternativeto
~ ~eliminate dustiiig -and avoid use ofwat r uring it ransportationi such as~ using closed trucks or closed
of ~fans conUMnPo wihrlaintthe total plant auiir poe osupin 1~21- Table 5_-3 and I ~
Th~~ is- somneere c6ntradiction regardingplnneotpu~t in both am tables 21-~ Tabl~e 1-33
We noticed tha~t yourall9 cacacapac t fatro75 tion ae asdnWe thilt ~that 7capacityshyfacto is tobo high for- an oil shale fired plant duketo lack of existing simila~r ~plants handl~~~firing oil adshale ~K
216~ The study iniae thtawet~coigtower wi11~used Actually a b
dry cooling should be consideda5ini ~HTP S inZ atomnmz so water rnumption4the cycle~ efficiency willbe reducedHenre YO33~reconsider calculating the cyclefficiy
U~~~~~ codnt umconsidered ofhorizontal -aretypethe~ the vertical cian type can alsobeh considered
shy ~ ~ ~ I~~
2~2 Kconcrete shy
shjell stepl fltstack is onidereconcrete shell brick flue Rt c ~s beCaconsidered3V
2-19~- Deminiraized water~ tank3 capacity~ is -76 ui(meterThe recommnended tank cameter- ui tyi 00cbc
220Designconditions Pa~ge (4-74)te5 hat bow 3down percentage splusmn ~fomrpra til re i hou I be 3~)~
PoD Z 2 m a ad~ - e 5 1 2 iJS~ ~ p A f amp ~ ~ y1
4
JO R ECTICITY AUTHORTIT 4L
~ 4
Date~
t etats ttthe quantityof s i S ~1 000Tons ra Sthis tuntity 11- be transporited for severIy --to tu ofI pit a~te torg P KM ra~erm Spower plIatS about 12 midilidoni CUIA(- met ryea
h e ndd mp e he (d u p in i n L
area wil evric power plant6t Please zn1 a te~tiv s tudY for dumping th r~ a enoug
-from the power plantr~~h~
S 2- Please provide deald-ifrat ao etbaaiedrawing hwn TH11 R thaU and~pV ra~te takcing illto o 6it v- consumptionn _uig themrining equipment
alternate~ study 0o Jine operation for 1 shiftday Vand twoshifts day -lt
224- Conceptua~l pflR 1 for mi ing anusdtransportation of oil- shale a 0 dmj of hs f u r therV examinedh iV~sdpatI ho u1d be
orderj to poe~ehicalq and~eoomca1 fesblt of t his operation
SYour are requested te) study and consider all- above - iPoin s at your earliest in rder -to be peete y oiAnimain on March 29-301989 peetdb~o 4 n
S9incerly-You S
WDIRECTORGENERAL -
I~ CCMR WLINTON ~vs
5N
Pa D~t~IoAmmn -Jordtn -Tel 815615 20 Bl76 15 -19j A VINO- AFf TY
MARCH 21 RESPONSE TO JEA QUESTIONS
Bechtel Power Corporation Engineers - Constructors
Fifty Beale Street San Francisco California Mail Address P 0 Box 3965 San Franclco CA 94119
March 21 1989
Mr M S Arafah Director General Jordan Electricity Authority PO Box 2310 Amman Jordan
Subject Jordan Oil Shale Prefeasibility Study
Dear Mr Arafah
Your letter of 15 March 1989 with comments on the Oil Shale to Power Prefeasibility Study draft report has been referred to me for reply
The attached responses to each item in the reference letter follows the order submitted
Also attached are three revised pages for the draft report - Volume I
Page 6-1 Page 6-21 Page 6-23
Please copy these revised pages into the report previously sent to you
We plan to review this material with JEA during the March 2930 and April 1 meetings in Amman
rsuVertrul yours
W Linton Project Manager
WHLdc
Attachments Questionnaire Response Three revised pages
cc C J Aulisio R R Buta G D Gould T J Wilbanks
32389
Page 1
RESPONSE TO MARCH 15 1989 QUESTIONAIRE
OIL SHALE TO POWER PREFEASIBILITY STUDY
This study examines economic prospects in terms of a 1995-2000 timeframe
FIRANCIAL AND ECONOMIC COMMENTS
11 It is likely that a BOT deal can be structured at present JEA
generation costs for either 20 MW or 50 MW size units if GOJ is
willing to subsidize the incremental power generation cost
Furthermore these incremental costs can be recovered during the 25
year operation of a Commercial Scale Project
12 A 3rd Party Test was proposed as an alternate means to raising
$100+ for an independent JEA sponsored 20 MW Demonstration
program
13 71 millsKWH for Shale Power
VS
JEA 1987 costs
Purchased Power 17 filsKWH = 51 mills
Produced Power 1360 filsKWH = 41 mills
19952000 Costs - Expected to be 30 to 40 higher and in line
with the cost estimate presented in this study
It also is important to recognize that the busbar cost of power
generated by any new power source can not be compared directly
with the cost of existing older installed capacity because of the
lower capital cost component of the latter (See enclosed Figure
1-1 which demonstrates how total capital carrying costs decline as
the investment is paid off) Any new capacity whether coal oil
or oil shale will be an unreasonable disadvantage compared with
costs for existing older capacity
l
024
o2
0De return
E 016Total carrying charge
012 qu return
S -008
ety taxes and n rcw vshy000 X 0 5 10 15 20 25
Figure 1-1 Year-by-year Carrying Charge Components for 15-yearTax Recovery Period
1-7
30
32389
Page 2
14 Infrastructure Cost
Total People
OperatorFamilies Installed Cost
20 MW $10000000 185700 $54000Operator
50 MW 15000000 3241200 46000Operator
400 MW 45000000 10364000 43000Operator
Factored allowance for grass roots desert installation
including housing and community facilities was developed as
follows for the 50 MW case study
Infrastructure
50 MW
Family Housing 200 30K = $ 6 Million
Bachelor Housing 100 20K = 2 M
HospitalClinic (8 Beds) 11 M
SchoolMosque I1 M
Stores Services amp Recreation = 2 M
Facilities
Roads Electricity Water Sewage = 3 M
$15 Million
Infrastructure costs for the 20 MW and 400 MW cases was ratioed
from this breakdown
At this conceptual level costs are order-of-magnitude In a Phase
II program these infrastructure costs can be developed in detail
32389
Page 3
15 Contract Mining Alternatives
Page 4-11 Mine Operation
Based on Bechtels evaluation of the mine contractors price as found in Section 15 of the Mining Report it was concluded that
the mine contractors price does not include costs for such things
as developing the mine with a box-cut ramp haul roads
developing an area for the waste material maintaining the
haulroads constructing the mine services facilities diversion
ditches sedimentation ponds water well crushing the oil shale
pre-mixing the oil shale at the mine and other items associated
with operating a mine to support a power plant If it is proven
that the mine contractors price includes cost for the above
mentioned scope of work in additi-n to drill blast load and
haul then the contractors price can be used but in the meantime
the all inclusive cost developed by Bechtel should be used
Contract Mining appears to be attractive for the smaller size
plants but not for the larger commercial scale operation Some
third party must provide the necessary capital for trucks
loading mining machines etc under a contract arrangement
16 Reassessment due to Dinar value change needs further study and can
not be evaluated given present budget limitations If average
labor rate of $300hr still valid then little change involve with
study
If deemed necessary reexamination of project economics can be
done in Phase IIwhen funded
17 Costs in this study are based on recent similar Bechtel experience
on Mount Poso project and on Montana I project The Mount Poso
project is a 50 MW unit firing coal in a Pyropower boiler The
Montana I project is a 35 MW unit firing coal in a Keeler Dorr
Oliver FBC boiler utilizing dry cooling
32389
Page 4
18 The Pyropower quote of $186000000 to futnish and erect the steam
generator stack and baghouse has been adjusted to include
engineering construction indirect cost etc to be consistant
with the rest of the costs shown in Table 65 p 6-10 No
further adjustment for location was made
19 Equity funding has the lowest priority of payoff in case of a
liquidation and carries greater risk Hence a higher rate of
return is needed to attract these funds Debt funding is a first
mortgage and has first priority for payoff in case of liquidation
and carries less risk Hence it requires lower rate of return
than equity funding
The risk taking equity owner will ask for greater interest rate
to make funds available The only way to minimize this expense is
to find a loaning agency willing to provide 90 or perhaps 95 of
the investment cost It is likely that banks will require some
minimum equity participation
This Prefeasibility Study was not based on a non-profit utility
operation
Even though JEA is a non-profit organization its service
contributors are profit making groups It is visualized that the
Jordan Oil Shale Co (JOSCO) will be a stand alone business
enterprise servicing JEA under long term contract To secure
funding for the proposed project JOSCO will need attractive
enough contract terms to attract both equity and debt capital
110 Additional work is needed to develop the requested information
This work can be preformed as part of the Phase II program
111 Bechtel includes contingency in all of its estimates to cover
error emissions and unforeseen items within the defined scope of
the project The level of contingency is dependent upon the
amount of scope definition For a prefeasible study such as this
15 contingency is lower than normal
32389
Page 5
112 Tables 89 through 816 include a present value calculation to
establish the relative benefit for a shale project vs coal and
oil
113 The variable maintenance cost of 1 millsKWH has been adjusted for CFB plants with an additional $200000 per year or 06 millsKWH
This yields the following
Variable Maintenance - 10 millsKWH
CFB Adjustment - 06
Fixed Maintenance Cost - 40
Total Cost 56 MillsKWH
114 Page 4-29
The royalty costs are included in the weighted average oil shale
costs for the 50 megawatt plant
Page 4-8
Shale fuel costs include return on equity and royalty These are
two separate cost items Royalty is the last item mentioned in
the sentence and it therefore reads as royalty and not return on
royalty
Page 4-31 gives rates used by Bechtel based on our calculations
using the referenced procedures
DebtEquity Capital Charge Rate
5050 153
8020 139
Table 69 displays the calculation of the 153 capital charge
rate (Line 7 of Table 69 is not used in the calculation and
should be deleted)
32389
Page 6
116 No water purchase charge from the Water Authority was added to the
operating expense based on the statement that no resource costs
will be charged
$020 per 1000 gallons is rule of thumb for USA installations in
absence of client data
Boiler make up water (p4-17) is treated in a demineralizer
train If deemed necessary comparison with reverse osmosis
process can be performed in Phase II
Water requirements were estimated to be
Cubic Metres Per Year
20 MW 50 MW 400 MW
Mine amp Shale Processing 455000 761000 773000
Power Block 3000 6000 42000
Infrastructure 80000 140000 448000
Total 538000 907000 1263000
117 Annual average operating costs shown on Table 6-1 are in error
Financing Option 5050 8020
Cost Shown 56606 48945
Corrected Cost 60396 53236
Average mining and shale processing costs are developed year by
year in the Mining Report Appendix 5 Table 12-10
32389
Page 7
118 We would be interested in receiving the breakdown of these current
power cost figures (ie capital charges fuel cost number of
operators etc) Further economic analysis employing these
figures can be developed in Phase II
119 Manpower requirements for the three case studies were estimated as
fol lows
Mining amp Shale Processing
Power Block
Operations
Maintenance
Management
20 MW 50 MW 400 MW
75 163 396
54 78 175
46 73 455
10 10 10
185 324 1036
Page 14-4 of the Mine Report is for mine and shale processing
only It should be noted that most of these manpower requirements
involved new jobs for Jordanian people
120 At the April 1988 Amman Meeting it was agreed that the following
costs would be omitted
o Permits and Licenses
o Local Taxes
o Import Taxes
If necessary such costs can be developed and added into a revised
economic analysis as part of the Phase II program
121 6 average inflation rate is the figure recommended by Bechtel
based on USA conditions for use in long term economic analyses of
new power ventures
32389
Page 8
122 This matter is referred to ORNL who prepared a rate of return
analysis
Bechtels conclusion is based on computed busbar costscumulative
benefits compared to alternate fuels in the timeframe 1995 to 2000
Relative Busbar Power Cost Net 25 Year
Mills per KWH Benefits - Million US$
Sultani Oil Shale 71-83 Base Cost
Imported Coal
$50tonne 68-88 778
$70tonne 78-107 2531
Imported Oil
$17Bbl 56-76 (18) $24Bbl 61-96 1810
The above results are based on a capacity factor of 75 which is
considered to be a reasonable target for a new plant over its 25 year
life The average selling price of 6 cents per KWH cited in the
questionnaire is based on existing plant costs which may not include
all cost elements of new capacity evaluated in this study
32389
Page 9
TECHNICAL COMMENTS
21 See answer to Item 116
Total power plant raw wate consumption rates and annual
consumptions including the water requirements for wetting ash at the truck loading p int within the power plant are given in Tables 43 and 44 for 50 MW unit and Tables 53 and 54 for 20 MW unit
The raw water requirements for 4x0 MW plant were factored
excepting the mine where a revised mine pldn is employed to reduce water request The quantities shown on these tables exclude raw
water requirements for housing complex mine and ash wetting if
required at the ash disposal site
Total power plant requirements shown in the above referred tables
are
50 MW 20 MW
Rate gpm 207 102 (See Drawing M004)
Annual Use
Gallons 1400000 675000
Cooling tower blowndown supplemented with raw water is used for
wetting ash at the truck loading point within the power plant Raw water quantities attributable for ash wetting at the power
truck loading point are
50 MW 20 MW
Rate gpm 75 325
Annual Use
Gallons 500000 215000
These quantities are included in the quantities shown in
the above referred tables
32389
Page 10
22 We recognize the POTENTIAL for leaching toxic compounds from the
spent ash However this matter is not yet defined well enough to
recommend specific action steps The Prefeasibility Study page
7-12 recommends creation of a ground water dispersion model to
determine whether more specific contaminated water mitigation
plans are needed It is anticipated that the leachate rate will
be low and that aquifer dispersion will keep problem compounds
bel3w health standards thresholds
23 Noted
We have not received up to date resource study material which
defines 50 billion tons resource base Please furnish
The resource base at Sultani alone is adequate to support two 400
MW power projects capacity subject water availability The
2-million cubic metre per year water allowance for oilshale will
limit development to about 600 MW
24 Selection of a combustion temperature is a balance between carbon
combustion efficiency and heat loss due carbonate decomposition
For purposes of the Prefeasibility Study we have opted for high
combustion efficiency At lower efficiency larger shale
mineprocessing plants will be needed
25 Bottom ash is cooled by water exchange before discharge
Cooling water is supplied to the ash screw coolers as specified by
Pyropower See Drawing MOO5 2140 gpm flow for 50 MW and 860 gpm
flow for 20 MW Heat removed by the cooling water from the ash
screw coolers is dissipated to atmosphere via a wet cooling
tower Pyropower should indicate the temperature of the ash
discharged to be 5OOF
32389
Page 11
Initially we had considered using a heat exchanger to cool the ash
and improve the cycle efficiency Considering low cost of fuel
the additional capital costs and the system complexities it was
decided not to employ such heat recovery systems for this project
26 The suggested alternates were looked at briefly and the potential
for wind blown air pollution from the ash disposal areas are too
great to warrant dry disposal unless GO(] and World Bank are
willing to accept such a potential problem Wetting the ash is
tne only practical solution Hopefully some cementation will
occur helping to reduce future leaching potential
27 JEA requirements are noted This is a conceptual study not a
final design Optimal design analysis can be performed during
Phase II
2829
JEA requirements are noted and can be incorporated into the Phase
II design
210 The transformer size is adequate for base load operation A
higher capacity can be considered at the final design stage if the
Client prefers
211 From our experience it does not appear to be economical to
provide additional dry cooling towers to take care of maximum
ambient temperatures which may prevail only for a short period of
time in a year To study this an annual dry bulb temperature
duration curve is required Also adding additional dry cooling
towers will change the plant performance It should also be noted
that the dry cooling towers are very expensive and the size should
be selected carefly considering performance and cost and not on the basis of maximum ambient temperatures This can be studied
during Phase II
32389
Page 12
212 The plant gross output varies with condenser pressure
Condenser
Pressure Design 55 in HgA Annual Ave 35 in HgA
Unit Size MW 20 50 4xlO0 20 50 4xlO0
Gross Output MW 234 593 496 2415 607 TBD
Net Output MW 1975 501 400 205 515 TBD
To be developed in Phase II
Output for 4x100 MW is estimated by others
213 The fan power consumption of the CFB boiler is about 30 to 35 of
the total auxiliary power The fan power consumption of the dry
cooling tower is about 20 to 25 of the total auxiliary power
214 Table 1-1 does not include plant net output Therefore do not
understand the comment
215 Commercial operating experience with coal fueled CFBC units in LISA
and Europe has been uniformly good showing high on stream
availability in early years (See Table 2-6 which reports on
Pyropower experience)
We expect operations with high ash content fuel like oilshale will
have unique scale up problems such as
o Solid handling in and out
o Internal solids circulation
o Erosioncorrosion steam generator intervals
o Heat recovery from bottom ash
Consequently we are recommending these items be worked out in a
single 50 MW prototype
32389
Page 13
216 Maximum dry cooling is used in this study A small wet cooling
tower is used on circulating service water system
217 Horizontal condensate pump is adequate with dry cooling tower and it is cheaper Vertical condensate pumps with cans can be
considered in the final design if required
218 A concrete shell brick lined flue stack will be larger in diameter and costs more than a steel lined stack Brick lined stack can be
considered in the final design
219 Demineralized water tank capacity for 50 MW is 76 cu meters or 20000 gallons not 1000 cu meters For 20 MW plant it is 38 cu
meters or 10000 gallons
220 It is US practice to use an average continuous blowdown rate of
1 and maximum biowdown rate of 3 for this type of plants
221 This can be studied during Phase II
222 Same as 221
223 Same as 221
224 The recommended action plan calls for continuing support studies covering the referenced items Additional effort is needed to
further define these matters and confirm the conceptual plan
The next step is to develop an outline for a project plan including
o Work Scope
o Schedule
o Budget
accommodate the increase in the number of employees and
equipment Truck bays to accommodate the 136 tonne trucks
will be added The truck bays used for the 77 tonne
trucks will be used for the maintenance of other
equipment The warehouse change house training room
offices and cafeteria will be expanded accordingly
6025 Mining and Processing Economics
Details of the oil shale mining and processing plant
economics for the 400 MW plant are included in the Mining
Report (Appendix 5) These details are of the same
magnitude as prepared for the 20 MW and 50 MW plants
The summary of the cash flow analysis for the mine and
shale processing plant is presented in Table 6-1
Table 6-1
SUMMARY OF 400 MW PLANT OIL SHALE MINING AND PROCESSING COSTS
5050 Debt-Equity 8020 Debt-Equity
US $1000 US $1000
Capital Cost
Mine Development 30915 30915
Mine Equipment 66012 66012
Process Plant Facilities 50889 50889
Spare Parts 5000 5000
Working Capital 10000 10000
Capi tal ized Interest
During Construction 24423 39075
TOTAL 187239 201891
Operating Costs and Other Costs
Annual Cost 60386 53236
Product Mined and Processed
Annual Tonnes x 1000 7783 7783
Unit Cost
US $Tonne (weighted average)
US $l06Btu (weighted average) 776
156
684
138
Year 12 costs taken as 25 year average
6-6
-Au
Table 610 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
- FCC plant sizes equivalent to proposed power application
Prefeasibility Study Oil Shale Fueled Power Generation
VOO94GEampJRI26
i
PYROFLOW UNITS IN THE US
COLORADOUTE IOYA STATE UNIV UNIV OFNUCLA CO NORTHERNAMES IA BF GOODRICH110 1o0MW(a) 2x170000 Ibhr HENRYILCEDAR FALLS IA 120000 Ibhr GENERALGULF OILu EiN P MOTORSSbtUpStart-UIL 1987 O A 1I N000 TC
NORT10 PONTIACH B MIRANCHWV00000 lbhr
CORN PRODUCTSSM NORTH-CAROLINA STOCKTOD CA
400000 lbbhl t
RUMF RD ME
CEMENT CO CALIF PORTLAND-COLTON CA
190000 Iblhr Start-Up 1985 TRUMTFTWN NYU
3I75ERTOWN N
etar t-Up loss ACE COGENERATIONCABI
TRONA CA Oper t~on l -Start-UP 1990 ~ rt upz 091Start-up loss Start-up PNeLAI 1991
MTKESFICOENERATIO-N1
BASFIELDp Start-uStar-Up WESTCA9 199otgoUp 1 MAHONEV PA|00000 Ibhr A Oz 2X365000 Ibhr
SETtr-Ups 188B CHAT TANOOGA TN
G ULF OIL EXPLORATION 8ta-rt-u) 1085BAKERSFIELD NORTH BRANCHCA SPRING GROVE PANORTH BRANCH WV 400000 IbhtOperational 19835 5 0 0 I b h 9 0 0 0 Iblh r- tart-Upi 1991 S t r - U p s l e s s
SOUTHEAST PAPER MFG CO UNIVOF NORTH CAROLINArDUBLIN GA UHAPEL HILL NO400000 IbhrStart-Ups logo Start-Ups2X250O000 1loseIbhr B
- Withdrawing ash from combustor - Withdrawing fly ash
a Internal solids circulation of the steam generator
m Erosioncorrosion of steam generatorinternals
Heat recovery from bottom ash
U Operation with low calorific-value fuel
Prefeasblity Study O Shari Fueled Power Generation
VOO7AI 27
Impact of Scale-Up
Project Size
20 MW
50 MW
100 MW
50 MW boiler in 100 MW plant
Potential Risk
Design Scale-upOperation of to 100 MW Initial Plant Plant
Low Significant
Modest Modest
High Low for duplicate units
Modest Low for duplicate units
Prefeasibility Study Oil Shaje Fueled Power Generation
VOO71-4GEAL4n2
i
Conclusions
Defined risk of CFBC boiler is acceptable
U Operating experience with commercial CFBC boilers built and under construction will strengthen confidencelevel and minimize risk for a plant built in 1995
SPrefeasibility Study Oil Shale Fueled Power Generation
V007GHAAE29
ENVIRONMENTAL ASSESSMENT
a Mine and shale processing
- Fugitive dust emissions
- Noise levels
- Leachability of disposal piles
Power plant
- Fugitive dust emissions
- Gaseous emissions
- Noise levels
- Water effluents
U Conclusions
Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel
Prefeasibility Study Oil Shale Fueled Power Generalon
- Coaloil prices will be at least 15 greater after 1995
- Discovery of indigenous conventional fuel resources is inadequate for power plant purposes
Prefeasibility Study
Oil Shale Fueled Power Generation
VOO) IDWFO
Feasibility(Contd)
N Suitable financing will be available
- For $200 million 50 MW prototypeproject
- For $1000 million 400 MW commercial project
Government of Jordan will make basic commitments
- Long-term power purchase agreement
- Long-term access to Sultani shale deposit
Adequate water and manpower resources
- Attractive tax incentives
Prefeasibility Study
Oil Shale Fueled Power Generaion
VO bull1DUJJRO 6
Timeliness
U Timely development of Jordan oil shale needs prompt action to create - Additional definitive information
- Suitable business plan
Prefeasibility Study
Oil Shale Fueled Power Generation
VooI DUJo 7
i
Expansion Conditions
U Continued expansion of powergeneration from oil shale in Jordan depends on water availability
Prospects for power export or importand domestic load growth will affect size of the needed shale-to-power program
Prefeasibility Sudy
Oil Shale Fueled Power Generation
yOWl lVuJO
Environmental Impacts
N Environmental impacts of shale development will be minimal
Prefeasibility Study Oi Shale Fueled Power Generation
i
Development Advantages
Will create significant new jobopportunities in Jordan
Will avoidreduce foreign exchangelosses for expanding alternate fuel imports
Prefeasibility Study
Oil Shale Fueled Power Generation
VOOIIULL tO
Recommended Action Plan
N Basic recommendation
N Conceptual development schedule
U Project development plan
Key plan elements
N Funding requirements
Prefeasibility Study Oil Shale Fueled Power Generation
VOO4II )U OII
i
Basic Recommendation
N Expand efforts to develop an oil shaleshyfueled power generation program at the Sultani deposit
- Conduct required supporting studies
- Define facilities costs and business plans
- Obtain project funding
Prefeasibility Study
Oil Shale Fueled Power Generation
VON I II)ILL 12
C
Conceptual DevelopmentSchedule
1989-1990
- Conduct supporting studies - Define costsbusiness plans for 50
MW prototype and 400 MW commercial projects
- Develop project financing
N 1990-1993 - Build and operate the prototype project
N 1994-1996 - Expand the 50 MW prototype to 100 MW scale
U 1996-2000 - Expand the project to 400 MW scale
N 2000-2005 - Build a second 400 MW commercial project if needed
i 1 Prefeasiblity Study
dOil Shale Fueled Power Generation
VW IMLITO 13
Conceptual Development Plan
Months
1 Project development plan - Define project
costs1busness plans
-24 -12 0 12 24 36 48 60 72 84 96 108 120
2 Secure funding
3 Build and operate 50 MW prototype
Dergn and procurement
Mine development
Plant construction
Startup and testing
Operations
L- -
4 Expand prototype to 100 MW
Design and procurement
bullConstruction
Startup
5 Expand project to 400 MW
2nd 100 MW unit
3rd100 MW unit
i 44
4th 100 MW unit -
O Project dacision point
i Prefeasib~ity Study Oil Shale Fueled Power Generation
17958562aJocdanV 3-14-89 rsO
18
Phase I - ProjectDevelopment Plan
n Program development
Seminar workshop on prefeasibilitystudy Oate project development plan woek scope schedule arid budget
U Carry out project planning program
- Conduct continuing support studies - Test Sultani shale in existing FBC
- Firm up designs and specifications
- Update costs and economic analysis
- Develop business plans and requirements
Explore project funding alternatives
i Prefeasibility Study
Oil Shale Fueled Power Generation
VO MItUOR 14 -0
Key Plan Elements
N Project feasibility analysis
- Firm up designs and equipmentspecifications for all facilities
- Update cost estimates based on preliminary designs and specifications
Explore arrangements for contract mining and mine development
Update forecasts for demand growthand for retirements of older generating capacity
- Create updated economic analysis
Preleasibility StudyO1 Shae Fueled Power Generation
VOO1IOLWRI
Key Plan Elements (Contd)
Business entity requirement
- Explore optionsconditions for a new company to managebuildoperate the project
- Explore optionsconditions for obtaining a concession agreement for Sultani development
Explore optionsconditions for water rights commitment
Prefeasibility Study Oil Shale Fueled Power Generation
VMIOIA)lj 16S
i
Key Plan Elements (Contd)
U Continuing supporting studies
- Combustion tests (additional pilot tests for design and warranty purposes contract for large-scale burn operations in existing plants if appropriate)
- Additional core drilling and core analysis
- Oil shale crushing tests
- Spent ash leaching tests
- Geotechnical data base including soils analysis
- Environmental baseline data
Prefeasibility Study O Shae Fueled Power Generation
VMMMUldMOA
Steps Required to Develop an Oil Shale-to-Power Project
Create a development business plan - Schedule - Decision tree
Develop a work scope and budget for the development plan program including - Firming up designsspecificationscosts
- Developing business entity requirements - Continuing support studies
Carry out development plan program
Assemble all planning results in a report for discussion with financial institutions
Explore project finance opportunities
Finalize business arrangements
Implement prototype project
i Prefeasibility Study
Oil Shale Fueled Power Generation
VM1-11UJROLI
MARCH 15 JEA QUESTIONS (M S ARAFAH) ON PREFEASIBILITY
STUDY DRAFT REPORT
Rt
DIR EScBSULIVAN PHD OFJCEop~BUREAU FOR SCIENCE AND~TECHNOLOGYAGENCY - --FOR INTERNATIONAL DEVELOPMhINTSWASHINGON DC x20523---------4
4 -
-SUBJ E CT - -C O H~ E T 4N l
Dr Mr sullivan ------shy
c-rommnents We ~efr-preaereorPla -tobYou lete dted Jan 91989 regardn~i4po4t P ea e1 f i nd y ubel ow our -e ot r XcOrcerned Jordanian deipartments
- --A ar o~nnYu Y o turjlt~ lt K
4 C~mments
~1 N i gFIN I~fANDECONOMIC1COIMEN S -
It sidicaed that Beohtel and US AIDWash ingtonj~4- re ojy nen ing that E 2hould und ertake the n e tshyihaisAre ~our c leometprogram n order shye-t im~ ate d f n t v design and budget cost
4Al1so Lthe study ncal--ttsutnilndcaei~ A-1 A thas ~ l 1 be eeded idb~~~~~ rn o ei t n i la itheMWa~-~5s~ 4
hrPro hehgemetTh trOfT ses~fnr4 BOT)Vmanu- a n-mnf~cure 4 r~j or contra c4-or ivoIlveiintijn I 4 4investmnt ude smi ~w 2 Zha tev e r --~4~prce e ec r it v p4~ f JA gertiy geeated-at 4 JEA 3 a l b u y ~the same average~~ A
~jithia oncot in4 ordrtan ecpoemic asess thespePower generatjoon J ordan3 oi sha I eroic c inr~etJordan 4
2P ge i1- 1 Aj iit eu that OPin he atocontr~ct 4with owner4 ofext3ing (oconstriiction r(FB rml-t
qu i of S 11 t to test large tonnagen j es StaniUti n d ajIe -for se veralIQf 31 hi
evrEAPreferpilot qr the dP 1prt7n -that the4mPIt
andi to(7 he instalI 1e 2 310 A
_
JODN ELECTRICITYAUTHORIT LL
Dac
operated in Jordan i n or~der~~t ~n nuex~on mnining crushing and haidi igQhre~ and sash Maeia nd aSootoget enough olr ndaita needed for einolre
CEBbole~ -i s~
ccordance with Jordaian oil shale
large to~ bfig
1 3 le 1-2 Page 1-7 Cost Of Pwer~i It i S menti-oned that the conmecial oil hle~ lt~project (4 X1OOmw) 1is ninacompetative roqt~range-~while table 12 indicates thattcost of-pow Ais~mill
q kwiihcii r 1
average wih i ii -much higher ihantheshy-ost of ~Power gnrtofomJEA therimaPower s ta tions Please~ indicate on what basi o ~~ shave-~made your-statement
PK
14 Pae 2 Sction 4-0sIt 1nlkly that theChousing and off- -site infrastructur-ommnity fakilitieR) to be onsidered for both the demo and prototyp prjcs oeoverwe~4 hnk that their~c_6t is raterojects Mo
iwcv~- age -1 1 Mine O(perationIIt is indicate~d that mining cot eevdfoMine contractor~ are ficomiplee h
r and iyudi-t~con qidder contract mnn opio fr4 the min4 cmflt2ng are reIanddrepres~ent the real costs derived from Phspat miin contractors in
lestfor the eo rPooypuat in order tlt7
P I eadenote tha detthe new exchangerate ofthJraian~ Di~nner you may add 20j6 Kto the quoted
1 6 P Ias e consider the followin ecn hage_
171- The new exchange ra teof tUSD=54o0 fils1 72-W2 The new~ aerage tariff for selIn~electricityhas decrreased to 120 8 f ilIsicwh
17- Page 1-7 TbIe 1-2 W bev th tthe cap ita1 cot for the pwhokand forthe min n d ash hMnd1ing equipen
P B~2Anaor a -Tl 8156152 8176 1Q MYf -t -Now 520 t 1U
JDNEECRICIT AU-RA L14lLiL
2 ~are very high We suggest~ thta You rerconsie (- telowerus e~+d accuracy est a rangethan +30
Page4-22 Table 4-5weno0ti ced( that- PyroPowe ha ddeta(IiacCst fori the bo1ilerlocation and terha dutdetlease isxtr fo~ l C~ io~ s~ e~~ 1a~ a if and indicate theonldjusted ~percentagefor construction foin Jordan
19 Page-7 Table 11-2 -Yo aeue ihrinterest rate on Equity thatn on1DehI~laseinclude~ adetaied explanation of thisrr -tni kepin in miUndie JEA is1thaIt a non profit~ shyorgaiztion unik oher private UJSA utility~in ktation
~-~110- Regarding shy
the ra4ital Rt fthe project it is~requesed tobre k it intdo foreignMeanwhile cthe nd lorcal c-osfoeigptario i nt-re3t~shol becnierdo-h
rr n ontiondonnotopdbon the 9 cnieelocal portion~onth
1-1- 237~Pa
oningeny 9tooi s high~~ a lower 4value -should be~
4~ gt ~112- -Tbles t1-1 -8-8~ inclu~de t~he c~alculationscuultie nt enefits for of Th shyunttypes l i4s difeen geeatnmrer likely tocluae
-~ Q~ J7present vk1u for tenet tthe~benefits in feralterntives -t-oa s the
49
ehliyoi shale
Wea gree with you9 tha t th e percentage used ~ an for thenua~l 0 ~amp-M rahr CFBo ndsomewha~t highervrate be n ededma y for a C B l n Me n h l ~ a e r
indir e ta~ts the -estimatedma i variablec st i ddition t he fi-xed-9i 1 mislkih We --
thinktttiis too lowK -5
shy
1-14- e 4-29
opprza tion-o to The o i1s h1 costs-nc I deAbo 1h
Pa10 mman ormTSI62 a
IB I
JORD N EtECTICI1~ 4 E~)~Is-s
Date ib-_
~ ~riii~g~nd~o9~ru~hng h~tnlin cot~u~tv yo
i Dae Jnryit
1ts c 7 4-
i smiig iniand fh co I eY
susendi ca tI t icag th t1 ~an~approximate 15 ~pita L tYII I (-~a~ge or he owe bl ockj f aniitjes isof +the capthe)t~ial7cpi~lrharge Uoratelformny SI~Uj(uiity installa~tions~ whle page 6-1T9 talJshyit is mentioned that~ the Capital rate pe-r JEA isshyi5~PeaseJustify this~matter since~w o
i16- Pae 6-1 6
1 I4~t is mentioned that the costs of 4process Water are ~ 4 ~0 2$1 000 gallons
r~j~lt IHave~You considered additionalvalue ofbying waterfrom~ the Wa ters Aito i ~or ditoa cost~f o revrseoqoesplant if ground water is used
~~ I1 7- Table 6-1 Page 6-6 Please explain how did You come ou ihteoil~ shale miniing and proces~sing uit~Icost
ltII~I~ 8- Please note 1 t hatj the average JEA~productinr ot frmthermal I power stationsr (Istationbus-barCOSt)i sbewen 6 3-17 3 fils 4kwh You may use this~
l4~ 19-i For ~4 X 100~AMW Plat iti etindo pag e14-4 VolI 11 that4 at tota I of W42 14 epoye W II eemplo~yer] And on page 69yo1Iiti mentioned that a~ tot 1 f1 ~p yeI iNbe enp1oyed a
is~ high asrmetitexeds100personorthe ~41X100~MWh~~j nsatnpPrlae
I 1 The 4 following iftemns are a sumed to1 be excluded from theraPi ta 1 cot xoI
120-1 Perits I icen es 7
1_207~3 Imprt ~xe on s7pare par ts -and c(7orfmurab -ma~teria Is
04f4 4
~4 R j4 4
D4
~ ~ ~ AIf eS taxesq in acrac ihteJraand regulations should be considered aw
21- p1ea4s e indic ate Your Ju t f c io r us ga 6
44122- Table 977App 5Page4 9-1 4L IK Car1Yiniae that the hIRR of the 4 Otplantis rather unattractive (66)most
-( Cns1er4 ngthe logical base 4csek c pwhen cii 6OL
average sell~ing prc CkhampDEratio L801~2O~Aoreover4M the ne siellin prcwh o JEA ati theamptime~ Abeing os4ltp n~ot exceed 4 Ckwh~-However Ipage 1shy~ and 14 0 T indicate that ecnms for a commeri
S4A4scale joil 4 shale projc ~
appear Piomisig-nug o4Ywarrant continued dee fgfluht 4 feaibiit 4tudy wihil cost sevea~lili
do ar~sf Plas lear wether the ~x step jqs~$j~~lt 4
gtt 9o be considered arCcording4to jthe 4unattractiveresul to mentioned in IRR7 Table 97 gt4
a C4 44fET2 4 144-4444 P a g 1 T b6 l
htte~We ~ ~ ae~ rqieetfrteX ~ noie ~~ ~ 444 MW un t44 r te4l w w e o p r d i th e w t r n rre u f4m or4444~ the4444 54M4rto y e Pg~A~44EHiveL det ile an l A44
s o awa er c n um t a4r f rofsho in P6Io erT
e ch 2 50 M W aPln wa e d 41004 MW4 1 consumption_____________
ma4~2 k e u p houin~44 p A44 4444444 C O 4ltI4
a nd a sh et in etc 4 2 4 1 -24 P a g e4 2 - 1 A P P 5
4Yo 4_ j1 4 4~h444 N44 44
1gro nd tce t hir fthe w bern coqir mna t efora4e 4X10A M 444444 4 r i n to 4 4 4lo w w ehA 7 n 2 cinCie h rh4 n ttthh1eb -e 4 44t Of3 E4O
ea h n~ ffl 4 4Jl44 4 4444 4giv
6 ig re sofrat4 de in cl ar f w w at5 c hrw pe o
s h b 444 o t h e g nd L 44 h u i n C
r 4ne a4 t44 e L(704 2 4 p ae) 2 - o Au P dn 5ai 7~e r 44 I Y (1t 44a
ve7 rn e qu 1saharvthe y
and n~~~o speci~~~l4 p n l nh i n t x
r ~rA M e d r o t eu n 8 1 wTtl t t h
- c re e N I wo6
~ n n a i n a t d h l7 A PP6 gt
J
S2~3- Page 2-4 ~ ~ It ~is i
that oil eindicated the- sha le r our~ Cesin Jordan are 10 billion tons -The anulp e reere maiy exeed 50 4 billion tons ~
~ 24- 4Page~2 -l1 iujntr We beiv thtCBcmuto~ep i s high and~alSo
~~ ~ -2 ~~ Page 4-1~6 j - shy
Please~~ indicates your procedure to cool the omn ashand atwa icagd-eprtr
A Have you~ considered~ additional he~at exchanger topcool th ash and to imrve h cycleef ficiency
-~2~6 Page 4-16 It s~ indicated that ash from each silo i Amixed19 ~with~fabout 20 waterKb weight to minimize generation of dust~during trnprtto to mine and disposalHave you~ coniidered other 4lternativeto
~ ~eliminate dustiiig -and avoid use ofwat r uring it ransportationi such as~ using closed trucks or closed
of ~fans conUMnPo wihrlaintthe total plant auiir poe osupin 1~21- Table 5_-3 and I ~
Th~~ is- somneere c6ntradiction regardingplnneotpu~t in both am tables 21-~ Tabl~e 1-33
We noticed tha~t yourall9 cacacapac t fatro75 tion ae asdnWe thilt ~that 7capacityshyfacto is tobo high for- an oil shale fired plant duketo lack of existing simila~r ~plants handl~~~firing oil adshale ~K
216~ The study iniae thtawet~coigtower wi11~used Actually a b
dry cooling should be consideda5ini ~HTP S inZ atomnmz so water rnumption4the cycle~ efficiency willbe reducedHenre YO33~reconsider calculating the cyclefficiy
U~~~~~ codnt umconsidered ofhorizontal -aretypethe~ the vertical cian type can alsobeh considered
shy ~ ~ ~ I~~
2~2 Kconcrete shy
shjell stepl fltstack is onidereconcrete shell brick flue Rt c ~s beCaconsidered3V
2-19~- Deminiraized water~ tank3 capacity~ is -76 ui(meterThe recommnended tank cameter- ui tyi 00cbc
220Designconditions Pa~ge (4-74)te5 hat bow 3down percentage splusmn ~fomrpra til re i hou I be 3~)~
PoD Z 2 m a ad~ - e 5 1 2 iJS~ ~ p A f amp ~ ~ y1
4
JO R ECTICITY AUTHORTIT 4L
~ 4
Date~
t etats ttthe quantityof s i S ~1 000Tons ra Sthis tuntity 11- be transporited for severIy --to tu ofI pit a~te torg P KM ra~erm Spower plIatS about 12 midilidoni CUIA(- met ryea
h e ndd mp e he (d u p in i n L
area wil evric power plant6t Please zn1 a te~tiv s tudY for dumping th r~ a enoug
-from the power plantr~~h~
S 2- Please provide deald-ifrat ao etbaaiedrawing hwn TH11 R thaU and~pV ra~te takcing illto o 6it v- consumptionn _uig themrining equipment
alternate~ study 0o Jine operation for 1 shiftday Vand twoshifts day -lt
224- Conceptua~l pflR 1 for mi ing anusdtransportation of oil- shale a 0 dmj of hs f u r therV examinedh iV~sdpatI ho u1d be
orderj to poe~ehicalq and~eoomca1 fesblt of t his operation
SYour are requested te) study and consider all- above - iPoin s at your earliest in rder -to be peete y oiAnimain on March 29-301989 peetdb~o 4 n
S9incerly-You S
WDIRECTORGENERAL -
I~ CCMR WLINTON ~vs
5N
Pa D~t~IoAmmn -Jordtn -Tel 815615 20 Bl76 15 -19j A VINO- AFf TY
MARCH 21 RESPONSE TO JEA QUESTIONS
Bechtel Power Corporation Engineers - Constructors
Fifty Beale Street San Francisco California Mail Address P 0 Box 3965 San Franclco CA 94119
March 21 1989
Mr M S Arafah Director General Jordan Electricity Authority PO Box 2310 Amman Jordan
Subject Jordan Oil Shale Prefeasibility Study
Dear Mr Arafah
Your letter of 15 March 1989 with comments on the Oil Shale to Power Prefeasibility Study draft report has been referred to me for reply
The attached responses to each item in the reference letter follows the order submitted
Also attached are three revised pages for the draft report - Volume I
Page 6-1 Page 6-21 Page 6-23
Please copy these revised pages into the report previously sent to you
We plan to review this material with JEA during the March 2930 and April 1 meetings in Amman
rsuVertrul yours
W Linton Project Manager
WHLdc
Attachments Questionnaire Response Three revised pages
cc C J Aulisio R R Buta G D Gould T J Wilbanks
32389
Page 1
RESPONSE TO MARCH 15 1989 QUESTIONAIRE
OIL SHALE TO POWER PREFEASIBILITY STUDY
This study examines economic prospects in terms of a 1995-2000 timeframe
FIRANCIAL AND ECONOMIC COMMENTS
11 It is likely that a BOT deal can be structured at present JEA
generation costs for either 20 MW or 50 MW size units if GOJ is
willing to subsidize the incremental power generation cost
Furthermore these incremental costs can be recovered during the 25
year operation of a Commercial Scale Project
12 A 3rd Party Test was proposed as an alternate means to raising
$100+ for an independent JEA sponsored 20 MW Demonstration
program
13 71 millsKWH for Shale Power
VS
JEA 1987 costs
Purchased Power 17 filsKWH = 51 mills
Produced Power 1360 filsKWH = 41 mills
19952000 Costs - Expected to be 30 to 40 higher and in line
with the cost estimate presented in this study
It also is important to recognize that the busbar cost of power
generated by any new power source can not be compared directly
with the cost of existing older installed capacity because of the
lower capital cost component of the latter (See enclosed Figure
1-1 which demonstrates how total capital carrying costs decline as
the investment is paid off) Any new capacity whether coal oil
or oil shale will be an unreasonable disadvantage compared with
costs for existing older capacity
l
024
o2
0De return
E 016Total carrying charge
012 qu return
S -008
ety taxes and n rcw vshy000 X 0 5 10 15 20 25
Figure 1-1 Year-by-year Carrying Charge Components for 15-yearTax Recovery Period
1-7
30
32389
Page 2
14 Infrastructure Cost
Total People
OperatorFamilies Installed Cost
20 MW $10000000 185700 $54000Operator
50 MW 15000000 3241200 46000Operator
400 MW 45000000 10364000 43000Operator
Factored allowance for grass roots desert installation
including housing and community facilities was developed as
follows for the 50 MW case study
Infrastructure
50 MW
Family Housing 200 30K = $ 6 Million
Bachelor Housing 100 20K = 2 M
HospitalClinic (8 Beds) 11 M
SchoolMosque I1 M
Stores Services amp Recreation = 2 M
Facilities
Roads Electricity Water Sewage = 3 M
$15 Million
Infrastructure costs for the 20 MW and 400 MW cases was ratioed
from this breakdown
At this conceptual level costs are order-of-magnitude In a Phase
II program these infrastructure costs can be developed in detail
32389
Page 3
15 Contract Mining Alternatives
Page 4-11 Mine Operation
Based on Bechtels evaluation of the mine contractors price as found in Section 15 of the Mining Report it was concluded that
the mine contractors price does not include costs for such things
as developing the mine with a box-cut ramp haul roads
developing an area for the waste material maintaining the
haulroads constructing the mine services facilities diversion
ditches sedimentation ponds water well crushing the oil shale
pre-mixing the oil shale at the mine and other items associated
with operating a mine to support a power plant If it is proven
that the mine contractors price includes cost for the above
mentioned scope of work in additi-n to drill blast load and
haul then the contractors price can be used but in the meantime
the all inclusive cost developed by Bechtel should be used
Contract Mining appears to be attractive for the smaller size
plants but not for the larger commercial scale operation Some
third party must provide the necessary capital for trucks
loading mining machines etc under a contract arrangement
16 Reassessment due to Dinar value change needs further study and can
not be evaluated given present budget limitations If average
labor rate of $300hr still valid then little change involve with
study
If deemed necessary reexamination of project economics can be
done in Phase IIwhen funded
17 Costs in this study are based on recent similar Bechtel experience
on Mount Poso project and on Montana I project The Mount Poso
project is a 50 MW unit firing coal in a Pyropower boiler The
Montana I project is a 35 MW unit firing coal in a Keeler Dorr
Oliver FBC boiler utilizing dry cooling
32389
Page 4
18 The Pyropower quote of $186000000 to futnish and erect the steam
generator stack and baghouse has been adjusted to include
engineering construction indirect cost etc to be consistant
with the rest of the costs shown in Table 65 p 6-10 No
further adjustment for location was made
19 Equity funding has the lowest priority of payoff in case of a
liquidation and carries greater risk Hence a higher rate of
return is needed to attract these funds Debt funding is a first
mortgage and has first priority for payoff in case of liquidation
and carries less risk Hence it requires lower rate of return
than equity funding
The risk taking equity owner will ask for greater interest rate
to make funds available The only way to minimize this expense is
to find a loaning agency willing to provide 90 or perhaps 95 of
the investment cost It is likely that banks will require some
minimum equity participation
This Prefeasibility Study was not based on a non-profit utility
operation
Even though JEA is a non-profit organization its service
contributors are profit making groups It is visualized that the
Jordan Oil Shale Co (JOSCO) will be a stand alone business
enterprise servicing JEA under long term contract To secure
funding for the proposed project JOSCO will need attractive
enough contract terms to attract both equity and debt capital
110 Additional work is needed to develop the requested information
This work can be preformed as part of the Phase II program
111 Bechtel includes contingency in all of its estimates to cover
error emissions and unforeseen items within the defined scope of
the project The level of contingency is dependent upon the
amount of scope definition For a prefeasible study such as this
15 contingency is lower than normal
32389
Page 5
112 Tables 89 through 816 include a present value calculation to
establish the relative benefit for a shale project vs coal and
oil
113 The variable maintenance cost of 1 millsKWH has been adjusted for CFB plants with an additional $200000 per year or 06 millsKWH
This yields the following
Variable Maintenance - 10 millsKWH
CFB Adjustment - 06
Fixed Maintenance Cost - 40
Total Cost 56 MillsKWH
114 Page 4-29
The royalty costs are included in the weighted average oil shale
costs for the 50 megawatt plant
Page 4-8
Shale fuel costs include return on equity and royalty These are
two separate cost items Royalty is the last item mentioned in
the sentence and it therefore reads as royalty and not return on
royalty
Page 4-31 gives rates used by Bechtel based on our calculations
using the referenced procedures
DebtEquity Capital Charge Rate
5050 153
8020 139
Table 69 displays the calculation of the 153 capital charge
rate (Line 7 of Table 69 is not used in the calculation and
should be deleted)
32389
Page 6
116 No water purchase charge from the Water Authority was added to the
operating expense based on the statement that no resource costs
will be charged
$020 per 1000 gallons is rule of thumb for USA installations in
absence of client data
Boiler make up water (p4-17) is treated in a demineralizer
train If deemed necessary comparison with reverse osmosis
process can be performed in Phase II
Water requirements were estimated to be
Cubic Metres Per Year
20 MW 50 MW 400 MW
Mine amp Shale Processing 455000 761000 773000
Power Block 3000 6000 42000
Infrastructure 80000 140000 448000
Total 538000 907000 1263000
117 Annual average operating costs shown on Table 6-1 are in error
Financing Option 5050 8020
Cost Shown 56606 48945
Corrected Cost 60396 53236
Average mining and shale processing costs are developed year by
year in the Mining Report Appendix 5 Table 12-10
32389
Page 7
118 We would be interested in receiving the breakdown of these current
power cost figures (ie capital charges fuel cost number of
operators etc) Further economic analysis employing these
figures can be developed in Phase II
119 Manpower requirements for the three case studies were estimated as
fol lows
Mining amp Shale Processing
Power Block
Operations
Maintenance
Management
20 MW 50 MW 400 MW
75 163 396
54 78 175
46 73 455
10 10 10
185 324 1036
Page 14-4 of the Mine Report is for mine and shale processing
only It should be noted that most of these manpower requirements
involved new jobs for Jordanian people
120 At the April 1988 Amman Meeting it was agreed that the following
costs would be omitted
o Permits and Licenses
o Local Taxes
o Import Taxes
If necessary such costs can be developed and added into a revised
economic analysis as part of the Phase II program
121 6 average inflation rate is the figure recommended by Bechtel
based on USA conditions for use in long term economic analyses of
new power ventures
32389
Page 8
122 This matter is referred to ORNL who prepared a rate of return
analysis
Bechtels conclusion is based on computed busbar costscumulative
benefits compared to alternate fuels in the timeframe 1995 to 2000
Relative Busbar Power Cost Net 25 Year
Mills per KWH Benefits - Million US$
Sultani Oil Shale 71-83 Base Cost
Imported Coal
$50tonne 68-88 778
$70tonne 78-107 2531
Imported Oil
$17Bbl 56-76 (18) $24Bbl 61-96 1810
The above results are based on a capacity factor of 75 which is
considered to be a reasonable target for a new plant over its 25 year
life The average selling price of 6 cents per KWH cited in the
questionnaire is based on existing plant costs which may not include
all cost elements of new capacity evaluated in this study
32389
Page 9
TECHNICAL COMMENTS
21 See answer to Item 116
Total power plant raw wate consumption rates and annual
consumptions including the water requirements for wetting ash at the truck loading p int within the power plant are given in Tables 43 and 44 for 50 MW unit and Tables 53 and 54 for 20 MW unit
The raw water requirements for 4x0 MW plant were factored
excepting the mine where a revised mine pldn is employed to reduce water request The quantities shown on these tables exclude raw
water requirements for housing complex mine and ash wetting if
required at the ash disposal site
Total power plant requirements shown in the above referred tables
are
50 MW 20 MW
Rate gpm 207 102 (See Drawing M004)
Annual Use
Gallons 1400000 675000
Cooling tower blowndown supplemented with raw water is used for
wetting ash at the truck loading point within the power plant Raw water quantities attributable for ash wetting at the power
truck loading point are
50 MW 20 MW
Rate gpm 75 325
Annual Use
Gallons 500000 215000
These quantities are included in the quantities shown in
the above referred tables
32389
Page 10
22 We recognize the POTENTIAL for leaching toxic compounds from the
spent ash However this matter is not yet defined well enough to
recommend specific action steps The Prefeasibility Study page
7-12 recommends creation of a ground water dispersion model to
determine whether more specific contaminated water mitigation
plans are needed It is anticipated that the leachate rate will
be low and that aquifer dispersion will keep problem compounds
bel3w health standards thresholds
23 Noted
We have not received up to date resource study material which
defines 50 billion tons resource base Please furnish
The resource base at Sultani alone is adequate to support two 400
MW power projects capacity subject water availability The
2-million cubic metre per year water allowance for oilshale will
limit development to about 600 MW
24 Selection of a combustion temperature is a balance between carbon
combustion efficiency and heat loss due carbonate decomposition
For purposes of the Prefeasibility Study we have opted for high
combustion efficiency At lower efficiency larger shale
mineprocessing plants will be needed
25 Bottom ash is cooled by water exchange before discharge
Cooling water is supplied to the ash screw coolers as specified by
Pyropower See Drawing MOO5 2140 gpm flow for 50 MW and 860 gpm
flow for 20 MW Heat removed by the cooling water from the ash
screw coolers is dissipated to atmosphere via a wet cooling
tower Pyropower should indicate the temperature of the ash
discharged to be 5OOF
32389
Page 11
Initially we had considered using a heat exchanger to cool the ash
and improve the cycle efficiency Considering low cost of fuel
the additional capital costs and the system complexities it was
decided not to employ such heat recovery systems for this project
26 The suggested alternates were looked at briefly and the potential
for wind blown air pollution from the ash disposal areas are too
great to warrant dry disposal unless GO(] and World Bank are
willing to accept such a potential problem Wetting the ash is
tne only practical solution Hopefully some cementation will
occur helping to reduce future leaching potential
27 JEA requirements are noted This is a conceptual study not a
final design Optimal design analysis can be performed during
Phase II
2829
JEA requirements are noted and can be incorporated into the Phase
II design
210 The transformer size is adequate for base load operation A
higher capacity can be considered at the final design stage if the
Client prefers
211 From our experience it does not appear to be economical to
provide additional dry cooling towers to take care of maximum
ambient temperatures which may prevail only for a short period of
time in a year To study this an annual dry bulb temperature
duration curve is required Also adding additional dry cooling
towers will change the plant performance It should also be noted
that the dry cooling towers are very expensive and the size should
be selected carefly considering performance and cost and not on the basis of maximum ambient temperatures This can be studied
during Phase II
32389
Page 12
212 The plant gross output varies with condenser pressure
Condenser
Pressure Design 55 in HgA Annual Ave 35 in HgA
Unit Size MW 20 50 4xlO0 20 50 4xlO0
Gross Output MW 234 593 496 2415 607 TBD
Net Output MW 1975 501 400 205 515 TBD
To be developed in Phase II
Output for 4x100 MW is estimated by others
213 The fan power consumption of the CFB boiler is about 30 to 35 of
the total auxiliary power The fan power consumption of the dry
cooling tower is about 20 to 25 of the total auxiliary power
214 Table 1-1 does not include plant net output Therefore do not
understand the comment
215 Commercial operating experience with coal fueled CFBC units in LISA
and Europe has been uniformly good showing high on stream
availability in early years (See Table 2-6 which reports on
Pyropower experience)
We expect operations with high ash content fuel like oilshale will
have unique scale up problems such as
o Solid handling in and out
o Internal solids circulation
o Erosioncorrosion steam generator intervals
o Heat recovery from bottom ash
Consequently we are recommending these items be worked out in a
single 50 MW prototype
32389
Page 13
216 Maximum dry cooling is used in this study A small wet cooling
tower is used on circulating service water system
217 Horizontal condensate pump is adequate with dry cooling tower and it is cheaper Vertical condensate pumps with cans can be
considered in the final design if required
218 A concrete shell brick lined flue stack will be larger in diameter and costs more than a steel lined stack Brick lined stack can be
considered in the final design
219 Demineralized water tank capacity for 50 MW is 76 cu meters or 20000 gallons not 1000 cu meters For 20 MW plant it is 38 cu
meters or 10000 gallons
220 It is US practice to use an average continuous blowdown rate of
1 and maximum biowdown rate of 3 for this type of plants
221 This can be studied during Phase II
222 Same as 221
223 Same as 221
224 The recommended action plan calls for continuing support studies covering the referenced items Additional effort is needed to
further define these matters and confirm the conceptual plan
The next step is to develop an outline for a project plan including
o Work Scope
o Schedule
o Budget
accommodate the increase in the number of employees and
equipment Truck bays to accommodate the 136 tonne trucks
will be added The truck bays used for the 77 tonne
trucks will be used for the maintenance of other
equipment The warehouse change house training room
offices and cafeteria will be expanded accordingly
6025 Mining and Processing Economics
Details of the oil shale mining and processing plant
economics for the 400 MW plant are included in the Mining
Report (Appendix 5) These details are of the same
magnitude as prepared for the 20 MW and 50 MW plants
The summary of the cash flow analysis for the mine and
shale processing plant is presented in Table 6-1
Table 6-1
SUMMARY OF 400 MW PLANT OIL SHALE MINING AND PROCESSING COSTS
5050 Debt-Equity 8020 Debt-Equity
US $1000 US $1000
Capital Cost
Mine Development 30915 30915
Mine Equipment 66012 66012
Process Plant Facilities 50889 50889
Spare Parts 5000 5000
Working Capital 10000 10000
Capi tal ized Interest
During Construction 24423 39075
TOTAL 187239 201891
Operating Costs and Other Costs
Annual Cost 60386 53236
Product Mined and Processed
Annual Tonnes x 1000 7783 7783
Unit Cost
US $Tonne (weighted average)
US $l06Btu (weighted average) 776
156
684
138
Year 12 costs taken as 25 year average
6-6
-Au
Table 610 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY
- FCC plant sizes equivalent to proposed power application
Prefeasibility Study Oil Shale Fueled Power Generation
VOO94GEampJRI26
i
PYROFLOW UNITS IN THE US
COLORADOUTE IOYA STATE UNIV UNIV OFNUCLA CO NORTHERNAMES IA BF GOODRICH110 1o0MW(a) 2x170000 Ibhr HENRYILCEDAR FALLS IA 120000 Ibhr GENERALGULF OILu EiN P MOTORSSbtUpStart-UIL 1987 O A 1I N000 TC
NORT10 PONTIACH B MIRANCHWV00000 lbhr
CORN PRODUCTSSM NORTH-CAROLINA STOCKTOD CA
400000 lbbhl t
RUMF RD ME
CEMENT CO CALIF PORTLAND-COLTON CA
190000 Iblhr Start-Up 1985 TRUMTFTWN NYU
3I75ERTOWN N
etar t-Up loss ACE COGENERATIONCABI
TRONA CA Oper t~on l -Start-UP 1990 ~ rt upz 091Start-up loss Start-up PNeLAI 1991
MTKESFICOENERATIO-N1
BASFIELDp Start-uStar-Up WESTCA9 199otgoUp 1 MAHONEV PA|00000 Ibhr A Oz 2X365000 Ibhr
SETtr-Ups 188B CHAT TANOOGA TN
G ULF OIL EXPLORATION 8ta-rt-u) 1085BAKERSFIELD NORTH BRANCHCA SPRING GROVE PANORTH BRANCH WV 400000 IbhtOperational 19835 5 0 0 I b h 9 0 0 0 Iblh r- tart-Upi 1991 S t r - U p s l e s s
SOUTHEAST PAPER MFG CO UNIVOF NORTH CAROLINArDUBLIN GA UHAPEL HILL NO400000 IbhrStart-Ups logo Start-Ups2X250O000 1loseIbhr B
- Withdrawing ash from combustor - Withdrawing fly ash
a Internal solids circulation of the steam generator
m Erosioncorrosion of steam generatorinternals
Heat recovery from bottom ash
U Operation with low calorific-value fuel
Prefeasblity Study O Shari Fueled Power Generation
VOO7AI 27
Impact of Scale-Up
Project Size
20 MW
50 MW
100 MW
50 MW boiler in 100 MW plant
Potential Risk
Design Scale-upOperation of to 100 MW Initial Plant Plant
Low Significant
Modest Modest
High Low for duplicate units
Modest Low for duplicate units
Prefeasibility Study Oil Shaje Fueled Power Generation
VOO71-4GEAL4n2
i
Conclusions
Defined risk of CFBC boiler is acceptable
U Operating experience with commercial CFBC boilers built and under construction will strengthen confidencelevel and minimize risk for a plant built in 1995
SPrefeasibility Study Oil Shale Fueled Power Generation
V007GHAAE29
ENVIRONMENTAL ASSESSMENT
a Mine and shale processing
- Fugitive dust emissions
- Noise levels
- Leachability of disposal piles
Power plant
- Fugitive dust emissions
- Gaseous emissions
- Noise levels
- Water effluents
U Conclusions
Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel
Prefeasibility Study Oil Shale Fueled Power Generalon
- Coaloil prices will be at least 15 greater after 1995
- Discovery of indigenous conventional fuel resources is inadequate for power plant purposes
Prefeasibility Study
Oil Shale Fueled Power Generation
VOO) IDWFO
Feasibility(Contd)
N Suitable financing will be available
- For $200 million 50 MW prototypeproject
- For $1000 million 400 MW commercial project
Government of Jordan will make basic commitments
- Long-term power purchase agreement
- Long-term access to Sultani shale deposit
Adequate water and manpower resources
- Attractive tax incentives
Prefeasibility Study
Oil Shale Fueled Power Generaion
VO bull1DUJJRO 6
Timeliness
U Timely development of Jordan oil shale needs prompt action to create - Additional definitive information
- Suitable business plan
Prefeasibility Study
Oil Shale Fueled Power Generation
VooI DUJo 7
i
Expansion Conditions
U Continued expansion of powergeneration from oil shale in Jordan depends on water availability
Prospects for power export or importand domestic load growth will affect size of the needed shale-to-power program
Prefeasibility Sudy
Oil Shale Fueled Power Generation
yOWl lVuJO
Environmental Impacts
N Environmental impacts of shale development will be minimal
Prefeasibility Study Oi Shale Fueled Power Generation
i
Development Advantages
Will create significant new jobopportunities in Jordan
Will avoidreduce foreign exchangelosses for expanding alternate fuel imports
Prefeasibility Study
Oil Shale Fueled Power Generation
VOOIIULL tO
Recommended Action Plan
N Basic recommendation
N Conceptual development schedule
U Project development plan
Key plan elements
N Funding requirements
Prefeasibility Study Oil Shale Fueled Power Generation
VOO4II )U OII
i
Basic Recommendation
N Expand efforts to develop an oil shaleshyfueled power generation program at the Sultani deposit
- Conduct required supporting studies
- Define facilities costs and business plans
- Obtain project funding
Prefeasibility Study
Oil Shale Fueled Power Generation
VON I II)ILL 12
C
Conceptual DevelopmentSchedule
1989-1990
- Conduct supporting studies - Define costsbusiness plans for 50
MW prototype and 400 MW commercial projects
- Develop project financing
N 1990-1993 - Build and operate the prototype project
N 1994-1996 - Expand the 50 MW prototype to 100 MW scale
U 1996-2000 - Expand the project to 400 MW scale
N 2000-2005 - Build a second 400 MW commercial project if needed
i 1 Prefeasiblity Study
dOil Shale Fueled Power Generation
VW IMLITO 13
Conceptual Development Plan
Months
1 Project development plan - Define project
costs1busness plans
-24 -12 0 12 24 36 48 60 72 84 96 108 120
2 Secure funding
3 Build and operate 50 MW prototype
Dergn and procurement
Mine development
Plant construction
Startup and testing
Operations
L- -
4 Expand prototype to 100 MW
Design and procurement
bullConstruction
Startup
5 Expand project to 400 MW
2nd 100 MW unit
3rd100 MW unit
i 44
4th 100 MW unit -
O Project dacision point
i Prefeasib~ity Study Oil Shale Fueled Power Generation
17958562aJocdanV 3-14-89 rsO
18
Phase I - ProjectDevelopment Plan
n Program development
Seminar workshop on prefeasibilitystudy Oate project development plan woek scope schedule arid budget
U Carry out project planning program
- Conduct continuing support studies - Test Sultani shale in existing FBC
- Firm up designs and specifications
- Update costs and economic analysis
- Develop business plans and requirements
Explore project funding alternatives
i Prefeasibility Study
Oil Shale Fueled Power Generation
VO MItUOR 14 -0
Key Plan Elements
N Project feasibility analysis
- Firm up designs and equipmentspecifications for all facilities
- Update cost estimates based on preliminary designs and specifications
Explore arrangements for contract mining and mine development
Update forecasts for demand growthand for retirements of older generating capacity
- Create updated economic analysis
Preleasibility StudyO1 Shae Fueled Power Generation
VOO1IOLWRI
Key Plan Elements (Contd)
Business entity requirement
- Explore optionsconditions for a new company to managebuildoperate the project
- Explore optionsconditions for obtaining a concession agreement for Sultani development
Explore optionsconditions for water rights commitment
Prefeasibility Study Oil Shale Fueled Power Generation
VMIOIA)lj 16S
i
Key Plan Elements (Contd)
U Continuing supporting studies
- Combustion tests (additional pilot tests for design and warranty purposes contract for large-scale burn operations in existing plants if appropriate)
- Additional core drilling and core analysis
- Oil shale crushing tests
- Spent ash leaching tests
- Geotechnical data base including soils analysis
- Environmental baseline data
Prefeasibility Study O Shae Fueled Power Generation
VMMMUldMOA
Steps Required to Develop an Oil Shale-to-Power Project
Create a development business plan - Schedule - Decision tree
Develop a work scope and budget for the development plan program including - Firming up designsspecificationscosts
- Developing business entity requirements - Continuing support studies
Carry out development plan program
Assemble all planning results in a report for discussion with financial institutions
Explore project finance opportunities
Finalize business arrangements
Implement prototype project
i Prefeasibility Study
Oil Shale Fueled Power Generation
VM1-11UJROLI
MARCH 15 JEA QUESTIONS (M S ARAFAH) ON PREFEASIBILITY
STUDY DRAFT REPORT
Rt
DIR EScBSULIVAN PHD OFJCEop~BUREAU FOR SCIENCE AND~TECHNOLOGYAGENCY - --FOR INTERNATIONAL DEVELOPMhINTSWASHINGON DC x20523---------4
4 -
-SUBJ E CT - -C O H~ E T 4N l
Dr Mr sullivan ------shy
c-rommnents We ~efr-preaereorPla -tobYou lete dted Jan 91989 regardn~i4po4t P ea e1 f i nd y ubel ow our -e ot r XcOrcerned Jordanian deipartments
- --A ar o~nnYu Y o turjlt~ lt K
4 C~mments
~1 N i gFIN I~fANDECONOMIC1COIMEN S -
It sidicaed that Beohtel and US AIDWash ingtonj~4- re ojy nen ing that E 2hould und ertake the n e tshyihaisAre ~our c leometprogram n order shye-t im~ ate d f n t v design and budget cost
4Al1so Lthe study ncal--ttsutnilndcaei~ A-1 A thas ~ l 1 be eeded idb~~~~~ rn o ei t n i la itheMWa~-~5s~ 4
hrPro hehgemetTh trOfT ses~fnr4 BOT)Vmanu- a n-mnf~cure 4 r~j or contra c4-or ivoIlveiintijn I 4 4investmnt ude smi ~w 2 Zha tev e r --~4~prce e ec r it v p4~ f JA gertiy geeated-at 4 JEA 3 a l b u y ~the same average~~ A
~jithia oncot in4 ordrtan ecpoemic asess thespePower generatjoon J ordan3 oi sha I eroic c inr~etJordan 4
2P ge i1- 1 Aj iit eu that OPin he atocontr~ct 4with owner4 ofext3ing (oconstriiction r(FB rml-t
qu i of S 11 t to test large tonnagen j es StaniUti n d ajIe -for se veralIQf 31 hi
evrEAPreferpilot qr the dP 1prt7n -that the4mPIt
andi to(7 he instalI 1e 2 310 A
_
JODN ELECTRICITYAUTHORIT LL
Dac
operated in Jordan i n or~der~~t ~n nuex~on mnining crushing and haidi igQhre~ and sash Maeia nd aSootoget enough olr ndaita needed for einolre
CEBbole~ -i s~
ccordance with Jordaian oil shale
large to~ bfig
1 3 le 1-2 Page 1-7 Cost Of Pwer~i It i S menti-oned that the conmecial oil hle~ lt~project (4 X1OOmw) 1is ninacompetative roqt~range-~while table 12 indicates thattcost of-pow Ais~mill
q kwiihcii r 1
average wih i ii -much higher ihantheshy-ost of ~Power gnrtofomJEA therimaPower s ta tions Please~ indicate on what basi o ~~ shave-~made your-statement
PK
14 Pae 2 Sction 4-0sIt 1nlkly that theChousing and off- -site infrastructur-ommnity fakilitieR) to be onsidered for both the demo and prototyp prjcs oeoverwe~4 hnk that their~c_6t is raterojects Mo
iwcv~- age -1 1 Mine O(perationIIt is indicate~d that mining cot eevdfoMine contractor~ are ficomiplee h
r and iyudi-t~con qidder contract mnn opio fr4 the min4 cmflt2ng are reIanddrepres~ent the real costs derived from Phspat miin contractors in
lestfor the eo rPooypuat in order tlt7
P I eadenote tha detthe new exchangerate ofthJraian~ Di~nner you may add 20j6 Kto the quoted
1 6 P Ias e consider the followin ecn hage_
171- The new exchange ra teof tUSD=54o0 fils1 72-W2 The new~ aerage tariff for selIn~electricityhas decrreased to 120 8 f ilIsicwh
17- Page 1-7 TbIe 1-2 W bev th tthe cap ita1 cot for the pwhokand forthe min n d ash hMnd1ing equipen
P B~2Anaor a -Tl 8156152 8176 1Q MYf -t -Now 520 t 1U
JDNEECRICIT AU-RA L14lLiL
2 ~are very high We suggest~ thta You rerconsie (- telowerus e~+d accuracy est a rangethan +30
Page4-22 Table 4-5weno0ti ced( that- PyroPowe ha ddeta(IiacCst fori the bo1ilerlocation and terha dutdetlease isxtr fo~ l C~ io~ s~ e~~ 1a~ a if and indicate theonldjusted ~percentagefor construction foin Jordan
19 Page-7 Table 11-2 -Yo aeue ihrinterest rate on Equity thatn on1DehI~laseinclude~ adetaied explanation of thisrr -tni kepin in miUndie JEA is1thaIt a non profit~ shyorgaiztion unik oher private UJSA utility~in ktation
~-~110- Regarding shy
the ra4ital Rt fthe project it is~requesed tobre k it intdo foreignMeanwhile cthe nd lorcal c-osfoeigptario i nt-re3t~shol becnierdo-h
rr n ontiondonnotopdbon the 9 cnieelocal portion~onth
1-1- 237~Pa
oningeny 9tooi s high~~ a lower 4value -should be~
4~ gt ~112- -Tbles t1-1 -8-8~ inclu~de t~he c~alculationscuultie nt enefits for of Th shyunttypes l i4s difeen geeatnmrer likely tocluae
-~ Q~ J7present vk1u for tenet tthe~benefits in feralterntives -t-oa s the
49
ehliyoi shale
Wea gree with you9 tha t th e percentage used ~ an for thenua~l 0 ~amp-M rahr CFBo ndsomewha~t highervrate be n ededma y for a C B l n Me n h l ~ a e r
indir e ta~ts the -estimatedma i variablec st i ddition t he fi-xed-9i 1 mislkih We --
thinktttiis too lowK -5
shy
1-14- e 4-29
opprza tion-o to The o i1s h1 costs-nc I deAbo 1h
Pa10 mman ormTSI62 a
IB I
JORD N EtECTICI1~ 4 E~)~Is-s
Date ib-_
~ ~riii~g~nd~o9~ru~hng h~tnlin cot~u~tv yo
i Dae Jnryit
1ts c 7 4-
i smiig iniand fh co I eY
susendi ca tI t icag th t1 ~an~approximate 15 ~pita L tYII I (-~a~ge or he owe bl ockj f aniitjes isof +the capthe)t~ial7cpi~lrharge Uoratelformny SI~Uj(uiity installa~tions~ whle page 6-1T9 talJshyit is mentioned that~ the Capital rate pe-r JEA isshyi5~PeaseJustify this~matter since~w o
i16- Pae 6-1 6
1 I4~t is mentioned that the costs of 4process Water are ~ 4 ~0 2$1 000 gallons
r~j~lt IHave~You considered additionalvalue ofbying waterfrom~ the Wa ters Aito i ~or ditoa cost~f o revrseoqoesplant if ground water is used
~~ I1 7- Table 6-1 Page 6-6 Please explain how did You come ou ihteoil~ shale miniing and proces~sing uit~Icost
ltII~I~ 8- Please note 1 t hatj the average JEA~productinr ot frmthermal I power stationsr (Istationbus-barCOSt)i sbewen 6 3-17 3 fils 4kwh You may use this~
l4~ 19-i For ~4 X 100~AMW Plat iti etindo pag e14-4 VolI 11 that4 at tota I of W42 14 epoye W II eemplo~yer] And on page 69yo1Iiti mentioned that a~ tot 1 f1 ~p yeI iNbe enp1oyed a
is~ high asrmetitexeds100personorthe ~41X100~MWh~~j nsatnpPrlae
I 1 The 4 following iftemns are a sumed to1 be excluded from theraPi ta 1 cot xoI
120-1 Perits I icen es 7
1_207~3 Imprt ~xe on s7pare par ts -and c(7orfmurab -ma~teria Is
04f4 4
~4 R j4 4
D4
~ ~ ~ AIf eS taxesq in acrac ihteJraand regulations should be considered aw
21- p1ea4s e indic ate Your Ju t f c io r us ga 6
44122- Table 977App 5Page4 9-1 4L IK Car1Yiniae that the hIRR of the 4 Otplantis rather unattractive (66)most
-( Cns1er4 ngthe logical base 4csek c pwhen cii 6OL
average sell~ing prc CkhampDEratio L801~2O~Aoreover4M the ne siellin prcwh o JEA ati theamptime~ Abeing os4ltp n~ot exceed 4 Ckwh~-However Ipage 1shy~ and 14 0 T indicate that ecnms for a commeri
S4A4scale joil 4 shale projc ~
appear Piomisig-nug o4Ywarrant continued dee fgfluht 4 feaibiit 4tudy wihil cost sevea~lili
do ar~sf Plas lear wether the ~x step jqs~$j~~lt 4
gtt 9o be considered arCcording4to jthe 4unattractiveresul to mentioned in IRR7 Table 97 gt4
a C4 44fET2 4 144-4444 P a g 1 T b6 l
htte~We ~ ~ ae~ rqieetfrteX ~ noie ~~ ~ 444 MW un t44 r te4l w w e o p r d i th e w t r n rre u f4m or4444~ the4444 54M4rto y e Pg~A~44EHiveL det ile an l A44
s o awa er c n um t a4r f rofsho in P6Io erT
e ch 2 50 M W aPln wa e d 41004 MW4 1 consumption_____________
ma4~2 k e u p houin~44 p A44 4444444 C O 4ltI4
a nd a sh et in etc 4 2 4 1 -24 P a g e4 2 - 1 A P P 5
4Yo 4_ j1 4 4~h444 N44 44
1gro nd tce t hir fthe w bern coqir mna t efora4e 4X10A M 444444 4 r i n to 4 4 4lo w w ehA 7 n 2 cinCie h rh4 n ttthh1eb -e 4 44t Of3 E4O
ea h n~ ffl 4 4Jl44 4 4444 4giv
6 ig re sofrat4 de in cl ar f w w at5 c hrw pe o
s h b 444 o t h e g nd L 44 h u i n C
r 4ne a4 t44 e L(704 2 4 p ae) 2 - o Au P dn 5ai 7~e r 44 I Y (1t 44a
ve7 rn e qu 1saharvthe y
and n~~~o speci~~~l4 p n l nh i n t x
r ~rA M e d r o t eu n 8 1 wTtl t t h
- c re e N I wo6
~ n n a i n a t d h l7 A PP6 gt
J
S2~3- Page 2-4 ~ ~ It ~is i
that oil eindicated the- sha le r our~ Cesin Jordan are 10 billion tons -The anulp e reere maiy exeed 50 4 billion tons ~
~ 24- 4Page~2 -l1 iujntr We beiv thtCBcmuto~ep i s high and~alSo
~~ ~ -2 ~~ Page 4-1~6 j - shy
Please~~ indicates your procedure to cool the omn ashand atwa icagd-eprtr
A Have you~ considered~ additional he~at exchanger topcool th ash and to imrve h cycleef ficiency
-~2~6 Page 4-16 It s~ indicated that ash from each silo i Amixed19 ~with~fabout 20 waterKb weight to minimize generation of dust~during trnprtto to mine and disposalHave you~ coniidered other 4lternativeto
~ ~eliminate dustiiig -and avoid use ofwat r uring it ransportationi such as~ using closed trucks or closed
of ~fans conUMnPo wihrlaintthe total plant auiir poe osupin 1~21- Table 5_-3 and I ~
Th~~ is- somneere c6ntradiction regardingplnneotpu~t in both am tables 21-~ Tabl~e 1-33
We noticed tha~t yourall9 cacacapac t fatro75 tion ae asdnWe thilt ~that 7capacityshyfacto is tobo high for- an oil shale fired plant duketo lack of existing simila~r ~plants handl~~~firing oil adshale ~K
216~ The study iniae thtawet~coigtower wi11~used Actually a b
dry cooling should be consideda5ini ~HTP S inZ atomnmz so water rnumption4the cycle~ efficiency willbe reducedHenre YO33~reconsider calculating the cyclefficiy
U~~~~~ codnt umconsidered ofhorizontal -aretypethe~ the vertical cian type can alsobeh considered
shy ~ ~ ~ I~~
2~2 Kconcrete shy
shjell stepl fltstack is onidereconcrete shell brick flue Rt c ~s beCaconsidered3V
2-19~- Deminiraized water~ tank3 capacity~ is -76 ui(meterThe recommnended tank cameter- ui tyi 00cbc
220Designconditions Pa~ge (4-74)te5 hat bow 3down percentage splusmn ~fomrpra til re i hou I be 3~)~
PoD Z 2 m a ad~ - e 5 1 2 iJS~ ~ p A f amp ~ ~ y1
4
JO R ECTICITY AUTHORTIT 4L
~ 4
Date~
t etats ttthe quantityof s i S ~1 000Tons ra Sthis tuntity 11- be transporited for severIy --to tu ofI pit a~te torg P KM ra~erm Spower plIatS about 12 midilidoni CUIA(- met ryea
h e ndd mp e he (d u p in i n L
area wil evric power plant6t Please zn1 a te~tiv s tudY for dumping th r~ a enoug
-from the power plantr~~h~
S 2- Please provide deald-ifrat ao etbaaiedrawing hwn TH11 R thaU and~pV ra~te takcing illto o 6it v- consumptionn _uig themrining equipment
alternate~ study 0o Jine operation for 1 shiftday Vand twoshifts day -lt
224- Conceptua~l pflR 1 for mi ing anusdtransportation of oil- shale a 0 dmj of hs f u r therV examinedh iV~sdpatI ho u1d be
orderj to poe~ehicalq and~eoomca1 fesblt of t his operation
SYour are requested te) study and consider all- above - iPoin s at your earliest in rder -to be peete y oiAnimain on March 29-301989 peetdb~o 4 n
S9incerly-You S
WDIRECTORGENERAL -
I~ CCMR WLINTON ~vs
5N
Pa D~t~IoAmmn -Jordtn -Tel 815615 20 Bl76 15 -19j A VINO- AFf TY
MARCH 21 RESPONSE TO JEA QUESTIONS
Bechtel Power Corporation Engineers - Constructors
Fifty Beale Street San Francisco California Mail Address P 0 Box 3965 San Franclco CA 94119
March 21 1989
Mr M S Arafah Director General Jordan Electricity Authority PO Box 2310 Amman Jordan
Subject Jordan Oil Shale Prefeasibility Study
Dear Mr Arafah
Your letter of 15 March 1989 with comments on the Oil Shale to Power Prefeasibility Study draft report has been referred to me for reply
The attached responses to each item in the reference letter follows the order submitted
Also attached are three revised pages for the draft report - Volume I
Page 6-1 Page 6-21 Page 6-23
Please copy these revised pages into the report previously sent to you
We plan to review this material with JEA during the March 2930 and April 1 meetings in Amman
rsuVertrul yours
W Linton Project Manager
WHLdc
Attachments Questionnaire Response Three revised pages
cc C J Aulisio R R Buta G D Gould T J Wilbanks
32389
Page 1
RESPONSE TO MARCH 15 1989 QUESTIONAIRE
OIL SHALE TO POWER PREFEASIBILITY STUDY
This study examines economic prospects in terms of a 1995-2000 timeframe
FIRANCIAL AND ECONOMIC COMMENTS
11 It is likely that a BOT deal can be structured at present JEA
generation costs for either 20 MW or 50 MW size units if GOJ is
willing to subsidize the incremental power generation cost
Furthermore these incremental costs can be recovered during the 25
year operation of a Commercial Scale Project
12 A 3rd Party Test was proposed as an alternate means to raising
$100+ for an independent JEA sponsored 20 MW Demonstration
program
13 71 millsKWH for Shale Power
VS
JEA 1987 costs
Purchased Power 17 filsKWH = 51 mills
Produced Power 1360 filsKWH = 41 mills
19952000 Costs - Expected to be 30 to 40 higher and in line
with the cost estimate presented in this study
It also is important to recognize that the busbar cost of power
generated by any new power source can not be compared directly
with the cost of existing older installed capacity because of the
lower capital cost component of the latter (See enclosed Figure
1-1 which demonstrates how total capital carrying costs decline as
the investment is paid off) Any new capacity whether coal oil
or oil shale will be an unreasonable disadvantage compared with
costs for existing older capacity
l
024
o2
0De return
E 016Total carrying charge
012 qu return
S -008
ety taxes and n rcw vshy000 X 0 5 10 15 20 25
Figure 1-1 Year-by-year Carrying Charge Components for 15-yearTax Recovery Period
1-7
30
32389
Page 2
14 Infrastructure Cost
Total People
OperatorFamilies Installed Cost
20 MW $10000000 185700 $54000Operator
50 MW 15000000 3241200 46000Operator
400 MW 45000000 10364000 43000Operator
Factored allowance for grass roots desert installation
including housing and community facilities was developed as
follows for the 50 MW case study
Infrastructure
50 MW
Family Housing 200 30K = $ 6 Million
Bachelor Housing 100 20K = 2 M
HospitalClinic (8 Beds) 11 M
SchoolMosque I1 M
Stores Services amp Recreation = 2 M
Facilities
Roads Electricity Water Sewage = 3 M
$15 Million
Infrastructure costs for the 20 MW and 400 MW cases was ratioed
from this breakdown
At this conceptual level costs are order-of-magnitude In a Phase
II program these infrastructure costs can be developed in detail
32389
Page 3
15 Contract Mining Alternatives
Page 4-11 Mine Operation
Based on Bechtels evaluation of the mine contractors price as found in Section 15 of the Mining Report it was concluded that
the mine contractors price does not include costs for such things
as developing the mine with a box-cut ramp haul roads
developing an area for the waste material maintaining the
haulroads constructing the mine services facilities diversion
ditches sedimentation ponds water well crushing the oil shale
pre-mixing the oil shale at the mine and other items associated
with operating a mine to support a power plant If it is proven
that the mine contractors price includes cost for the above
mentioned scope of work in additi-n to drill blast load and
haul then the contractors price can be used but in the meantime
the all inclusive cost developed by Bechtel should be used
Contract Mining appears to be attractive for the smaller size
plants but not for the larger commercial scale operation Some
third party must provide the necessary capital for trucks
loading mining machines etc under a contract arrangement
16 Reassessment due to Dinar value change needs further study and can
not be evaluated given present budget limitations If average
labor rate of $300hr still valid then little change involve with
study
If deemed necessary reexamination of project economics can be
done in Phase IIwhen funded
17 Costs in this study are based on recent similar Bechtel experience
on Mount Poso project and on Montana I project The Mount Poso
project is a 50 MW unit firing coal in a Pyropower boiler The
Montana I project is a 35 MW unit firing coal in a Keeler Dorr
Oliver FBC boiler utilizing dry cooling
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18 The Pyropower quote of $186000000 to futnish and erect the steam
generator stack and baghouse has been adjusted to include
engineering construction indirect cost etc to be consistant
with the rest of the costs shown in Table 65 p 6-10 No
further adjustment for location was made
19 Equity funding has the lowest priority of payoff in case of a
liquidation and carries greater risk Hence a higher rate of
return is needed to attract these funds Debt funding is a first
mortgage and has first priority for payoff in case of liquidation
and carries less risk Hence it requires lower rate of return
than equity funding
The risk taking equity owner will ask for greater interest rate
to make funds available The only way to minimize this expense is
to find a loaning agency willing to provide 90 or perhaps 95 of
the investment cost It is likely that banks will require some
minimum equity participation
This Prefeasibility Study was not based on a non-profit utility
operation
Even though JEA is a non-profit organization its service
contributors are profit making groups It is visualized that the
Jordan Oil Shale Co (JOSCO) will be a stand alone business
enterprise servicing JEA under long term contract To secure
funding for the proposed project JOSCO will need attractive
enough contract terms to attract both equity and debt capital
110 Additional work is needed to develop the requested information
This work can be preformed as part of the Phase II program
111 Bechtel includes contingency in all of its estimates to cover
error emissions and unforeseen items within the defined scope of
the project The level of contingency is dependent upon the
amount of scope definition For a prefeasible study such as this
15 contingency is lower than normal
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112 Tables 89 through 816 include a present value calculation to
establish the relative benefit for a shale project vs coal and
oil
113 The variable maintenance cost of 1 millsKWH has been adjusted for CFB plants with an additional $200000 per year or 06 millsKWH
This yields the following
Variable Maintenance - 10 millsKWH
CFB Adjustment - 06
Fixed Maintenance Cost - 40
Total Cost 56 MillsKWH
114 Page 4-29
The royalty costs are included in the weighted average oil shale
costs for the 50 megawatt plant
Page 4-8
Shale fuel costs include return on equity and royalty These are
two separate cost items Royalty is the last item mentioned in
the sentence and it therefore reads as royalty and not return on
royalty
Page 4-31 gives rates used by Bechtel based on our calculations
using the referenced procedures
DebtEquity Capital Charge Rate
5050 153
8020 139
Table 69 displays the calculation of the 153 capital charge
rate (Line 7 of Table 69 is not used in the calculation and
should be deleted)
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116 No water purchase charge from the Water Authority was added to the
operating expense based on the statement that no resource costs
will be charged
$020 per 1000 gallons is rule of thumb for USA installations in
absence of client data
Boiler make up water (p4-17) is treated in a demineralizer
train If deemed necessary comparison with reverse osmosis
process can be performed in Phase II
Water requirements were estimated to be
Cubic Metres Per Year
20 MW 50 MW 400 MW
Mine amp Shale Processing 455000 761000 773000
Power Block 3000 6000 42000
Infrastructure 80000 140000 448000
Total 538000 907000 1263000
117 Annual average operating costs shown on Table 6-1 are in error
Financing Option 5050 8020
Cost Shown 56606 48945
Corrected Cost 60396 53236
Average mining and shale processing costs are developed year by
year in the Mining Report Appendix 5 Table 12-10
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118 We would be interested in receiving the breakdown of these current
power cost figures (ie capital charges fuel cost number of
operators etc) Further economic analysis employing these
figures can be developed in Phase II
119 Manpower requirements for the three case studies were estimated as
fol lows
Mining amp Shale Processing
Power Block
Operations
Maintenance
Management
20 MW 50 MW 400 MW
75 163 396
54 78 175
46 73 455
10 10 10
185 324 1036
Page 14-4 of the Mine Report is for mine and shale processing
only It should be noted that most of these manpower requirements
involved new jobs for Jordanian people
120 At the April 1988 Amman Meeting it was agreed that the following
costs would be omitted
o Permits and Licenses
o Local Taxes
o Import Taxes
If necessary such costs can be developed and added into a revised
economic analysis as part of the Phase II program
121 6 average inflation rate is the figure recommended by Bechtel
based on USA conditions for use in long term economic analyses of
new power ventures
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122 This matter is referred to ORNL who prepared a rate of return
analysis
Bechtels conclusion is based on computed busbar costscumulative
benefits compared to alternate fuels in the timeframe 1995 to 2000
Relative Busbar Power Cost Net 25 Year
Mills per KWH Benefits - Million US$
Sultani Oil Shale 71-83 Base Cost
Imported Coal
$50tonne 68-88 778
$70tonne 78-107 2531
Imported Oil
$17Bbl 56-76 (18) $24Bbl 61-96 1810
The above results are based on a capacity factor of 75 which is
considered to be a reasonable target for a new plant over its 25 year
life The average selling price of 6 cents per KWH cited in the
questionnaire is based on existing plant costs which may not include
all cost elements of new capacity evaluated in this study
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TECHNICAL COMMENTS
21 See answer to Item 116
Total power plant raw wate consumption rates and annual
consumptions including the water requirements for wetting ash at the truck loading p int within the power plant are given in Tables 43 and 44 for 50 MW unit and Tables 53 and 54 for 20 MW unit
The raw water requirements for 4x0 MW plant were factored
excepting the mine where a revised mine pldn is employed to reduce water request The quantities shown on these tables exclude raw
water requirements for housing complex mine and ash wetting if
required at the ash disposal site
Total power plant requirements shown in the above referred tables
are
50 MW 20 MW
Rate gpm 207 102 (See Drawing M004)
Annual Use
Gallons 1400000 675000
Cooling tower blowndown supplemented with raw water is used for
wetting ash at the truck loading point within the power plant Raw water quantities attributable for ash wetting at the power
truck loading point are
50 MW 20 MW
Rate gpm 75 325
Annual Use
Gallons 500000 215000
These quantities are included in the quantities shown in
the above referred tables
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22 We recognize the POTENTIAL for leaching toxic compounds from the
spent ash However this matter is not yet defined well enough to
recommend specific action steps The Prefeasibility Study page
7-12 recommends creation of a ground water dispersion model to
determine whether more specific contaminated water mitigation
plans are needed It is anticipated that the leachate rate will
be low and that aquifer dispersion will keep problem compounds
bel3w health standards thresholds
23 Noted
We have not received up to date resource study material which
defines 50 billion tons resource base Please furnish
The resource base at Sultani alone is adequate to support two 400
MW power projects capacity subject water availability The
2-million cubic metre per year water allowance for oilshale will
limit development to about 600 MW
24 Selection of a combustion temperature is a balance between carbon
combustion efficiency and heat loss due carbonate decomposition
For purposes of the Prefeasibility Study we have opted for high
combustion efficiency At lower efficiency larger shale
mineprocessing plants will be needed
25 Bottom ash is cooled by water exchange before discharge
Cooling water is supplied to the ash screw coolers as specified by
Pyropower See Drawing MOO5 2140 gpm flow for 50 MW and 860 gpm
flow for 20 MW Heat removed by the cooling water from the ash
screw coolers is dissipated to atmosphere via a wet cooling
tower Pyropower should indicate the temperature of the ash
discharged to be 5OOF
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Initially we had considered using a heat exchanger to cool the ash
and improve the cycle efficiency Considering low cost of fuel
the additional capital costs and the system complexities it was
decided not to employ such heat recovery systems for this project
26 The suggested alternates were looked at briefly and the potential
for wind blown air pollution from the ash disposal areas are too
great to warrant dry disposal unless GO(] and World Bank are
willing to accept such a potential problem Wetting the ash is
tne only practical solution Hopefully some cementation will
occur helping to reduce future leaching potential
27 JEA requirements are noted This is a conceptual study not a
final design Optimal design analysis can be performed during
Phase II
2829
JEA requirements are noted and can be incorporated into the Phase
II design
210 The transformer size is adequate for base load operation A
higher capacity can be considered at the final design stage if the
Client prefers
211 From our experience it does not appear to be economical to
provide additional dry cooling towers to take care of maximum
ambient temperatures which may prevail only for a short period of
time in a year To study this an annual dry bulb temperature
duration curve is required Also adding additional dry cooling
towers will change the plant performance It should also be noted
that the dry cooling towers are very expensive and the size should
be selected carefly considering performance and cost and not on the basis of maximum ambient temperatures This can be studied
during Phase II
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212 The plant gross output varies with condenser pressure
Condenser
Pressure Design 55 in HgA Annual Ave 35 in HgA
Unit Size MW 20 50 4xlO0 20 50 4xlO0
Gross Output MW 234 593 496 2415 607 TBD
Net Output MW 1975 501 400 205 515 TBD
To be developed in Phase II
Output for 4x100 MW is estimated by others
213 The fan power consumption of the CFB boiler is about 30 to 35 of
the total auxiliary power The fan power consumption of the dry
cooling tower is about 20 to 25 of the total auxiliary power
214 Table 1-1 does not include plant net output Therefore do not
understand the comment
215 Commercial operating experience with coal fueled CFBC units in LISA
and Europe has been uniformly good showing high on stream
availability in early years (See Table 2-6 which reports on
Pyropower experience)
We expect operations with high ash content fuel like oilshale will
have unique scale up problems such as
o Solid handling in and out
o Internal solids circulation
o Erosioncorrosion steam generator intervals
o Heat recovery from bottom ash
Consequently we are recommending these items be worked out in a
single 50 MW prototype
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216 Maximum dry cooling is used in this study A small wet cooling
tower is used on circulating service water system
217 Horizontal condensate pump is adequate with dry cooling tower and it is cheaper Vertical condensate pumps with cans can be
considered in the final design if required
218 A concrete shell brick lined flue stack will be larger in diameter and costs more than a steel lined stack Brick lined stack can be
considered in the final design
219 Demineralized water tank capacity for 50 MW is 76 cu meters or 20000 gallons not 1000 cu meters For 20 MW plant it is 38 cu
meters or 10000 gallons
220 It is US practice to use an average continuous blowdown rate of
1 and maximum biowdown rate of 3 for this type of plants
221 This can be studied during Phase II
222 Same as 221
223 Same as 221
224 The recommended action plan calls for continuing support studies covering the referenced items Additional effort is needed to
further define these matters and confirm the conceptual plan
The next step is to develop an outline for a project plan including
o Work Scope
o Schedule
o Budget
accommodate the increase in the number of employees and
equipment Truck bays to accommodate the 136 tonne trucks
will be added The truck bays used for the 77 tonne
trucks will be used for the maintenance of other
equipment The warehouse change house training room
offices and cafeteria will be expanded accordingly
6025 Mining and Processing Economics
Details of the oil shale mining and processing plant
economics for the 400 MW plant are included in the Mining
Report (Appendix 5) These details are of the same
magnitude as prepared for the 20 MW and 50 MW plants
The summary of the cash flow analysis for the mine and
shale processing plant is presented in Table 6-1
Table 6-1
SUMMARY OF 400 MW PLANT OIL SHALE MINING AND PROCESSING COSTS
5050 Debt-Equity 8020 Debt-Equity
US $1000 US $1000
Capital Cost
Mine Development 30915 30915
Mine Equipment 66012 66012
Process Plant Facilities 50889 50889
Spare Parts 5000 5000
Working Capital 10000 10000
Capi tal ized Interest
During Construction 24423 39075
TOTAL 187239 201891
Operating Costs and Other Costs
Annual Cost 60386 53236
Product Mined and Processed
Annual Tonnes x 1000 7783 7783
Unit Cost
US $Tonne (weighted average)
US $l06Btu (weighted average) 776
156
684
138
Year 12 costs taken as 25 year average
6-6
-Au
Table 610 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY