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Carl Bozzuto Seminar PDF
Carl Bozzuto Seminar PDF
Carl Bozzuto
ALSTOM 2006. We reserve all rights in this document and in the information contained therein.
Reproduction, use or disclosure to third parties without express authority is strictly forbidden
Overview
Economic Terms
Economic Methodologies
Cost Models
Pitfalls
Cost Studies
Results
Conclusions
Economic Terms
z
Leverage = Assets/Equity
PE Ratio = Stock Market Price (per share)/Net after tax (per share)
Why do we care?
The Discount Rate considers risk as well interest rates and inflation
The discount rate is often a project hurdle rate
Economic Methodologies
Plant Cost
z
Today, we really dont know what the final cost of a plant will be.
Raw material escalation
Shipping costs
Labor costs
Economic Methodologies
Simple payback
Return on Equity
For regulated utilities, the ROE is set by the regulatory body. The equity is determined
by the total plant cost being allowed in the rate base. The equity portion is determined by
the leverage of the company. The ROE is applied to the equity and added to the cost in
determining the cost of electricity and thus the rate to be charged to the customer.
This is the rate to be charged on the capital cost of the plant in order to convert capital
costs (ie investment) into operating costs (or annual costs). This rate can be estimated
in a number of ways. This rate generally includes most of our ignorance about the future
(ie interest rates, ROE, inflation, taxes, etc.)
Economic Methodologies
z
Cost Models
z
10
The goal is to estimate the cash flows of the project over the life of the
plant. A significant number of variables are involved and must be
estimated or assumed in order to make the spread sheet work.
Input variables include net output, capacity factor, availability, net plant heat rate
(HHV), degradation, EPC price, construction period, insurance, initial
spares/consumables, fixed O&M, variable O&M, fuel price, fuel heating value (HHV),
financial closing date, reference date, depreciation, analysis horizon, owners
contingency, development costs, permitting costs, advisory/legal fees, start up fuel, fuel
storage, inflation rates, interest rates, debt level, taxes, construction cash flow,
discount rate, and ROE.
A detailed cash flow analysis is set up for each year of the project. For shorter term
projects, these estimated cash flows are more realistic. For longer term projects, the
accuracy is debatable.
Since the cash generation may be variable, it is often desirable to perform some kind of
levelizing function to generate an average that is understandable. There are risks
associated with this step.
The most common application is to assume a market price for electricity and then try to
maximize the IRR for the project.
11
The model assumes that we know a lot about the project and the
number of variables. What if we dont know very much about the future
project? For example, what if we dont know where the plant will be
located? What if we dont know which technology we will use for the
plant? What if we want to compare technologies on a consistent basis?
-100,000
-200,000
-300,000
-400,000
-500,000
-600,000
13
47
45
43
41
39
37
35
33
31
29
27
25
23
21
19
17
15
13
11
50,000
0
(50,000)
(100,000)
(150,000)
(200,000)
(250,000)
(300,000)
(350,000)
14
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
41
Pitfalls
z
The biggest pitfall is thinking that these numbers are real. They are
only indicative. Just because a computer can calculate numbers to the
penny does not mean that the numbers are accurate. There is a lot of
uncertainty due to the number of assumptions that have to be made.
The analysis itself does not identify the risks. The analyzer must
consider the risks and ask the appropriate what if questions. In the
following study, over 3,000 spread sheet runs were made in order to
analyze the comparisons effectively.
1,200 GW
Major Competitors
Technology
Maturity
Alstom,MHI, B&W, FW
and Several Others
Mature
Alstom,MHI, B&W
Proven
Super-Critical PC
265 GW
PFBC
0.5 GW
IGCC
1 GW
Demo
CFB
20 GW
Alstom, FW
Proven
Mature
NGCC
200 GW GT
100 GW ST
16
Demo
IGCC
400
400
400
400
1,000
1,050
1,100
1,380
9,374
8,385
8,405
8,700
80
80
80
80
36
36
48
48
31.14
32.11
33.69
39.08
0.77
0.69
1.01
0.42
(MW)
Capital Cost
($/ kW)
Heat Rate
(Btu/ kWh)
Availability
(%)
Cycle Time
(months)
Fixed O&M
($/ kW)
Variable O&M
(mills/ kWh)
Source:
17
Market
Market
ABB
GE
Size
CFB
P200 PFBC
NGCC
100
100
270
1,000
1,200
500
10,035
8,815
6,640
80
80
80
30
32
24
44.13
55. 41
16.92
1.18
1.06
0.01
(MW)
Capital Cost
($/ kW)
Heat Rate
(Btu/ kWh)
Availability
(%)
Cycle Time
(months)
Fixed O&M
($/ kW)
Variable O&M
(mills/ kWh)
Source:
18
Market
ABB
PGT
400
400
400
400
750
750
750
1,100
8,750
8,125
8,030
7,800
80
80
80
80
24
24
30
36
26.33
26.33
26.95
33.69
0.81
0.75
1.05
0.37
BA Plan
BA Plan
(MW)
Capital Cost
($/ kW)
Heat Rate
(Btu/ kWh)
Availability
(%)
Cycle Time
(months)
Fixed O&M
($/ kW)
Variable O&M
(mills/ kWh)
Source:
19
SECAR
GE
Size
CFB
P200 PFBC
NGCC
100
100
270
725
850
325
9,350
8,530
6195
80
80
80
18
22
18
38.84
48.67
16.44
1.15
1.12
0.01
(MW)
Capital Cost
($/ kW)
Heat Rate
(Btu/ kWh)
Availability
(%)
Cycle Time
(months)
Fixed O&M
($/ kW)
Variable O&M
(mills/ kWh)
Source:
20
BA Plan
SECAR
PGT
21
Horizon (years)
40
30
15
15
10
5.75
7.75
8.75
8.75
8.25
40
30
10
Depreciation (years)
40
30
15
15
10
Equity (%)
50
30
50
75
Debt (%)
100
50
70
50
25
ROE (%)
n/a
10
20
20
23
Taxes (%)
20
30
30
30
8.0
Financial
Fixed O&M
Variable O&M
Fuel
ts have
s
o
c
l
a
i
c
Finan
n COE
o
e
c
n
e
u
l
major inf
7.0
6.0
5.0
4.0
3.0
2.0
1.0
0.0
Municipal
Utility
IPP-1
Financing Arrangement
22
IPP-2
Industrial
Comparison of Technologies
Municipal Financing - 1997
(80% CF, $1.20 coal and $3.00 gas)
4.0
Financial
Fixed O&M
3.5
Variable O&M
Fuel
3.0
2.5
2.0
1.5
1.0
0.5
0.0
Subcrit PC
(400 MW)
23
Super PC
(400 MW)
P-800
(400 MW)
IGCC
(400 MW)
P-200
(100 MW)
CFB
(100 MW)
NGCC
(270 MW)
Comparison of Technologies
Utility Financing - 1997
(80% CF, $1.20 coal and $3.00 gas)
5.0
4.5
4.0
3.5
3.0
2.5
Financial
NGCC lo
oks bett
er on to
but wor
tal COE
se on di
,
spatch b
asis.
t
s
o
ncial c
a
n
i
f
r
e
h
g
Hi
ce on
n
e
u
l
f
n
i
s
increase
CO E
Fixed O&M
Variable O&M
Fuel
2.0
1.5
1.0
0.5
0.0
Subcrit PC
(400 MW)
24
Super PC
(400 MW)
P-800
(400 MW)
IGCC
(400 MW)
P-200
(100 MW)
CFB
(100 MW)
NGCC
(270 MW)
Comparison of Technologies
IPP(1) Financing - 1997
(80% CF, $1.20 coal and $3.00 gas)
8.0
Financial
Fixed O&M
7.0
Variable O&M
Fuel
6.0
5.0
4.0
3.0
2.0
1.0
0.0
Subcrit PC
(400 MW)
25
Super PC
(400 MW)
P-800
(400 MW)
IGCC
(400 MW)
P-200
(100 MW)
CFB
(100 MW)
NGCC
(270 MW)
Comparison of Technologies
IPP(2) Financing - 1997
(80% CF, $1.20 coal and $3.00 gas)
9.0
Financial
Fixed O&M
8.0
Variable O&M
Fuel
7.0
6.0
5.0
4.0
3.0
2.0
1.0
0.0
Subcrit PC
(400 MW)
26
Super PC
(400 MW)
P-800
(400 MW)
IGCC
(400 MW)
P-200
(100 MW)
CFB
(100 MW)
NGCC
(270 MW)
Comparison of Technologies
Industrial Financing - 1997
(80% CF, $1.20 coal and $3.00 gas)
16.0
14.0
Financial
Fixed O&M
Variable O&M
Fuel
12.0
10.0
8.0
6.0
4.0
2.0
0.0
Subcrit PC
(400 MW)
27
Super PC
(400 MW)
P-800
(400 MW)
IGCC
(400 MW)
P-200
(100 MW)
CFB
(100 MW)
NGCC
(270 MW)
7.0
P-800
IGCC
D is
P-200
patc
CFB
h ra
NGCC
hav
t
e
a
em
ajor nd/or c
influ apac
i
en c
e on ty facto
COE r
6.0
5.0
4.0
3.0
2.0
20%
30%
40%
50%
60%
70%
80%
90%
100%
3.5
3.4
3.3
3.2
Subcrit PC
Supercrit PC
3.1
3.0
2.9
2.8
~5 days
2.7
2.6
2.5
6,500
6,600
6,700
6,800
6,900
7,000
7,100
7,200
7,300
7,400
7,500
Sensitivity Analysis
Subcritical PC
1997 IPP1 Financing - $1.20 coal
20%
ty a nd
i
l
i
b
a
l
i
a
v
CO E
nge in a
n
a
o
h
e
c
c
,
n
e
%
u
In
est infl
h
g
i
h
e
v
a
eh
EPC pric
15%
10%
5%
0%
-5%
-10%
Availability
EPC price
Plant heat rate
Fixed O&M
Cycle time
Var O&M
-15%
-20%
-20%
-15%
-10%
-5%
0%
5%
10%
15%
20%
Sensitivity Analysis
NGCC
1997 IPP1 Financing - $3.00 gas
20%
and
y
t
i
l
i
b
a
l
i
a
e in av
g
n
a
h
c
,
on COE
e
%
c
C
n
C
e
u
G
l
f
N
For
ighest in
h
e
v
a
h
efficiency
15%
10%
5%
0%
-5%
Availability
EPC price
Plant heat rate
Fixed O&M
Cycle time
Var O&M
-10%
-15%
-20%
-20%
-15%
-10%
-5%
0%
5%
10%
15%
20%
Comparison of Technologies
China 1997 Municipal Financing Conditions
($1.80 coal and $5.00 LNG)
4.0
3.5
3.0
gh
NGCC hi
el
due to fu
cost
r ta nt
o
p
m
i
s
s
t le
h c os t
First cos
g
i
h
o
t
e
itive du
s
n
e
s
l
e
u
f
2.5
2.0
1.5
1.0
Financial
Fixed O&M
Variable O&M
0.5
Fuel
0.0
Subcrit
PC
32
Supercrit
PC
P-800
IGCC
P-200
CFB
NGCC
Comparison of Technologies
China 1997 IPP Financing Conditions
($1.80 coal and $5.00 LNG)
7.00
6.00
5.00
4.00
3.00
2.00
Financial
Fixed O&M
1.00
Variable O&M
Fuel
0.00
Subcrit
PC
33
Supercrit
PC
P-800
IGCC
P-200
CFB
NGCC
Comparison of Technologies
Japan Market Conditions - 1997
($2.90 coal and $5.00 LNG)
5.0
4.5
4.0
3.5
3.0
2.5
2.0
o r ta nt
p
m
i
s
s
e
l
t
c os t
h
First cos
g
i
h
o
t
v e due
i
t
i
s
n
e
s
l
fue
1.5
1.0
Financial
Fixed O&M
Variable O&M
Fuel
0.5
0.0
Subcrit PC
(400 MW)
34
Super PC
(400 MW)
P-800
(400 MW)
IGCC
(400 MW)
P-200
(100 MW)
CFB
(100 MW)
NGCC
(270 MW)
9,350
10,035
8,530
8,815
10%
7%
7%
6,195
8%
6,640
7,800
8,000
8,700
8,030
8,405
8,125
8,385
8,750
9,375
10%
7%
6,000
6%
4%
4,000
4%
3%
3%
2,000
1997
2005
Improvement
0%
Subcrit PC
(400 MW)
35
2%
Super PC
(400 MW)
PFBC-P800
(400 MW)
IGCC
(400 MW)
PFBC-P200
(100 MW)
CFB
(100 MW)
NGCC
(270 MW)
10,000
12%
$1,000
29%
30%
28%
25%
$725
$850
$750
$750
$750
25%
35%
$1,200
$1,100
$1,100
$1,000
20%
20%
$600
$400
$325
15%
$350
$800
29%
32%
1997
2005
% Decrease
10%
7%
$200
5%
$0
0%
Subcrit PC
(400 MW)
36
Super PC
(400 MW)
PFBC-P800
(400 MW)
IGCC
(400 MW)
PFBC-P200
(100 MW)
CFB
(100 MW)
NGCC
(270 MW)
$1,000
$1,050
$1,400
$1,200
40%
$1,380
$1,600
2,000
1,800
Subcritical PC
Supercritical PC
P800
P200
1,600
1,400
1,200
1,000
800
600
all
4
have 00 MW t
echn
the s
olog
ame
ies
mid
term
targ
et
400
200
0
1989
1991
1993
1995
1997
Year
37
1999
2001
2003
2005
Market Trends
Carbon Steel Price Trends
175
150
125
100
01/02
01/03
01/04
Month
38
01/05
01/06
January
February
March
April
May
June
July
August
September
October
November
December
January
February
March
April
May
June
July
August
September
October
November
December
January
February
March
April
May
June
July
August
September
October
November
December
January
February
March
April
May
June
July
August
September
October
November
December
January
February
March
April
May
June
July
August
September
October
November
December
January
February
March
April
May
June
July
August
September
October
November
December
January
February
March
April
May
June
July
August
September
October
November
December
Spot Nickel
Market Trends
Nickel Trend: 2000 - 2006
39
16.20
15.80
15.40
15.00
14.60
14.20
13.80
13.40
13.00
12.60
12.20
11.80
11.40
11.00
10.60
10.20
9.80
9.40
9.00
8.60
8.20
7.80
7.40
7.00
6.60
6.20
5.80
5.40
5.00
4.60
4.20
3.80
3.40
3.00
2.60
2.20
1.80
2000
2001
2002
Month / Year
2003
Low Ni
Avg. Spot Ni
2004
High Ni
2005
2006
The claim for the future is that the cost of capture of CO2 to mitigate
greenhouse gas concentrations in the atmosphere will be more
expensive for PC than for IGCC. Further, as IGCC develops, its costs
will come down (learning curve).
As we are in a state of flux with regard to present day costs for plants,
the best we can assume (to one significant figure) is that costs have
escalated from their 1997 level to about double. That is, a PC plant is
now about $2000/Kw and an IGCC is about $3000/Kw (EPC). Recall
that the forecast in 1997 was for PC to be $750/Kw and the IGCC to be
$1100/Kw. Unfortunately, that is one of the dangers of forecasting.
40
Fuel costs have also escalated. Recent data for fuel costs delivered to
new plants is about $1.75/MMBTU for coal and $6.50/MMBTU for gas.
We can input these new costs into the spread sheet model and get an
estimate for the COE for a utility trying to make a decision today.
Under these conditions, with no CO2 capture, the COE for the PC plant would be 6.55
cents/Kwhr and the IGCC plant would be 9.41 cents/Kwhr.
The natural gas plant would again look competitive at 6.3 cents/Kwhr with an 80%
capacity factor. However, at a more typical 40% capacity factor, the COE is 8.30
cents/Kwhr.
As a result, we see a lot of utilities considering supercritical pulverized coal plants.
Efficiency
Critical to emissions strategy
Source: National Coal Council
From EPRI study
100% Coal
Coal w/ 10%
co-firingbiomass
Commercial
Supercritical/
First of kind IGCC
Existing US coal
fleet @ avg 33%
42
43
50
40
30
20
10
0
POLK/WABASH
IGCC
SCPC Today
USC Target
9Increase efficiency
Maximize MWs per lb of carbon processed
9Fuel switch with biomass
Partial replacement of fossil fuels =
proportional reduction in CO2
9Then, and only then .Capture remaining CO2
for EOR/Sequestration
= Logical path to lowest cost of carbon reduction
44
Status
CO2 Frosting
Process Being Developed by Ecole de Mines de Paris, France, with ALSTOM Support
CO2 Wheel
Use Regenerative Air-Heater-Like Device with Solid Absorbent Material to Capture ~ 60% CO2
from Flue Gas.
Being Developed by Toshiba, with Support from ALSTOM
Being Developed by the University of Oslo & SINTEF Materials & Chemistry (Oslo, Norway),
in Cooperation with ALSTOM
45
46
Without CO2
Removal
MEA-Fluor Dan.
Proc.
NH3
528
652
648
462
329
421
5.15
8.56
6.21
1.71
0.24
0.19
Base
51.1
19.7
3000
ABB
Lumnus
2500
Values From
Current
Projects
2000
1500
1,350 BTU/lb
1000
ALSTOMs
Chilled
Ammonia
Process
2001 Parsons
Study (Fluor)
500
0
1990
Process
Optimization
1995
1995
2000
2000
Advanced
Amines
2005
2005
Process
Innovations
2010
2010
2015
2015
2020
10
8
6
4
2
w
/M
O
EA
xy
fir
in
g
w
SC
CO
PC
2
ad
v
am
in
IG
es
CC
F
tu
rb
in
e
SC
PC
US
NH
IG
C
3
CC
PC
H
ad
tu
v
rb
C
O
in
2
e
w
ad
v
CO
2
SC
PC
IG
CC
0
SC
PC
Note: Costs include compression , but do not include sequestration equal for all technologies
48
Economic Comparison
Cost of Electricity (common basis)
Ref Air fired CFB w/o
capture
9.00
8.50
8.00
O2 fired PC w/
capture
(Cents/kWhr)
7.50
7.00
6.50
6.00
Ammonia scrubbing
5.50
5.00
Chemical Looping
4.50
4.00
0
10
20
30
40
50
Conclusions
50