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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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Page 1: fo; - pdf.usaid.gov

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

Pilot Plant Test Program (Contd)

U Analyzed one blended sample of shale

- Calorific value = 532 - 597 MJkg (approx 2250 BtuIlb)

- Carbon content (dry solids) = 162 - 187 wto

- Sulfur content (dry solids) = 30 - 33 wt

- Ash content (dry solids) = 667 - 684 wt

- Shale size = minus 8 mm

Key items determined

- Combustion efficiency

- Product ash distribution

- Product gas S02NOxCO content

- Data for boiler design

- Sulfur emissions reduction by Ca in fuel

S Prefeasibility Study Oil Shale Fueled Power Generation

VOO74GEAJI 10

Pilot Plant Test Results

U Combustion efficiency exceeded 985 in all tests

Ash distribution (btm ashfly ash) was 3565 to 4753 at 100 load typically4060

Low emissions were demonstrated

Typically S02 10 to 200 ppm gt 95 removal

limestone addition not required

NOx 60 to 120 ppm lt 020 lb106 Btu

Co 10 to 90 ppm lt 50 ppm

Prefeasibility Study Oi Shale Fueled Power Generation

TITLE

Ternpe -al-CuA vs 6 Ik

00

I00

7SA-A-

Fly Ai h

0

85 e

80-

0

00

i I 800 860 oo

T-er pe -

DATE OWN APPD DCNO- ------ -

_______f - _ IPG_

Pilot Plant Test Conclusions

It is technically feasible to burn the Sultani oil shale furnished by NRA in a Pyropower boiler

A high combustion efficiency in excess of 985 was demonstrated

SO2NOxCO emissions are all acceptably low with no limestone addition required

Prefeasibility StudyO Shale Fueled Power Generation

Conceptual Design Studies Scope

m Three project sizes

- 20 MW

- 50 MW

- 400 MW (4x100) factored for power plant portion

m Open-pit mine

- Shale processing at the surface - Waste disposal system

Power block

- Boiler

- Steam turbine

- Auxiliaries

Prefeasibility Study Oil Shale Fueled Power Generation

VOn 4FAIR 1

i

Project Layout 9 fc =f4j

deg2

o r -w (031

5_7EC 45U

iPefeaibiity tud

OlSeFuedP erGr in

179581113i~o(atyvv11

n1- 14 4pc

C)

Sultani Oil Shale Reserves

North South Area Area Total

Mineable shale tonne x 106 320 658 978

Fischer assay oil content wt 744 761 765

Overburden m3 x 106 384 627 1011

Stripping ratio m3m3 2161 1711 1861

bull Based on NRA core drilling and core analysis

Prefeasibility Study Oil Shale Fueled Power Generation

VWO41OFEAMI14

i

Sultani Oil Shale Analyses

Moisture

Ash (less CO 2 in CaCO 3 )

CO 2 (in CaCO 3 )

Carbon (organic)

Hydrogen

Nitrogen

Sulfur

Oxygen (by diff)

Total

High heating value BtuIb

Fischer assay oil content

bull Percent by weight

Design Basis Fuel

320

6680

1387

1132

113

048

255

065

10000

2250

840

Low High Calorific Calorific

Value Fuel Value Fuel

320 320

6730 6625

1414 1337

1020 1250

102 125

058 038

238 271

118 034

10000 10000

2000 2500

750 925

Preteasibility Study Oil Shale Fueled Power Generation

vo0N d-GEAR 1S

50 MW Oil Shale ProcessingPrototype Plant

Mlne Plant

_ 14 0 Haul0___) to Plant 1 Sorage

Portable Crusher

(-)100 mm Storage

(-) 100 mm Hopper UIU 400 th

Feed Bin

J 50

250 tvb

8 -m Circulating Load Impact3or0 0 30 0 0shy+8mm25

30 0L Sampler 0 1 30 0

p3 Day Storage

To Power Plant

Preleasibility StudyOil Shale Fueled Power Generation

17958101 SaJordanli 18 3-14-89 rsipc1

20 MW Oil Shale Demonstration Plant

Mine Plant

Haul00- 01 o

= Pb n Storage Portable _

110 mm Stora e 0

()100 mm r Hopper

U 400V

Feed Bin

CirculatingLoad3 Day Stoge

Prefea~ltSudy Shale Fueled Power Generation

179S 111p 1 11Joda3 yl 3-202-89 8vk2

I

Mine and Shale ProcessingDesign - 2050 MW Project

I Overburden removal (north pit area) 10-meter benches

- Drill and blast

- 10 m3 front-end loader

- 77-ton truck haulage

I Oil shale mining 10-meter benches

- Rippe and auger scraper

- Front-end loader

- Portable in-pit crusher

- 77-ton truck haulage

Oil shale processing

- Feed = minus 100 mm

- Product = minus 8 mm

- Capacity = 250 tph

- Reversible impactor

- Two vibrating screens

1 Prefeasibility Study Oil Shale Fueled Power Generation

V -M 1AMI1ARt46

400 MW Full-Scale Oil Shale ProcessingPlant

Feed MTnus 200 mm Samplerr

1000 bull 10000 Tonnes Live Storage Grade

200 m long(-) 200 mm -- =-- Plow Feeders

00 h 100000 Tonnes Live Storage

Stream 3 - Sampler Bin Stream 2

Stream th 31Da2000

Circulating Load 2i

NFw Feed r -17000t1 170001l 170 t 17000 t 17000 t

1000 th Silo with 7 Impactor (-1)8 mm Reapro- 3 Day Storage at Aver age Loadn

0 20 Feeders 20 m Diameter by 40 m High

JJJTHT To Power Plant

Prefeasibility Study Oil Shale Fueled Power Generation

179589 6aJordarV 1I8 3-14-89 rsipc1

Mine and Shale ProcessingDesign - 4x100 MW Project

m Overburden removal (north area) 10-meter benches

- Drill and blast

- Three 20 m3 shovels

- 136-ton truck haulage

m Oil shale mining 10-meter benches

- Two mechanical surface miners

- 136-ton trucks to pit hopper

- Belt conveyor = 2000 tph

- Traveling stacker

m Oil shale processing

- Feed = minus 200 mm

- Product = minus 8 mm

- Capacity = three 1000 tph units

Prefeasibility Study Oil Shale Fueled Power Generation

VOO79-ampGEAIAt 17

i

Steady-State Production Schedule

Overburden removal bench m3

20 MW demo project 5n MW prototype 4x100 MW full-scale plant

Oil shale mining and shale processing tonnes

20 MW project 50 MW project 4x100 MW project

HourlyDesign Capacity

282 234

1850

HourlyDesign Capacity

250 250

2000

Avg Daily Annual PEQuctiQa Production

1690 507000 4217 13 million

33333 10 million

Max Daily(a) Annual(b) Production Production

1733 390000 4324 973000

34578 78 million

(a) Based on 100 operating factor for power block

(b) Based on 75 operating factor for power block ( 20 MW project = 300 shiftsyr 50 MW project = 900 shiftsyr 400 MW project = 900 shiftsyr)

Prefeasibility Study Oil Shale Fueled Power Generation

Conceptual Power Plant Plans

m Pyroflow boiler

Power generating facilities

m Auxiliaries

S Preleasibility Study Oil ShaJe Fueled Power Generation

vo0o7dEAO 19

Pyroflow Boiler SteamConciflons

Flow rate 226700 kghr (500000 Ibhr)

Pressure 1099 kgcm2 abs (15635 psia)

Temperature 51280C (9550F)

Same for 20 50 and 100 MW designs

Prefeasibility Study Oil ShaJe Fueled Power Generation

vooGALMI 20

HtomCOPUIOTP

- 50005 5op

-- LEVAThUM ORPORAION

0

-VI

DZ 4

Power Block

Fuel handling system

- Day binsscrew feeders

Boiler

- Pyroflow circulating fluid bed combustor

Power generation

- Non reheat condensing steam turbine

- Conventional Rankin steam cycle

Ash handling system (btm ash irom combustor and flyash from bag house)

- Wetted in pug mill to add 20plusmn wt wpter

Plant service water

- Air-cooled condensors and small cooling tower from circulating trim water coolers

Plant raw water

- To cooling tower makeup

- To drinking water system

- To pump seals etc

Plant treated makeup water

- Demineralizer train

Preteasibility Study Oil Shale Fueled Power Generation

i

Onsite Infrastructure

Project office

Control house

U Maintenance shops warehouse

Laboratory

Employee service facility

Site developmentoperations service facilities

- Fire controlsecurity

- Communications

- Lighting

- Roads drainage and sewage

Prefeasibility StudyQ1I Shale Fueled Power Generation

voo4JG m 0 JV

i

BechtellPyropower50 MW Cogeneration Plant - Mt Poso California

W4t Prefeasibility Study --- 7 Oil Shale Fueled Power Generation

179586122aJordarv 118 3-14-89 rsO

Characteristics of Three Size Operations

Oil shale fuel tpy

Mine development excavation bank m3

Spent ash disposal tpy (wetted)

Water consumption 1000 m3yr

Staffing required

Community population

400 MW

20 MW 50 MW (4x1 00)

390000 973000 78 million

500000 1 million 85 million

327000 815000 61 million

538 907 1263

185 324 1046

700 1200 4000

Prefeasibility Study Oil Shale Fueled Power Generation

V000ofllAM1 23

Conceptual Designs Summary

N All BOP facilities involve conventional equipment and technology

100 MW unit operation involves boiler scale-up considerations

N Water consumption estimates

- Requirement for 4x100 MW project is 13 million m3 yr

- Water allocation of 2 million m3yr of water supports 6x100 MW

N Water availability probably limits total power generation from oil shale in Jordan

Prefeasibility Study Oil Shale Fueled Power Generation

V007041GEAOLMI

i

TECHNOLOGY RISK ASSESSMENT

Basic concepts

Key boiler scale-up design issues

Impact of scale-up

U Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Prefeasibility Study O1 Shale Fueled Power Generation

VOOh-7AEAAO 2

Basic Concepts

U CFBC is relatively new in the powerindustry

- Existing plants are small typically 20 to 50 MW

- There is limited operating experience with high-ash fuels

- Existing designs for lignite biomass and coal wastes show good plant performance

I Application of CFBC boiler design to oil shale fuel has defined risk that relates to scale-up of existing design

Similar CFBC technology is used in petroleum refining industry

- FCC cracking plant regenerators burn carbon residue off spent catalyst

- 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

FUEL ANALYSES

High Ash Fuel Projects Total Solids Input Basis

Gilberton Cambria North Branch

Carbon 4653 2749 1822 Hydrogen 153 164 160 Sulfur 073 222 234 Nitrogen 085 051 043 Oxygen 282 218 468 Moisture 1451 514 557 Ash 3303 6 0 6Z16

10000 10000 10000

HHVBtulb 7485 4809 3453

includes limestone feed a3 ash

includes CO2 in Ca~o3

CA89029 CAkw

Oil Shale

1132

113

255

048

065

320

-8062

10000

2250

Key Boiler Scale-Up DesignIssues

m Solids handling

- Feeding shale to combustor

- 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

Voo4tGEAMI 30

i

Mine and Shale Processing

U Fugitive dust emissions are controllable

- Wetting mine roads

- Enclose crushing plant equipment

Noise levels are controllable

- Enclose crushing plant equipment - Muffle truck exhausts

- Engineered waste disposal

Water effluents can be controlled

- Need good mine drainage design - Continue leachability studies on

waste dump piles

Prefeasibilily StudyOil Shale Fueled Po r Generaton

V0079OOG-4O 31

1

Power Plant

II Fugitive dust emissions are controllable

- Baghouse designoperation will minimize particulates in flue gas

- Wetting spent ash before disposal

N Gaseous emissions are controllable

- Pilot test results show acceptable SO2NOxCO in flue gas

- Develop baseline data for Sultani area

Develop air dispersion model for Sultani

Prefeasibility StudyOil Shale Fueled Power Generatio

V00 V-4GEA l32

i

Power Plant (Contd)

Noise levels are controllable

- Enclose boiler plant fans as required - Enclose turbines and pumps as

required

Water effluents are controllable

- Continue leachability studies on spent ash disposal

- Develop aquifer dispersion model

- Develop sewage and garbage disposal plan

Prefeasibility SludyOil Shale Fueled Power Generation

V00-4FAAI 33

Conclusions

No environmental constraints are anticipated on oil shale powerdevelopment

Gas effluents will meet World Bank standards

- Ash disposal is manageable

- The potential for groundwatercontamination appears low

- Water effluents will be minimal

Continued studies to develop air and groundwater baseline data are recommended

S Prefeasibility Study Oil Shale Fueled Power Generation

v0 9ampGLAMR 34

Power Demand vs SupplyAssessment

m Demand growth forecasts

Electrical generating capacity

= Power supply forecasts

= Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Preleasibility Study Oil Shaie Fuelod Power Generation

VO9- uLIROI

1

Power Demand Forecasts

Percent Annual Growth

JEA

Meta systems HaglerBailey and Bechtel National Inc

JEA Peak Demand Growth

1980 (actual) 1985 (actual) 1987 (actual) 1995 (forecast) 2005 (forecast)

1986 1990 to to

1990 2000

97 60

49 39

200 MW 475 MW 593 MW 900 MW

1400 MW

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOO-DLURO2

i

JEA ElectricityGeneratingCapacity

1987 Installed

Capacity (MW) Aqaba 260

22

Zarqa 395

Marka 102

Karak 23

Miscellaneous 67

Subtotal JEA capacity 869

Other capacity - industrial 110

Total 979

Prefeasibility Study Oi1 Shale Fueled Power Generation

V000-6O0LFJRO3 (

Forecast New Power Generating Capacity Required

Fcst 1987 Required

New Peak Available Installed

Demand Capacity Shortfall (a) Capacity (b) (MM (MW) (MW) (MW)

Assumed capacityfactor (65) (75)

1995 requirement 900 636 264 352

2005 requirement 1400 636 764 1019

(a) Excludes proposed additions and retirements (b) Excludes possible power exports or imports

Load shedding or levelizing not considered

Preteasibility Study Oil Shale Fueled Power Generation

Vflcmf-R)LLAO4

i

Supply vs Demand Evaluation

1800

1600

1400 Forecast Peak Demands

1200 -

E Installed Capacity

0 800shy75--

U) Assumed Available Calcit

a 6 Ao600 shy0 o 65

400 shy

200

I I I I I I I I I I I I I I I I I I I I I I I 1 1 1980 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958f738aIJordarV 118 3-14-89 rspCO

Conclusions

Additional power generating capacity is needed to meet forecasted 19952005demand growth

A 400 MW oil shale-to-power project at Sultani can meet a portion of this need

U A second 400 MW oil shale project maybe required if water is available

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOW0O-8LURO5

i

Economic Feasibility

N Order-of-magnitude costs

N Economic analysis

- Jordan study options

- Project size effect

m Comparison with alternative fuels

- Fuel requirement

- Project financing effect

- Alternate fuel price effect

- Estimated cost of electricity

N Summary financial analysis

bull Material was developed by Bechtel Power Company

Prefeasibility Study

go Oil Shale Fueled Power Generation VOOSO-ampDtJROh

ORDER-OF-MAGNITUDE COSTS

U Oil shale fuel

Power plant

I Integrated project- busbar

Preteasibility Study

Oil Shale Fueled Power Generation

VOO9O-ampDLUROS

Oil Shale Fuel Costs

Installed Capital Cost

Mine Development

Mine Equipment

Processing Plant

Spare Parts

Working Capital

Capitalized Interest

Total

Annual Operating Cost

Fuel Cost $UStonne

bull Based on 8020 debtequity ratio

20 MW

4900

11090

6945

1200

1200

4054

29389

5582

1431

US $1000 Factored

50 MW 4x100 MW

7833 30915

12202 66012

8388 50889

1300 5000

2200 10000

5108 39075

37031 201891

11556 53236

1188 684

Prefeasibility Study

Oil Shale Fueled Power Generation

VCO-ampDLUJ1O

Power Plant Costs

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Cost

Power faciities 57500 91800 567800

Owners cost 10200 20400 192700

Total 67700 112200 760500

Annual Operating Cost 2205 3248 17157(excluding fuel cost)

bullBased on 8020 debtequity ratio oil shale fueled

Prefeasibility Study

Oil Shale Fueled Power Generation

V00O8c4LLMO9

i

INTEGRATED PROJECT -BUSBAR COST

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Costs Mine amp shale processingPower block Waste disposal Infrastructure

29359 67700

1664 10000

37031 112200

2381 15000

201891 760500

8714 45000

TOTAL 108753 166612 1016105

Annual Operating Cost Mine amp shale processingPower block Waste disposal Infrastructure (a)

5582 2205

316

11556 3248

710

56430(b) 18186(b) 6004

Subtotal 8103 15514 80620

Capital Charges 139 9410 15596 106000

Total 17513 31110 186620

25-year levelized cost - - 218000

Busbar Cost millskWh First year 128 92 71 25-year levelized 83

(a) Housing and community facilities assumed self-liquidating(b) Includes first-year inflation adjustment

Based on 8020 debtequity ratio

Prefeasibility StudyOil Shale Fueled Power Generaion

VOOOO-8MLtROi0

ECONOMIC ANALYSIS

n Jordan study options

Project size effect

Fuel requirement

Project financing effect

Alternative fuel price effect

Estimated electricity cost

Summary financial analysis results

Prefeasibility Study

Oil Shale Fueled Powr Generation

VOOeO-BOCLLO1 I

i

Jordan Study Options

U Project size

- Demonstration = 20 MW

- Prototype = 50 MW

- Commercial = 400 MW (4x100)

Project financing

- Debtequity 8020

- Debtequity 5050

Imported alternative fuels cost assumptions

A B Crude oil $17bbl $24bbl

$120onne $170tonne

Low sulfur coal $ 50tonne $ 70tonne See Chevron forecast supporting assumptions

Prefeasibility StudyOil Shale Fueled Power Generation

VOOOO-8DLIJRO12

i

Crude Oil Price Trends

60

Source World Energy Outlook Chevron Corporation Oclober 1987

40

High trend

No Ir 20 ~~~~Arabian Light Spot I A u

IILowYUII trend

0 1970 1975 1980 1985 1990 1995

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958246aJodar 118 3-14-89 rsO

2000

Project Size Effect Shale Fuel Option

Project Size

Integrated facilities installed capital cost$ US million

Shale cost $UStonne(8020 debtequity)

Cost of power millskWh(8020 debtequity ratio)

20 MW

109

143

128

50 MW

167

118

92

400 MW (4x1 00)

1016

68

71

Prefeasibility Study Oil Sampae Fueled Power Generation

VOO O-8I0LJRO13

gt1

1

Power Block Investment Cost

3000

$2875 Excluding mining and offsite 2800

2600

2400

2200

2000

$1836 1800

$1613 1600

$1420 1400 1I 1 I

0 100 200 300 400 MWe

August 1988

Preleasibility Study OilShale Fueled Power Generation

179581147aJodar1 18 3-14-89 rspcl

Fuel Requirement - 4x100 MW Project

Coal = 12 million tpy

n Oil = 503000 tpy

Oil shale = 78 million tpy

Preleasibility Study

Oil Shale Fueled Power Generation

IO060-OLLIRO14

Financing Effect -Project

Oil Shale Fuel Option

Mine and shale processing

Power block

Waste disposal

Community facilities

Total

Coal-Fired Power Plant

Oil-Fired Power Plant

400 MW

Capital Cost ($US MM)

DebtEquity

8020 5050

202 187

760 760

9 8

45 45

1016 1000

647 647

463 463

Prefeasibility StudyOil Shale Fueled Power Generation

VOe-BD1JRO15

Financing Effect shy400 MW Project

Operating Costs ($US millionyr)

DebtEquity

8020 5050

Coal $70tonne 282 282

Oil $24bbl 254 254

Oil shale-fueled 218 236

Including fuel

Prefeasibility Study

SOil Shale Fueled Power Generaion

VOOIt JLMO I

Alternate Fuel Price Effect shy4x100 MW Project

Financing Basis DebtEquity Ratio

Alternate Fuel Price

Imported coal $50tonne $70tonne

Imported oil $17bbl ($120tonne) $24bbl ($170tonne)

Cumulative 25-yr Net Benefit

Favoring Oil Shale (US $MM) shy

8020 5050

778 315 2531 2068

(18) (506)1810 1322

Prefeasibility Study

Oil Shale Fueled Power Generation

Voo -I DLU-A 2

i

Comparison of Cumulative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

32 Pay Out Year shy

400 MW PlantOil Shale vs Imported Coal (8020 debtequty)

30

28 -Cumulative fuel cost savings forcoal $70ton

Cumulative fuel cost savings for coaJ $50ton

26---------- Cumulative Incremental capital plus OampM costs

24

22 -

18 -0

W- Cumulative net benefit for shae vs coal $50ton 2B Cumulative net benefit for shale vs coal $70ton

co16C -

14 -

12 -

10 -

09

06 -Payout inyear 1

Payout Inyear 9 for coal $50ton - -- - - -shy

02 0 I

0 1 2 3 4 5 Nowl Yewr in which sauings in fWe colsacm-ewi tat hsawinitl

ca=al wosaand OampM costs

6

_iiM

7 8

9 10

------ - -amp -

11 12 13 14Year of Operation

--

15

- - --shy

16 17

I

18

1

19

I

20

I

21

I

22

I

23

I

24 25

Prefeasibility StudyOil Shale Fueled Power Generation

17958d351aJordanr 3-14-89 rsO

118

Comparison of Cumuiative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

28 Pay Out Year shy

400 MW Plant Oil Shale vs Imported Coal (5050 debtequity)

26shy2

24-

Cumulaive fuel nst savings for coal 0 $70ton Cumulative fuel cost savings for coal $50ton Cumulative Incremental capital plus OampM corts

22 -

20 -

18 -- Cumuladve net benefit for shle vs coal $50ton B Cumuarve net benefit for sale vs coal $70ton

16 -

C 14

12

10

08 -06 - Payout In year 1for coal $50ton

04

Payout Inyear 1

for coal $70ton02~

0 0

-No

02-

1 2

Yew inrY MCM cajlaI rl

3 4 5 6

sngm inW coas 0 ort hghWcentWin

0tOM cori

7

--

8

- -

9 10 11 12 13 14

Year of Operation

15 16 17

I

18

IIII

19 20 21 22 23 24 25

Preieasibility Study Oil Shale Fueled Power Generation

17958451 bJordarV118 3-14-89 rsipcI

Estimated Cost of Power- 400 MW (4 x 100)

FUEL

ImportedCoal

$50T

$70fT

1st Year

68 88

Levelized

78 107

Sultani Oil Shale

71 83

ImportedOil

$1713

$2413

56

67

76

96

0 10 20 30 40 50

I 60

I 70

I 80

I 90 100 110 120

Mills per kWh

Prefeasibility Study Oil Shale Fueled Power Generation

179581251 cJordarVl 18 3-14-89 rspc1

Summary Financial Analysis Results

Project size

Debt equity ratio

- Investment cost

- Power cost

- 25-year net benefit

- Project implementation

Alternative fuel price

Economic Comparison

Very significant

Not significant

Not significant

Very significant

Critical

Very significant

Prefeasibility Study

Oil Shale Fueled Power Generation

VY0 tDLUAi3

i

Study Conclusions

Feasibility

Timeliness

Expansion conditions

Environmental impacts

Development advantages

Prefeasibility Study

Oil Shale Fueled Power Generation VW41-1AiUA

4

Feasibility

Oil shale fueled power generation is technically and economically justifiedunder certain conditions

N Need for additional generating capacity

exists

- 6 annual peak demand growth - Orderly retirement of olderhigh cost

generating capacity needed

U Higher costs are expected for imported fuels

- 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

-OP b i j~~4shy

-4protntiYPe 4 demo plnt orP42 t~Plant orPootypeProje(-7hould

that Rj

demo 4Therefore-44 JEA anxinus

the

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

27Pag 4- 1 2S c i n 4 4

4i2Sectjo4-18-4 Secio 4-4 014

lt th~ae hi4h -tasisso syste thrug27 ~ 04lag arstl~art-p tasforme ed 2p27132Kvdieanwhy notthroug

EAto- is protmm~~ thegnJgt~~ pracie an ect ~ platqrby

28Pg 4 s heonnenotedto~the 32K rc powr

It not8 Scection rie049teoervnrain prctc de1

rh u n trae f2V3K anerd not throughgeterAntor

27 P3e-1r p ant weung-a

-If I

2tEll10 DRWE-jOi ASOt Mint~~al d~c~e o hepwrgnrto

ELCTRInYJORD UTHORITY-

Ate~

21Pge41 ection 4 04- 5

sindicated~ t hthigh the unit outputredu f hecondenser Injengtd~ibbvePressureed incg desrin hi h riseb vmbi nt emperatureWe bel~ieve

PleaIse provide us with th rscrapcity for th-e three options n nt generating~

21-Iisidca ted that~ thediaatgeofCBi theSheavy fn oe consumnptionPlease~ providethe us withpecntgA

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

400 MW COAL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO 5050

NET GENERATION - MWe 40000 CAPACITY FACTOR - 75 ANNUAL GENERATION MKWhYR 2628 SUB TOTAL PLANT COSTS (TPC) $1000 $620000

FIXED 0 amp M COSTS MH $ MH FIRST YEAR COST$1O00

------- --------- --- ---- --- --- ------------

OPERATING LABOR 351936 $3 $1100 MAINTENANCE LABOR 4000 of 150 OF TPC 3720

MAINTENANCE MATERIAL 6000

ADMIN LABOR of 150

3000 OF TPC

OF 0 amp M LABOR 5580 1446

SUB TOTAL FIXED OampM COSTS $11846

VARIABLE 0 amp M COSTS QUANTITY UNIT COST

VARIABLE MAINTENANCE 2628 MKWh 10 MILLKWH $ 2628 PROCESS WATER 13500000 GALLON 02 SGAL $ 2700 GENERAL PLANT CHEMICALS ALLOW 50 FUEL OIL 1000000 GALLON 035 $GAL $ 350 WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290SPECIAL BOILER MAINT ALLOW 0

SUB TOTAL VARIABLE OampM COSTS $ 8018

TOTAL FIXED amp VARIABLE OampM COSTS $19864 TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $8227 $TN $99139

(INCL INFLATION ADJUSTMENT)

B DEBT EQUITY RATIO =========== 8020

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $17574

WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290

TOTAL FIXED amp VARIABLE OampM COSTS $19864TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $5877 $TN $70814

(INCL INFLATION ADJUSTMENT)

6-21

Table 612 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY

400 MW OIL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO

NET GENERATION -

CAPACITY FACTOR -

ANNUAL GENERATION SUB TOTAL PLANT COSTS (TPC)

FIXED 0 amp M COSTS

OPERATING LABOR MAINTENANCE LABOR 4000 of

MAINTENANCE MATERIAL 6000 of

ADMIN LABOR

SUB TOTAL FIXED OampM COSTS

VARIABLE 0 amp M COSTS

VARIABLE MAINTENANCE PROCESS WATER GENERAL PLANT CHEMICALS FUEL OIL WASTE DISPOSAL (Section 6027) SPECIAL BOILER MAINT

SUB TOTAL VARIABLE OampM COSTS

5050

MWe

MKWhYR $1000

MH

262080

150

150 3000

QUANTITY

2628 MKWh 13500000 GALLON

1000000 GALLON 0 TNYR

TOTAL FIXED amp VARIABLE OampM COSTS FUEL OIL 503000 TNYR

B DEBT EQUITY RATIO =8020

40000 75

268 $443000

FIRST YEAR $ MH COST$1O00

$3 $ 800

OF TPC 2658

OF TPC 3987 OF 0 amp M LABOR 1037

$ 8482

UNIT COST

05 MILLKWH $ 1314 02 $GAL $ 2700

ALLOW 50 035 $GAL $ 350

$1000 $TN $ 0 ALLOW 0

$ 4414

$12896 $19981 $TN $100502

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $12896

WASTE DISPOSAL (Section 6027) 0 TNYR $1000 $TN $ 0

TOTAL FIXED amp VARIABLE OampM COSTS $12896 FUEL OIL 503000 TNYR $14104 $TN $70943

6-23

Page 2: fo; - pdf.usaid.gov

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

Pilot Plant Test Program (Contd)

U Analyzed one blended sample of shale

- Calorific value = 532 - 597 MJkg (approx 2250 BtuIlb)

- Carbon content (dry solids) = 162 - 187 wto

- Sulfur content (dry solids) = 30 - 33 wt

- Ash content (dry solids) = 667 - 684 wt

- Shale size = minus 8 mm

Key items determined

- Combustion efficiency

- Product ash distribution

- Product gas S02NOxCO content

- Data for boiler design

- Sulfur emissions reduction by Ca in fuel

S Prefeasibility Study Oil Shale Fueled Power Generation

VOO74GEAJI 10

Pilot Plant Test Results

U Combustion efficiency exceeded 985 in all tests

Ash distribution (btm ashfly ash) was 3565 to 4753 at 100 load typically4060

Low emissions were demonstrated

Typically S02 10 to 200 ppm gt 95 removal

limestone addition not required

NOx 60 to 120 ppm lt 020 lb106 Btu

Co 10 to 90 ppm lt 50 ppm

Prefeasibility Study Oi Shale Fueled Power Generation

TITLE

Ternpe -al-CuA vs 6 Ik

00

I00

7SA-A-

Fly Ai h

0

85 e

80-

0

00

i I 800 860 oo

T-er pe -

DATE OWN APPD DCNO- ------ -

_______f - _ IPG_

Pilot Plant Test Conclusions

It is technically feasible to burn the Sultani oil shale furnished by NRA in a Pyropower boiler

A high combustion efficiency in excess of 985 was demonstrated

SO2NOxCO emissions are all acceptably low with no limestone addition required

Prefeasibility StudyO Shale Fueled Power Generation

Conceptual Design Studies Scope

m Three project sizes

- 20 MW

- 50 MW

- 400 MW (4x100) factored for power plant portion

m Open-pit mine

- Shale processing at the surface - Waste disposal system

Power block

- Boiler

- Steam turbine

- Auxiliaries

Prefeasibility Study Oil Shale Fueled Power Generation

VOn 4FAIR 1

i

Project Layout 9 fc =f4j

deg2

o r -w (031

5_7EC 45U

iPefeaibiity tud

OlSeFuedP erGr in

179581113i~o(atyvv11

n1- 14 4pc

C)

Sultani Oil Shale Reserves

North South Area Area Total

Mineable shale tonne x 106 320 658 978

Fischer assay oil content wt 744 761 765

Overburden m3 x 106 384 627 1011

Stripping ratio m3m3 2161 1711 1861

bull Based on NRA core drilling and core analysis

Prefeasibility Study Oil Shale Fueled Power Generation

VWO41OFEAMI14

i

Sultani Oil Shale Analyses

Moisture

Ash (less CO 2 in CaCO 3 )

CO 2 (in CaCO 3 )

Carbon (organic)

Hydrogen

Nitrogen

Sulfur

Oxygen (by diff)

Total

High heating value BtuIb

Fischer assay oil content

bull Percent by weight

Design Basis Fuel

320

6680

1387

1132

113

048

255

065

10000

2250

840

Low High Calorific Calorific

Value Fuel Value Fuel

320 320

6730 6625

1414 1337

1020 1250

102 125

058 038

238 271

118 034

10000 10000

2000 2500

750 925

Preteasibility Study Oil Shale Fueled Power Generation

vo0N d-GEAR 1S

50 MW Oil Shale ProcessingPrototype Plant

Mlne Plant

_ 14 0 Haul0___) to Plant 1 Sorage

Portable Crusher

(-)100 mm Storage

(-) 100 mm Hopper UIU 400 th

Feed Bin

J 50

250 tvb

8 -m Circulating Load Impact3or0 0 30 0 0shy+8mm25

30 0L Sampler 0 1 30 0

p3 Day Storage

To Power Plant

Preleasibility StudyOil Shale Fueled Power Generation

17958101 SaJordanli 18 3-14-89 rsipc1

20 MW Oil Shale Demonstration Plant

Mine Plant

Haul00- 01 o

= Pb n Storage Portable _

110 mm Stora e 0

()100 mm r Hopper

U 400V

Feed Bin

CirculatingLoad3 Day Stoge

Prefea~ltSudy Shale Fueled Power Generation

179S 111p 1 11Joda3 yl 3-202-89 8vk2

I

Mine and Shale ProcessingDesign - 2050 MW Project

I Overburden removal (north pit area) 10-meter benches

- Drill and blast

- 10 m3 front-end loader

- 77-ton truck haulage

I Oil shale mining 10-meter benches

- Rippe and auger scraper

- Front-end loader

- Portable in-pit crusher

- 77-ton truck haulage

Oil shale processing

- Feed = minus 100 mm

- Product = minus 8 mm

- Capacity = 250 tph

- Reversible impactor

- Two vibrating screens

1 Prefeasibility Study Oil Shale Fueled Power Generation

V -M 1AMI1ARt46

400 MW Full-Scale Oil Shale ProcessingPlant

Feed MTnus 200 mm Samplerr

1000 bull 10000 Tonnes Live Storage Grade

200 m long(-) 200 mm -- =-- Plow Feeders

00 h 100000 Tonnes Live Storage

Stream 3 - Sampler Bin Stream 2

Stream th 31Da2000

Circulating Load 2i

NFw Feed r -17000t1 170001l 170 t 17000 t 17000 t

1000 th Silo with 7 Impactor (-1)8 mm Reapro- 3 Day Storage at Aver age Loadn

0 20 Feeders 20 m Diameter by 40 m High

JJJTHT To Power Plant

Prefeasibility Study Oil Shale Fueled Power Generation

179589 6aJordarV 1I8 3-14-89 rsipc1

Mine and Shale ProcessingDesign - 4x100 MW Project

m Overburden removal (north area) 10-meter benches

- Drill and blast

- Three 20 m3 shovels

- 136-ton truck haulage

m Oil shale mining 10-meter benches

- Two mechanical surface miners

- 136-ton trucks to pit hopper

- Belt conveyor = 2000 tph

- Traveling stacker

m Oil shale processing

- Feed = minus 200 mm

- Product = minus 8 mm

- Capacity = three 1000 tph units

Prefeasibility Study Oil Shale Fueled Power Generation

VOO79-ampGEAIAt 17

i

Steady-State Production Schedule

Overburden removal bench m3

20 MW demo project 5n MW prototype 4x100 MW full-scale plant

Oil shale mining and shale processing tonnes

20 MW project 50 MW project 4x100 MW project

HourlyDesign Capacity

282 234

1850

HourlyDesign Capacity

250 250

2000

Avg Daily Annual PEQuctiQa Production

1690 507000 4217 13 million

33333 10 million

Max Daily(a) Annual(b) Production Production

1733 390000 4324 973000

34578 78 million

(a) Based on 100 operating factor for power block

(b) Based on 75 operating factor for power block ( 20 MW project = 300 shiftsyr 50 MW project = 900 shiftsyr 400 MW project = 900 shiftsyr)

Prefeasibility Study Oil Shale Fueled Power Generation

Conceptual Power Plant Plans

m Pyroflow boiler

Power generating facilities

m Auxiliaries

S Preleasibility Study Oil ShaJe Fueled Power Generation

vo0o7dEAO 19

Pyroflow Boiler SteamConciflons

Flow rate 226700 kghr (500000 Ibhr)

Pressure 1099 kgcm2 abs (15635 psia)

Temperature 51280C (9550F)

Same for 20 50 and 100 MW designs

Prefeasibility Study Oil ShaJe Fueled Power Generation

vooGALMI 20

HtomCOPUIOTP

- 50005 5op

-- LEVAThUM ORPORAION

0

-VI

DZ 4

Power Block

Fuel handling system

- Day binsscrew feeders

Boiler

- Pyroflow circulating fluid bed combustor

Power generation

- Non reheat condensing steam turbine

- Conventional Rankin steam cycle

Ash handling system (btm ash irom combustor and flyash from bag house)

- Wetted in pug mill to add 20plusmn wt wpter

Plant service water

- Air-cooled condensors and small cooling tower from circulating trim water coolers

Plant raw water

- To cooling tower makeup

- To drinking water system

- To pump seals etc

Plant treated makeup water

- Demineralizer train

Preteasibility Study Oil Shale Fueled Power Generation

i

Onsite Infrastructure

Project office

Control house

U Maintenance shops warehouse

Laboratory

Employee service facility

Site developmentoperations service facilities

- Fire controlsecurity

- Communications

- Lighting

- Roads drainage and sewage

Prefeasibility StudyQ1I Shale Fueled Power Generation

voo4JG m 0 JV

i

BechtellPyropower50 MW Cogeneration Plant - Mt Poso California

W4t Prefeasibility Study --- 7 Oil Shale Fueled Power Generation

179586122aJordarv 118 3-14-89 rsO

Characteristics of Three Size Operations

Oil shale fuel tpy

Mine development excavation bank m3

Spent ash disposal tpy (wetted)

Water consumption 1000 m3yr

Staffing required

Community population

400 MW

20 MW 50 MW (4x1 00)

390000 973000 78 million

500000 1 million 85 million

327000 815000 61 million

538 907 1263

185 324 1046

700 1200 4000

Prefeasibility Study Oil Shale Fueled Power Generation

V000ofllAM1 23

Conceptual Designs Summary

N All BOP facilities involve conventional equipment and technology

100 MW unit operation involves boiler scale-up considerations

N Water consumption estimates

- Requirement for 4x100 MW project is 13 million m3 yr

- Water allocation of 2 million m3yr of water supports 6x100 MW

N Water availability probably limits total power generation from oil shale in Jordan

Prefeasibility Study Oil Shale Fueled Power Generation

V007041GEAOLMI

i

TECHNOLOGY RISK ASSESSMENT

Basic concepts

Key boiler scale-up design issues

Impact of scale-up

U Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Prefeasibility Study O1 Shale Fueled Power Generation

VOOh-7AEAAO 2

Basic Concepts

U CFBC is relatively new in the powerindustry

- Existing plants are small typically 20 to 50 MW

- There is limited operating experience with high-ash fuels

- Existing designs for lignite biomass and coal wastes show good plant performance

I Application of CFBC boiler design to oil shale fuel has defined risk that relates to scale-up of existing design

Similar CFBC technology is used in petroleum refining industry

- FCC cracking plant regenerators burn carbon residue off spent catalyst

- 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

FUEL ANALYSES

High Ash Fuel Projects Total Solids Input Basis

Gilberton Cambria North Branch

Carbon 4653 2749 1822 Hydrogen 153 164 160 Sulfur 073 222 234 Nitrogen 085 051 043 Oxygen 282 218 468 Moisture 1451 514 557 Ash 3303 6 0 6Z16

10000 10000 10000

HHVBtulb 7485 4809 3453

includes limestone feed a3 ash

includes CO2 in Ca~o3

CA89029 CAkw

Oil Shale

1132

113

255

048

065

320

-8062

10000

2250

Key Boiler Scale-Up DesignIssues

m Solids handling

- Feeding shale to combustor

- 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

Voo4tGEAMI 30

i

Mine and Shale Processing

U Fugitive dust emissions are controllable

- Wetting mine roads

- Enclose crushing plant equipment

Noise levels are controllable

- Enclose crushing plant equipment - Muffle truck exhausts

- Engineered waste disposal

Water effluents can be controlled

- Need good mine drainage design - Continue leachability studies on

waste dump piles

Prefeasibilily StudyOil Shale Fueled Po r Generaton

V0079OOG-4O 31

1

Power Plant

II Fugitive dust emissions are controllable

- Baghouse designoperation will minimize particulates in flue gas

- Wetting spent ash before disposal

N Gaseous emissions are controllable

- Pilot test results show acceptable SO2NOxCO in flue gas

- Develop baseline data for Sultani area

Develop air dispersion model for Sultani

Prefeasibility StudyOil Shale Fueled Power Generatio

V00 V-4GEA l32

i

Power Plant (Contd)

Noise levels are controllable

- Enclose boiler plant fans as required - Enclose turbines and pumps as

required

Water effluents are controllable

- Continue leachability studies on spent ash disposal

- Develop aquifer dispersion model

- Develop sewage and garbage disposal plan

Prefeasibility SludyOil Shale Fueled Power Generation

V00-4FAAI 33

Conclusions

No environmental constraints are anticipated on oil shale powerdevelopment

Gas effluents will meet World Bank standards

- Ash disposal is manageable

- The potential for groundwatercontamination appears low

- Water effluents will be minimal

Continued studies to develop air and groundwater baseline data are recommended

S Prefeasibility Study Oil Shale Fueled Power Generation

v0 9ampGLAMR 34

Power Demand vs SupplyAssessment

m Demand growth forecasts

Electrical generating capacity

= Power supply forecasts

= Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Preleasibility Study Oil Shaie Fuelod Power Generation

VO9- uLIROI

1

Power Demand Forecasts

Percent Annual Growth

JEA

Meta systems HaglerBailey and Bechtel National Inc

JEA Peak Demand Growth

1980 (actual) 1985 (actual) 1987 (actual) 1995 (forecast) 2005 (forecast)

1986 1990 to to

1990 2000

97 60

49 39

200 MW 475 MW 593 MW 900 MW

1400 MW

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOO-DLURO2

i

JEA ElectricityGeneratingCapacity

1987 Installed

Capacity (MW) Aqaba 260

22

Zarqa 395

Marka 102

Karak 23

Miscellaneous 67

Subtotal JEA capacity 869

Other capacity - industrial 110

Total 979

Prefeasibility Study Oi1 Shale Fueled Power Generation

V000-6O0LFJRO3 (

Forecast New Power Generating Capacity Required

Fcst 1987 Required

New Peak Available Installed

Demand Capacity Shortfall (a) Capacity (b) (MM (MW) (MW) (MW)

Assumed capacityfactor (65) (75)

1995 requirement 900 636 264 352

2005 requirement 1400 636 764 1019

(a) Excludes proposed additions and retirements (b) Excludes possible power exports or imports

Load shedding or levelizing not considered

Preteasibility Study Oil Shale Fueled Power Generation

Vflcmf-R)LLAO4

i

Supply vs Demand Evaluation

1800

1600

1400 Forecast Peak Demands

1200 -

E Installed Capacity

0 800shy75--

U) Assumed Available Calcit

a 6 Ao600 shy0 o 65

400 shy

200

I I I I I I I I I I I I I I I I I I I I I I I 1 1 1980 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958f738aIJordarV 118 3-14-89 rspCO

Conclusions

Additional power generating capacity is needed to meet forecasted 19952005demand growth

A 400 MW oil shale-to-power project at Sultani can meet a portion of this need

U A second 400 MW oil shale project maybe required if water is available

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOW0O-8LURO5

i

Economic Feasibility

N Order-of-magnitude costs

N Economic analysis

- Jordan study options

- Project size effect

m Comparison with alternative fuels

- Fuel requirement

- Project financing effect

- Alternate fuel price effect

- Estimated cost of electricity

N Summary financial analysis

bull Material was developed by Bechtel Power Company

Prefeasibility Study

go Oil Shale Fueled Power Generation VOOSO-ampDtJROh

ORDER-OF-MAGNITUDE COSTS

U Oil shale fuel

Power plant

I Integrated project- busbar

Preteasibility Study

Oil Shale Fueled Power Generation

VOO9O-ampDLUROS

Oil Shale Fuel Costs

Installed Capital Cost

Mine Development

Mine Equipment

Processing Plant

Spare Parts

Working Capital

Capitalized Interest

Total

Annual Operating Cost

Fuel Cost $UStonne

bull Based on 8020 debtequity ratio

20 MW

4900

11090

6945

1200

1200

4054

29389

5582

1431

US $1000 Factored

50 MW 4x100 MW

7833 30915

12202 66012

8388 50889

1300 5000

2200 10000

5108 39075

37031 201891

11556 53236

1188 684

Prefeasibility Study

Oil Shale Fueled Power Generation

VCO-ampDLUJ1O

Power Plant Costs

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Cost

Power faciities 57500 91800 567800

Owners cost 10200 20400 192700

Total 67700 112200 760500

Annual Operating Cost 2205 3248 17157(excluding fuel cost)

bullBased on 8020 debtequity ratio oil shale fueled

Prefeasibility Study

Oil Shale Fueled Power Generation

V00O8c4LLMO9

i

INTEGRATED PROJECT -BUSBAR COST

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Costs Mine amp shale processingPower block Waste disposal Infrastructure

29359 67700

1664 10000

37031 112200

2381 15000

201891 760500

8714 45000

TOTAL 108753 166612 1016105

Annual Operating Cost Mine amp shale processingPower block Waste disposal Infrastructure (a)

5582 2205

316

11556 3248

710

56430(b) 18186(b) 6004

Subtotal 8103 15514 80620

Capital Charges 139 9410 15596 106000

Total 17513 31110 186620

25-year levelized cost - - 218000

Busbar Cost millskWh First year 128 92 71 25-year levelized 83

(a) Housing and community facilities assumed self-liquidating(b) Includes first-year inflation adjustment

Based on 8020 debtequity ratio

Prefeasibility StudyOil Shale Fueled Power Generaion

VOOOO-8MLtROi0

ECONOMIC ANALYSIS

n Jordan study options

Project size effect

Fuel requirement

Project financing effect

Alternative fuel price effect

Estimated electricity cost

Summary financial analysis results

Prefeasibility Study

Oil Shale Fueled Powr Generation

VOOeO-BOCLLO1 I

i

Jordan Study Options

U Project size

- Demonstration = 20 MW

- Prototype = 50 MW

- Commercial = 400 MW (4x100)

Project financing

- Debtequity 8020

- Debtequity 5050

Imported alternative fuels cost assumptions

A B Crude oil $17bbl $24bbl

$120onne $170tonne

Low sulfur coal $ 50tonne $ 70tonne See Chevron forecast supporting assumptions

Prefeasibility StudyOil Shale Fueled Power Generation

VOOOO-8DLIJRO12

i

Crude Oil Price Trends

60

Source World Energy Outlook Chevron Corporation Oclober 1987

40

High trend

No Ir 20 ~~~~Arabian Light Spot I A u

IILowYUII trend

0 1970 1975 1980 1985 1990 1995

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958246aJodar 118 3-14-89 rsO

2000

Project Size Effect Shale Fuel Option

Project Size

Integrated facilities installed capital cost$ US million

Shale cost $UStonne(8020 debtequity)

Cost of power millskWh(8020 debtequity ratio)

20 MW

109

143

128

50 MW

167

118

92

400 MW (4x1 00)

1016

68

71

Prefeasibility Study Oil Sampae Fueled Power Generation

VOO O-8I0LJRO13

gt1

1

Power Block Investment Cost

3000

$2875 Excluding mining and offsite 2800

2600

2400

2200

2000

$1836 1800

$1613 1600

$1420 1400 1I 1 I

0 100 200 300 400 MWe

August 1988

Preleasibility Study OilShale Fueled Power Generation

179581147aJodar1 18 3-14-89 rspcl

Fuel Requirement - 4x100 MW Project

Coal = 12 million tpy

n Oil = 503000 tpy

Oil shale = 78 million tpy

Preleasibility Study

Oil Shale Fueled Power Generation

IO060-OLLIRO14

Financing Effect -Project

Oil Shale Fuel Option

Mine and shale processing

Power block

Waste disposal

Community facilities

Total

Coal-Fired Power Plant

Oil-Fired Power Plant

400 MW

Capital Cost ($US MM)

DebtEquity

8020 5050

202 187

760 760

9 8

45 45

1016 1000

647 647

463 463

Prefeasibility StudyOil Shale Fueled Power Generation

VOe-BD1JRO15

Financing Effect shy400 MW Project

Operating Costs ($US millionyr)

DebtEquity

8020 5050

Coal $70tonne 282 282

Oil $24bbl 254 254

Oil shale-fueled 218 236

Including fuel

Prefeasibility Study

SOil Shale Fueled Power Generaion

VOOIt JLMO I

Alternate Fuel Price Effect shy4x100 MW Project

Financing Basis DebtEquity Ratio

Alternate Fuel Price

Imported coal $50tonne $70tonne

Imported oil $17bbl ($120tonne) $24bbl ($170tonne)

Cumulative 25-yr Net Benefit

Favoring Oil Shale (US $MM) shy

8020 5050

778 315 2531 2068

(18) (506)1810 1322

Prefeasibility Study

Oil Shale Fueled Power Generation

Voo -I DLU-A 2

i

Comparison of Cumulative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

32 Pay Out Year shy

400 MW PlantOil Shale vs Imported Coal (8020 debtequty)

30

28 -Cumulative fuel cost savings forcoal $70ton

Cumulative fuel cost savings for coaJ $50ton

26---------- Cumulative Incremental capital plus OampM costs

24

22 -

18 -0

W- Cumulative net benefit for shae vs coal $50ton 2B Cumulative net benefit for shale vs coal $70ton

co16C -

14 -

12 -

10 -

09

06 -Payout inyear 1

Payout Inyear 9 for coal $50ton - -- - - -shy

02 0 I

0 1 2 3 4 5 Nowl Yewr in which sauings in fWe colsacm-ewi tat hsawinitl

ca=al wosaand OampM costs

6

_iiM

7 8

9 10

------ - -amp -

11 12 13 14Year of Operation

--

15

- - --shy

16 17

I

18

1

19

I

20

I

21

I

22

I

23

I

24 25

Prefeasibility StudyOil Shale Fueled Power Generation

17958d351aJordanr 3-14-89 rsO

118

Comparison of Cumuiative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

28 Pay Out Year shy

400 MW Plant Oil Shale vs Imported Coal (5050 debtequity)

26shy2

24-

Cumulaive fuel nst savings for coal 0 $70ton Cumulative fuel cost savings for coal $50ton Cumulative Incremental capital plus OampM corts

22 -

20 -

18 -- Cumuladve net benefit for shle vs coal $50ton B Cumuarve net benefit for sale vs coal $70ton

16 -

C 14

12

10

08 -06 - Payout In year 1for coal $50ton

04

Payout Inyear 1

for coal $70ton02~

0 0

-No

02-

1 2

Yew inrY MCM cajlaI rl

3 4 5 6

sngm inW coas 0 ort hghWcentWin

0tOM cori

7

--

8

- -

9 10 11 12 13 14

Year of Operation

15 16 17

I

18

IIII

19 20 21 22 23 24 25

Preieasibility Study Oil Shale Fueled Power Generation

17958451 bJordarV118 3-14-89 rsipcI

Estimated Cost of Power- 400 MW (4 x 100)

FUEL

ImportedCoal

$50T

$70fT

1st Year

68 88

Levelized

78 107

Sultani Oil Shale

71 83

ImportedOil

$1713

$2413

56

67

76

96

0 10 20 30 40 50

I 60

I 70

I 80

I 90 100 110 120

Mills per kWh

Prefeasibility Study Oil Shale Fueled Power Generation

179581251 cJordarVl 18 3-14-89 rspc1

Summary Financial Analysis Results

Project size

Debt equity ratio

- Investment cost

- Power cost

- 25-year net benefit

- Project implementation

Alternative fuel price

Economic Comparison

Very significant

Not significant

Not significant

Very significant

Critical

Very significant

Prefeasibility Study

Oil Shale Fueled Power Generation

VY0 tDLUAi3

i

Study Conclusions

Feasibility

Timeliness

Expansion conditions

Environmental impacts

Development advantages

Prefeasibility Study

Oil Shale Fueled Power Generation VW41-1AiUA

4

Feasibility

Oil shale fueled power generation is technically and economically justifiedunder certain conditions

N Need for additional generating capacity

exists

- 6 annual peak demand growth - Orderly retirement of olderhigh cost

generating capacity needed

U Higher costs are expected for imported fuels

- 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

-OP b i j~~4shy

-4protntiYPe 4 demo plnt orP42 t~Plant orPootypeProje(-7hould

that Rj

demo 4Therefore-44 JEA anxinus

the

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

27Pag 4- 1 2S c i n 4 4

4i2Sectjo4-18-4 Secio 4-4 014

lt th~ae hi4h -tasisso syste thrug27 ~ 04lag arstl~art-p tasforme ed 2p27132Kvdieanwhy notthroug

EAto- is protmm~~ thegnJgt~~ pracie an ect ~ platqrby

28Pg 4 s heonnenotedto~the 32K rc powr

It not8 Scection rie049teoervnrain prctc de1

rh u n trae f2V3K anerd not throughgeterAntor

27 P3e-1r p ant weung-a

-If I

2tEll10 DRWE-jOi ASOt Mint~~al d~c~e o hepwrgnrto

ELCTRInYJORD UTHORITY-

Ate~

21Pge41 ection 4 04- 5

sindicated~ t hthigh the unit outputredu f hecondenser Injengtd~ibbvePressureed incg desrin hi h riseb vmbi nt emperatureWe bel~ieve

PleaIse provide us with th rscrapcity for th-e three options n nt generating~

21-Iisidca ted that~ thediaatgeofCBi theSheavy fn oe consumnptionPlease~ providethe us withpecntgA

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

400 MW COAL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO 5050

NET GENERATION - MWe 40000 CAPACITY FACTOR - 75 ANNUAL GENERATION MKWhYR 2628 SUB TOTAL PLANT COSTS (TPC) $1000 $620000

FIXED 0 amp M COSTS MH $ MH FIRST YEAR COST$1O00

------- --------- --- ---- --- --- ------------

OPERATING LABOR 351936 $3 $1100 MAINTENANCE LABOR 4000 of 150 OF TPC 3720

MAINTENANCE MATERIAL 6000

ADMIN LABOR of 150

3000 OF TPC

OF 0 amp M LABOR 5580 1446

SUB TOTAL FIXED OampM COSTS $11846

VARIABLE 0 amp M COSTS QUANTITY UNIT COST

VARIABLE MAINTENANCE 2628 MKWh 10 MILLKWH $ 2628 PROCESS WATER 13500000 GALLON 02 SGAL $ 2700 GENERAL PLANT CHEMICALS ALLOW 50 FUEL OIL 1000000 GALLON 035 $GAL $ 350 WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290SPECIAL BOILER MAINT ALLOW 0

SUB TOTAL VARIABLE OampM COSTS $ 8018

TOTAL FIXED amp VARIABLE OampM COSTS $19864 TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $8227 $TN $99139

(INCL INFLATION ADJUSTMENT)

B DEBT EQUITY RATIO =========== 8020

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $17574

WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290

TOTAL FIXED amp VARIABLE OampM COSTS $19864TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $5877 $TN $70814

(INCL INFLATION ADJUSTMENT)

6-21

Table 612 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY

400 MW OIL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO

NET GENERATION -

CAPACITY FACTOR -

ANNUAL GENERATION SUB TOTAL PLANT COSTS (TPC)

FIXED 0 amp M COSTS

OPERATING LABOR MAINTENANCE LABOR 4000 of

MAINTENANCE MATERIAL 6000 of

ADMIN LABOR

SUB TOTAL FIXED OampM COSTS

VARIABLE 0 amp M COSTS

VARIABLE MAINTENANCE PROCESS WATER GENERAL PLANT CHEMICALS FUEL OIL WASTE DISPOSAL (Section 6027) SPECIAL BOILER MAINT

SUB TOTAL VARIABLE OampM COSTS

5050

MWe

MKWhYR $1000

MH

262080

150

150 3000

QUANTITY

2628 MKWh 13500000 GALLON

1000000 GALLON 0 TNYR

TOTAL FIXED amp VARIABLE OampM COSTS FUEL OIL 503000 TNYR

B DEBT EQUITY RATIO =8020

40000 75

268 $443000

FIRST YEAR $ MH COST$1O00

$3 $ 800

OF TPC 2658

OF TPC 3987 OF 0 amp M LABOR 1037

$ 8482

UNIT COST

05 MILLKWH $ 1314 02 $GAL $ 2700

ALLOW 50 035 $GAL $ 350

$1000 $TN $ 0 ALLOW 0

$ 4414

$12896 $19981 $TN $100502

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $12896

WASTE DISPOSAL (Section 6027) 0 TNYR $1000 $TN $ 0

TOTAL FIXED amp VARIABLE OampM COSTS $12896 FUEL OIL 503000 TNYR $14104 $TN $70943

6-23

Page 3: fo; - pdf.usaid.gov

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

Pilot Plant Test Program (Contd)

U Analyzed one blended sample of shale

- Calorific value = 532 - 597 MJkg (approx 2250 BtuIlb)

- Carbon content (dry solids) = 162 - 187 wto

- Sulfur content (dry solids) = 30 - 33 wt

- Ash content (dry solids) = 667 - 684 wt

- Shale size = minus 8 mm

Key items determined

- Combustion efficiency

- Product ash distribution

- Product gas S02NOxCO content

- Data for boiler design

- Sulfur emissions reduction by Ca in fuel

S Prefeasibility Study Oil Shale Fueled Power Generation

VOO74GEAJI 10

Pilot Plant Test Results

U Combustion efficiency exceeded 985 in all tests

Ash distribution (btm ashfly ash) was 3565 to 4753 at 100 load typically4060

Low emissions were demonstrated

Typically S02 10 to 200 ppm gt 95 removal

limestone addition not required

NOx 60 to 120 ppm lt 020 lb106 Btu

Co 10 to 90 ppm lt 50 ppm

Prefeasibility Study Oi Shale Fueled Power Generation

TITLE

Ternpe -al-CuA vs 6 Ik

00

I00

7SA-A-

Fly Ai h

0

85 e

80-

0

00

i I 800 860 oo

T-er pe -

DATE OWN APPD DCNO- ------ -

_______f - _ IPG_

Pilot Plant Test Conclusions

It is technically feasible to burn the Sultani oil shale furnished by NRA in a Pyropower boiler

A high combustion efficiency in excess of 985 was demonstrated

SO2NOxCO emissions are all acceptably low with no limestone addition required

Prefeasibility StudyO Shale Fueled Power Generation

Conceptual Design Studies Scope

m Three project sizes

- 20 MW

- 50 MW

- 400 MW (4x100) factored for power plant portion

m Open-pit mine

- Shale processing at the surface - Waste disposal system

Power block

- Boiler

- Steam turbine

- Auxiliaries

Prefeasibility Study Oil Shale Fueled Power Generation

VOn 4FAIR 1

i

Project Layout 9 fc =f4j

deg2

o r -w (031

5_7EC 45U

iPefeaibiity tud

OlSeFuedP erGr in

179581113i~o(atyvv11

n1- 14 4pc

C)

Sultani Oil Shale Reserves

North South Area Area Total

Mineable shale tonne x 106 320 658 978

Fischer assay oil content wt 744 761 765

Overburden m3 x 106 384 627 1011

Stripping ratio m3m3 2161 1711 1861

bull Based on NRA core drilling and core analysis

Prefeasibility Study Oil Shale Fueled Power Generation

VWO41OFEAMI14

i

Sultani Oil Shale Analyses

Moisture

Ash (less CO 2 in CaCO 3 )

CO 2 (in CaCO 3 )

Carbon (organic)

Hydrogen

Nitrogen

Sulfur

Oxygen (by diff)

Total

High heating value BtuIb

Fischer assay oil content

bull Percent by weight

Design Basis Fuel

320

6680

1387

1132

113

048

255

065

10000

2250

840

Low High Calorific Calorific

Value Fuel Value Fuel

320 320

6730 6625

1414 1337

1020 1250

102 125

058 038

238 271

118 034

10000 10000

2000 2500

750 925

Preteasibility Study Oil Shale Fueled Power Generation

vo0N d-GEAR 1S

50 MW Oil Shale ProcessingPrototype Plant

Mlne Plant

_ 14 0 Haul0___) to Plant 1 Sorage

Portable Crusher

(-)100 mm Storage

(-) 100 mm Hopper UIU 400 th

Feed Bin

J 50

250 tvb

8 -m Circulating Load Impact3or0 0 30 0 0shy+8mm25

30 0L Sampler 0 1 30 0

p3 Day Storage

To Power Plant

Preleasibility StudyOil Shale Fueled Power Generation

17958101 SaJordanli 18 3-14-89 rsipc1

20 MW Oil Shale Demonstration Plant

Mine Plant

Haul00- 01 o

= Pb n Storage Portable _

110 mm Stora e 0

()100 mm r Hopper

U 400V

Feed Bin

CirculatingLoad3 Day Stoge

Prefea~ltSudy Shale Fueled Power Generation

179S 111p 1 11Joda3 yl 3-202-89 8vk2

I

Mine and Shale ProcessingDesign - 2050 MW Project

I Overburden removal (north pit area) 10-meter benches

- Drill and blast

- 10 m3 front-end loader

- 77-ton truck haulage

I Oil shale mining 10-meter benches

- Rippe and auger scraper

- Front-end loader

- Portable in-pit crusher

- 77-ton truck haulage

Oil shale processing

- Feed = minus 100 mm

- Product = minus 8 mm

- Capacity = 250 tph

- Reversible impactor

- Two vibrating screens

1 Prefeasibility Study Oil Shale Fueled Power Generation

V -M 1AMI1ARt46

400 MW Full-Scale Oil Shale ProcessingPlant

Feed MTnus 200 mm Samplerr

1000 bull 10000 Tonnes Live Storage Grade

200 m long(-) 200 mm -- =-- Plow Feeders

00 h 100000 Tonnes Live Storage

Stream 3 - Sampler Bin Stream 2

Stream th 31Da2000

Circulating Load 2i

NFw Feed r -17000t1 170001l 170 t 17000 t 17000 t

1000 th Silo with 7 Impactor (-1)8 mm Reapro- 3 Day Storage at Aver age Loadn

0 20 Feeders 20 m Diameter by 40 m High

JJJTHT To Power Plant

Prefeasibility Study Oil Shale Fueled Power Generation

179589 6aJordarV 1I8 3-14-89 rsipc1

Mine and Shale ProcessingDesign - 4x100 MW Project

m Overburden removal (north area) 10-meter benches

- Drill and blast

- Three 20 m3 shovels

- 136-ton truck haulage

m Oil shale mining 10-meter benches

- Two mechanical surface miners

- 136-ton trucks to pit hopper

- Belt conveyor = 2000 tph

- Traveling stacker

m Oil shale processing

- Feed = minus 200 mm

- Product = minus 8 mm

- Capacity = three 1000 tph units

Prefeasibility Study Oil Shale Fueled Power Generation

VOO79-ampGEAIAt 17

i

Steady-State Production Schedule

Overburden removal bench m3

20 MW demo project 5n MW prototype 4x100 MW full-scale plant

Oil shale mining and shale processing tonnes

20 MW project 50 MW project 4x100 MW project

HourlyDesign Capacity

282 234

1850

HourlyDesign Capacity

250 250

2000

Avg Daily Annual PEQuctiQa Production

1690 507000 4217 13 million

33333 10 million

Max Daily(a) Annual(b) Production Production

1733 390000 4324 973000

34578 78 million

(a) Based on 100 operating factor for power block

(b) Based on 75 operating factor for power block ( 20 MW project = 300 shiftsyr 50 MW project = 900 shiftsyr 400 MW project = 900 shiftsyr)

Prefeasibility Study Oil Shale Fueled Power Generation

Conceptual Power Plant Plans

m Pyroflow boiler

Power generating facilities

m Auxiliaries

S Preleasibility Study Oil ShaJe Fueled Power Generation

vo0o7dEAO 19

Pyroflow Boiler SteamConciflons

Flow rate 226700 kghr (500000 Ibhr)

Pressure 1099 kgcm2 abs (15635 psia)

Temperature 51280C (9550F)

Same for 20 50 and 100 MW designs

Prefeasibility Study Oil ShaJe Fueled Power Generation

vooGALMI 20

HtomCOPUIOTP

- 50005 5op

-- LEVAThUM ORPORAION

0

-VI

DZ 4

Power Block

Fuel handling system

- Day binsscrew feeders

Boiler

- Pyroflow circulating fluid bed combustor

Power generation

- Non reheat condensing steam turbine

- Conventional Rankin steam cycle

Ash handling system (btm ash irom combustor and flyash from bag house)

- Wetted in pug mill to add 20plusmn wt wpter

Plant service water

- Air-cooled condensors and small cooling tower from circulating trim water coolers

Plant raw water

- To cooling tower makeup

- To drinking water system

- To pump seals etc

Plant treated makeup water

- Demineralizer train

Preteasibility Study Oil Shale Fueled Power Generation

i

Onsite Infrastructure

Project office

Control house

U Maintenance shops warehouse

Laboratory

Employee service facility

Site developmentoperations service facilities

- Fire controlsecurity

- Communications

- Lighting

- Roads drainage and sewage

Prefeasibility StudyQ1I Shale Fueled Power Generation

voo4JG m 0 JV

i

BechtellPyropower50 MW Cogeneration Plant - Mt Poso California

W4t Prefeasibility Study --- 7 Oil Shale Fueled Power Generation

179586122aJordarv 118 3-14-89 rsO

Characteristics of Three Size Operations

Oil shale fuel tpy

Mine development excavation bank m3

Spent ash disposal tpy (wetted)

Water consumption 1000 m3yr

Staffing required

Community population

400 MW

20 MW 50 MW (4x1 00)

390000 973000 78 million

500000 1 million 85 million

327000 815000 61 million

538 907 1263

185 324 1046

700 1200 4000

Prefeasibility Study Oil Shale Fueled Power Generation

V000ofllAM1 23

Conceptual Designs Summary

N All BOP facilities involve conventional equipment and technology

100 MW unit operation involves boiler scale-up considerations

N Water consumption estimates

- Requirement for 4x100 MW project is 13 million m3 yr

- Water allocation of 2 million m3yr of water supports 6x100 MW

N Water availability probably limits total power generation from oil shale in Jordan

Prefeasibility Study Oil Shale Fueled Power Generation

V007041GEAOLMI

i

TECHNOLOGY RISK ASSESSMENT

Basic concepts

Key boiler scale-up design issues

Impact of scale-up

U Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Prefeasibility Study O1 Shale Fueled Power Generation

VOOh-7AEAAO 2

Basic Concepts

U CFBC is relatively new in the powerindustry

- Existing plants are small typically 20 to 50 MW

- There is limited operating experience with high-ash fuels

- Existing designs for lignite biomass and coal wastes show good plant performance

I Application of CFBC boiler design to oil shale fuel has defined risk that relates to scale-up of existing design

Similar CFBC technology is used in petroleum refining industry

- FCC cracking plant regenerators burn carbon residue off spent catalyst

- 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

FUEL ANALYSES

High Ash Fuel Projects Total Solids Input Basis

Gilberton Cambria North Branch

Carbon 4653 2749 1822 Hydrogen 153 164 160 Sulfur 073 222 234 Nitrogen 085 051 043 Oxygen 282 218 468 Moisture 1451 514 557 Ash 3303 6 0 6Z16

10000 10000 10000

HHVBtulb 7485 4809 3453

includes limestone feed a3 ash

includes CO2 in Ca~o3

CA89029 CAkw

Oil Shale

1132

113

255

048

065

320

-8062

10000

2250

Key Boiler Scale-Up DesignIssues

m Solids handling

- Feeding shale to combustor

- 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

Voo4tGEAMI 30

i

Mine and Shale Processing

U Fugitive dust emissions are controllable

- Wetting mine roads

- Enclose crushing plant equipment

Noise levels are controllable

- Enclose crushing plant equipment - Muffle truck exhausts

- Engineered waste disposal

Water effluents can be controlled

- Need good mine drainage design - Continue leachability studies on

waste dump piles

Prefeasibilily StudyOil Shale Fueled Po r Generaton

V0079OOG-4O 31

1

Power Plant

II Fugitive dust emissions are controllable

- Baghouse designoperation will minimize particulates in flue gas

- Wetting spent ash before disposal

N Gaseous emissions are controllable

- Pilot test results show acceptable SO2NOxCO in flue gas

- Develop baseline data for Sultani area

Develop air dispersion model for Sultani

Prefeasibility StudyOil Shale Fueled Power Generatio

V00 V-4GEA l32

i

Power Plant (Contd)

Noise levels are controllable

- Enclose boiler plant fans as required - Enclose turbines and pumps as

required

Water effluents are controllable

- Continue leachability studies on spent ash disposal

- Develop aquifer dispersion model

- Develop sewage and garbage disposal plan

Prefeasibility SludyOil Shale Fueled Power Generation

V00-4FAAI 33

Conclusions

No environmental constraints are anticipated on oil shale powerdevelopment

Gas effluents will meet World Bank standards

- Ash disposal is manageable

- The potential for groundwatercontamination appears low

- Water effluents will be minimal

Continued studies to develop air and groundwater baseline data are recommended

S Prefeasibility Study Oil Shale Fueled Power Generation

v0 9ampGLAMR 34

Power Demand vs SupplyAssessment

m Demand growth forecasts

Electrical generating capacity

= Power supply forecasts

= Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Preleasibility Study Oil Shaie Fuelod Power Generation

VO9- uLIROI

1

Power Demand Forecasts

Percent Annual Growth

JEA

Meta systems HaglerBailey and Bechtel National Inc

JEA Peak Demand Growth

1980 (actual) 1985 (actual) 1987 (actual) 1995 (forecast) 2005 (forecast)

1986 1990 to to

1990 2000

97 60

49 39

200 MW 475 MW 593 MW 900 MW

1400 MW

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOO-DLURO2

i

JEA ElectricityGeneratingCapacity

1987 Installed

Capacity (MW) Aqaba 260

22

Zarqa 395

Marka 102

Karak 23

Miscellaneous 67

Subtotal JEA capacity 869

Other capacity - industrial 110

Total 979

Prefeasibility Study Oi1 Shale Fueled Power Generation

V000-6O0LFJRO3 (

Forecast New Power Generating Capacity Required

Fcst 1987 Required

New Peak Available Installed

Demand Capacity Shortfall (a) Capacity (b) (MM (MW) (MW) (MW)

Assumed capacityfactor (65) (75)

1995 requirement 900 636 264 352

2005 requirement 1400 636 764 1019

(a) Excludes proposed additions and retirements (b) Excludes possible power exports or imports

Load shedding or levelizing not considered

Preteasibility Study Oil Shale Fueled Power Generation

Vflcmf-R)LLAO4

i

Supply vs Demand Evaluation

1800

1600

1400 Forecast Peak Demands

1200 -

E Installed Capacity

0 800shy75--

U) Assumed Available Calcit

a 6 Ao600 shy0 o 65

400 shy

200

I I I I I I I I I I I I I I I I I I I I I I I 1 1 1980 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958f738aIJordarV 118 3-14-89 rspCO

Conclusions

Additional power generating capacity is needed to meet forecasted 19952005demand growth

A 400 MW oil shale-to-power project at Sultani can meet a portion of this need

U A second 400 MW oil shale project maybe required if water is available

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOW0O-8LURO5

i

Economic Feasibility

N Order-of-magnitude costs

N Economic analysis

- Jordan study options

- Project size effect

m Comparison with alternative fuels

- Fuel requirement

- Project financing effect

- Alternate fuel price effect

- Estimated cost of electricity

N Summary financial analysis

bull Material was developed by Bechtel Power Company

Prefeasibility Study

go Oil Shale Fueled Power Generation VOOSO-ampDtJROh

ORDER-OF-MAGNITUDE COSTS

U Oil shale fuel

Power plant

I Integrated project- busbar

Preteasibility Study

Oil Shale Fueled Power Generation

VOO9O-ampDLUROS

Oil Shale Fuel Costs

Installed Capital Cost

Mine Development

Mine Equipment

Processing Plant

Spare Parts

Working Capital

Capitalized Interest

Total

Annual Operating Cost

Fuel Cost $UStonne

bull Based on 8020 debtequity ratio

20 MW

4900

11090

6945

1200

1200

4054

29389

5582

1431

US $1000 Factored

50 MW 4x100 MW

7833 30915

12202 66012

8388 50889

1300 5000

2200 10000

5108 39075

37031 201891

11556 53236

1188 684

Prefeasibility Study

Oil Shale Fueled Power Generation

VCO-ampDLUJ1O

Power Plant Costs

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Cost

Power faciities 57500 91800 567800

Owners cost 10200 20400 192700

Total 67700 112200 760500

Annual Operating Cost 2205 3248 17157(excluding fuel cost)

bullBased on 8020 debtequity ratio oil shale fueled

Prefeasibility Study

Oil Shale Fueled Power Generation

V00O8c4LLMO9

i

INTEGRATED PROJECT -BUSBAR COST

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Costs Mine amp shale processingPower block Waste disposal Infrastructure

29359 67700

1664 10000

37031 112200

2381 15000

201891 760500

8714 45000

TOTAL 108753 166612 1016105

Annual Operating Cost Mine amp shale processingPower block Waste disposal Infrastructure (a)

5582 2205

316

11556 3248

710

56430(b) 18186(b) 6004

Subtotal 8103 15514 80620

Capital Charges 139 9410 15596 106000

Total 17513 31110 186620

25-year levelized cost - - 218000

Busbar Cost millskWh First year 128 92 71 25-year levelized 83

(a) Housing and community facilities assumed self-liquidating(b) Includes first-year inflation adjustment

Based on 8020 debtequity ratio

Prefeasibility StudyOil Shale Fueled Power Generaion

VOOOO-8MLtROi0

ECONOMIC ANALYSIS

n Jordan study options

Project size effect

Fuel requirement

Project financing effect

Alternative fuel price effect

Estimated electricity cost

Summary financial analysis results

Prefeasibility Study

Oil Shale Fueled Powr Generation

VOOeO-BOCLLO1 I

i

Jordan Study Options

U Project size

- Demonstration = 20 MW

- Prototype = 50 MW

- Commercial = 400 MW (4x100)

Project financing

- Debtequity 8020

- Debtequity 5050

Imported alternative fuels cost assumptions

A B Crude oil $17bbl $24bbl

$120onne $170tonne

Low sulfur coal $ 50tonne $ 70tonne See Chevron forecast supporting assumptions

Prefeasibility StudyOil Shale Fueled Power Generation

VOOOO-8DLIJRO12

i

Crude Oil Price Trends

60

Source World Energy Outlook Chevron Corporation Oclober 1987

40

High trend

No Ir 20 ~~~~Arabian Light Spot I A u

IILowYUII trend

0 1970 1975 1980 1985 1990 1995

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958246aJodar 118 3-14-89 rsO

2000

Project Size Effect Shale Fuel Option

Project Size

Integrated facilities installed capital cost$ US million

Shale cost $UStonne(8020 debtequity)

Cost of power millskWh(8020 debtequity ratio)

20 MW

109

143

128

50 MW

167

118

92

400 MW (4x1 00)

1016

68

71

Prefeasibility Study Oil Sampae Fueled Power Generation

VOO O-8I0LJRO13

gt1

1

Power Block Investment Cost

3000

$2875 Excluding mining and offsite 2800

2600

2400

2200

2000

$1836 1800

$1613 1600

$1420 1400 1I 1 I

0 100 200 300 400 MWe

August 1988

Preleasibility Study OilShale Fueled Power Generation

179581147aJodar1 18 3-14-89 rspcl

Fuel Requirement - 4x100 MW Project

Coal = 12 million tpy

n Oil = 503000 tpy

Oil shale = 78 million tpy

Preleasibility Study

Oil Shale Fueled Power Generation

IO060-OLLIRO14

Financing Effect -Project

Oil Shale Fuel Option

Mine and shale processing

Power block

Waste disposal

Community facilities

Total

Coal-Fired Power Plant

Oil-Fired Power Plant

400 MW

Capital Cost ($US MM)

DebtEquity

8020 5050

202 187

760 760

9 8

45 45

1016 1000

647 647

463 463

Prefeasibility StudyOil Shale Fueled Power Generation

VOe-BD1JRO15

Financing Effect shy400 MW Project

Operating Costs ($US millionyr)

DebtEquity

8020 5050

Coal $70tonne 282 282

Oil $24bbl 254 254

Oil shale-fueled 218 236

Including fuel

Prefeasibility Study

SOil Shale Fueled Power Generaion

VOOIt JLMO I

Alternate Fuel Price Effect shy4x100 MW Project

Financing Basis DebtEquity Ratio

Alternate Fuel Price

Imported coal $50tonne $70tonne

Imported oil $17bbl ($120tonne) $24bbl ($170tonne)

Cumulative 25-yr Net Benefit

Favoring Oil Shale (US $MM) shy

8020 5050

778 315 2531 2068

(18) (506)1810 1322

Prefeasibility Study

Oil Shale Fueled Power Generation

Voo -I DLU-A 2

i

Comparison of Cumulative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

32 Pay Out Year shy

400 MW PlantOil Shale vs Imported Coal (8020 debtequty)

30

28 -Cumulative fuel cost savings forcoal $70ton

Cumulative fuel cost savings for coaJ $50ton

26---------- Cumulative Incremental capital plus OampM costs

24

22 -

18 -0

W- Cumulative net benefit for shae vs coal $50ton 2B Cumulative net benefit for shale vs coal $70ton

co16C -

14 -

12 -

10 -

09

06 -Payout inyear 1

Payout Inyear 9 for coal $50ton - -- - - -shy

02 0 I

0 1 2 3 4 5 Nowl Yewr in which sauings in fWe colsacm-ewi tat hsawinitl

ca=al wosaand OampM costs

6

_iiM

7 8

9 10

------ - -amp -

11 12 13 14Year of Operation

--

15

- - --shy

16 17

I

18

1

19

I

20

I

21

I

22

I

23

I

24 25

Prefeasibility StudyOil Shale Fueled Power Generation

17958d351aJordanr 3-14-89 rsO

118

Comparison of Cumuiative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

28 Pay Out Year shy

400 MW Plant Oil Shale vs Imported Coal (5050 debtequity)

26shy2

24-

Cumulaive fuel nst savings for coal 0 $70ton Cumulative fuel cost savings for coal $50ton Cumulative Incremental capital plus OampM corts

22 -

20 -

18 -- Cumuladve net benefit for shle vs coal $50ton B Cumuarve net benefit for sale vs coal $70ton

16 -

C 14

12

10

08 -06 - Payout In year 1for coal $50ton

04

Payout Inyear 1

for coal $70ton02~

0 0

-No

02-

1 2

Yew inrY MCM cajlaI rl

3 4 5 6

sngm inW coas 0 ort hghWcentWin

0tOM cori

7

--

8

- -

9 10 11 12 13 14

Year of Operation

15 16 17

I

18

IIII

19 20 21 22 23 24 25

Preieasibility Study Oil Shale Fueled Power Generation

17958451 bJordarV118 3-14-89 rsipcI

Estimated Cost of Power- 400 MW (4 x 100)

FUEL

ImportedCoal

$50T

$70fT

1st Year

68 88

Levelized

78 107

Sultani Oil Shale

71 83

ImportedOil

$1713

$2413

56

67

76

96

0 10 20 30 40 50

I 60

I 70

I 80

I 90 100 110 120

Mills per kWh

Prefeasibility Study Oil Shale Fueled Power Generation

179581251 cJordarVl 18 3-14-89 rspc1

Summary Financial Analysis Results

Project size

Debt equity ratio

- Investment cost

- Power cost

- 25-year net benefit

- Project implementation

Alternative fuel price

Economic Comparison

Very significant

Not significant

Not significant

Very significant

Critical

Very significant

Prefeasibility Study

Oil Shale Fueled Power Generation

VY0 tDLUAi3

i

Study Conclusions

Feasibility

Timeliness

Expansion conditions

Environmental impacts

Development advantages

Prefeasibility Study

Oil Shale Fueled Power Generation VW41-1AiUA

4

Feasibility

Oil shale fueled power generation is technically and economically justifiedunder certain conditions

N Need for additional generating capacity

exists

- 6 annual peak demand growth - Orderly retirement of olderhigh cost

generating capacity needed

U Higher costs are expected for imported fuels

- 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

-OP b i j~~4shy

-4protntiYPe 4 demo plnt orP42 t~Plant orPootypeProje(-7hould

that Rj

demo 4Therefore-44 JEA anxinus

the

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

27Pag 4- 1 2S c i n 4 4

4i2Sectjo4-18-4 Secio 4-4 014

lt th~ae hi4h -tasisso syste thrug27 ~ 04lag arstl~art-p tasforme ed 2p27132Kvdieanwhy notthroug

EAto- is protmm~~ thegnJgt~~ pracie an ect ~ platqrby

28Pg 4 s heonnenotedto~the 32K rc powr

It not8 Scection rie049teoervnrain prctc de1

rh u n trae f2V3K anerd not throughgeterAntor

27 P3e-1r p ant weung-a

-If I

2tEll10 DRWE-jOi ASOt Mint~~al d~c~e o hepwrgnrto

ELCTRInYJORD UTHORITY-

Ate~

21Pge41 ection 4 04- 5

sindicated~ t hthigh the unit outputredu f hecondenser Injengtd~ibbvePressureed incg desrin hi h riseb vmbi nt emperatureWe bel~ieve

PleaIse provide us with th rscrapcity for th-e three options n nt generating~

21-Iisidca ted that~ thediaatgeofCBi theSheavy fn oe consumnptionPlease~ providethe us withpecntgA

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

400 MW COAL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO 5050

NET GENERATION - MWe 40000 CAPACITY FACTOR - 75 ANNUAL GENERATION MKWhYR 2628 SUB TOTAL PLANT COSTS (TPC) $1000 $620000

FIXED 0 amp M COSTS MH $ MH FIRST YEAR COST$1O00

------- --------- --- ---- --- --- ------------

OPERATING LABOR 351936 $3 $1100 MAINTENANCE LABOR 4000 of 150 OF TPC 3720

MAINTENANCE MATERIAL 6000

ADMIN LABOR of 150

3000 OF TPC

OF 0 amp M LABOR 5580 1446

SUB TOTAL FIXED OampM COSTS $11846

VARIABLE 0 amp M COSTS QUANTITY UNIT COST

VARIABLE MAINTENANCE 2628 MKWh 10 MILLKWH $ 2628 PROCESS WATER 13500000 GALLON 02 SGAL $ 2700 GENERAL PLANT CHEMICALS ALLOW 50 FUEL OIL 1000000 GALLON 035 $GAL $ 350 WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290SPECIAL BOILER MAINT ALLOW 0

SUB TOTAL VARIABLE OampM COSTS $ 8018

TOTAL FIXED amp VARIABLE OampM COSTS $19864 TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $8227 $TN $99139

(INCL INFLATION ADJUSTMENT)

B DEBT EQUITY RATIO =========== 8020

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $17574

WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290

TOTAL FIXED amp VARIABLE OampM COSTS $19864TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $5877 $TN $70814

(INCL INFLATION ADJUSTMENT)

6-21

Table 612 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY

400 MW OIL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO

NET GENERATION -

CAPACITY FACTOR -

ANNUAL GENERATION SUB TOTAL PLANT COSTS (TPC)

FIXED 0 amp M COSTS

OPERATING LABOR MAINTENANCE LABOR 4000 of

MAINTENANCE MATERIAL 6000 of

ADMIN LABOR

SUB TOTAL FIXED OampM COSTS

VARIABLE 0 amp M COSTS

VARIABLE MAINTENANCE PROCESS WATER GENERAL PLANT CHEMICALS FUEL OIL WASTE DISPOSAL (Section 6027) SPECIAL BOILER MAINT

SUB TOTAL VARIABLE OampM COSTS

5050

MWe

MKWhYR $1000

MH

262080

150

150 3000

QUANTITY

2628 MKWh 13500000 GALLON

1000000 GALLON 0 TNYR

TOTAL FIXED amp VARIABLE OampM COSTS FUEL OIL 503000 TNYR

B DEBT EQUITY RATIO =8020

40000 75

268 $443000

FIRST YEAR $ MH COST$1O00

$3 $ 800

OF TPC 2658

OF TPC 3987 OF 0 amp M LABOR 1037

$ 8482

UNIT COST

05 MILLKWH $ 1314 02 $GAL $ 2700

ALLOW 50 035 $GAL $ 350

$1000 $TN $ 0 ALLOW 0

$ 4414

$12896 $19981 $TN $100502

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $12896

WASTE DISPOSAL (Section 6027) 0 TNYR $1000 $TN $ 0

TOTAL FIXED amp VARIABLE OampM COSTS $12896 FUEL OIL 503000 TNYR $14104 $TN $70943

6-23

Page 4: fo; - pdf.usaid.gov

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

Pilot Plant Test Program (Contd)

U Analyzed one blended sample of shale

- Calorific value = 532 - 597 MJkg (approx 2250 BtuIlb)

- Carbon content (dry solids) = 162 - 187 wto

- Sulfur content (dry solids) = 30 - 33 wt

- Ash content (dry solids) = 667 - 684 wt

- Shale size = minus 8 mm

Key items determined

- Combustion efficiency

- Product ash distribution

- Product gas S02NOxCO content

- Data for boiler design

- Sulfur emissions reduction by Ca in fuel

S Prefeasibility Study Oil Shale Fueled Power Generation

VOO74GEAJI 10

Pilot Plant Test Results

U Combustion efficiency exceeded 985 in all tests

Ash distribution (btm ashfly ash) was 3565 to 4753 at 100 load typically4060

Low emissions were demonstrated

Typically S02 10 to 200 ppm gt 95 removal

limestone addition not required

NOx 60 to 120 ppm lt 020 lb106 Btu

Co 10 to 90 ppm lt 50 ppm

Prefeasibility Study Oi Shale Fueled Power Generation

TITLE

Ternpe -al-CuA vs 6 Ik

00

I00

7SA-A-

Fly Ai h

0

85 e

80-

0

00

i I 800 860 oo

T-er pe -

DATE OWN APPD DCNO- ------ -

_______f - _ IPG_

Pilot Plant Test Conclusions

It is technically feasible to burn the Sultani oil shale furnished by NRA in a Pyropower boiler

A high combustion efficiency in excess of 985 was demonstrated

SO2NOxCO emissions are all acceptably low with no limestone addition required

Prefeasibility StudyO Shale Fueled Power Generation

Conceptual Design Studies Scope

m Three project sizes

- 20 MW

- 50 MW

- 400 MW (4x100) factored for power plant portion

m Open-pit mine

- Shale processing at the surface - Waste disposal system

Power block

- Boiler

- Steam turbine

- Auxiliaries

Prefeasibility Study Oil Shale Fueled Power Generation

VOn 4FAIR 1

i

Project Layout 9 fc =f4j

deg2

o r -w (031

5_7EC 45U

iPefeaibiity tud

OlSeFuedP erGr in

179581113i~o(atyvv11

n1- 14 4pc

C)

Sultani Oil Shale Reserves

North South Area Area Total

Mineable shale tonne x 106 320 658 978

Fischer assay oil content wt 744 761 765

Overburden m3 x 106 384 627 1011

Stripping ratio m3m3 2161 1711 1861

bull Based on NRA core drilling and core analysis

Prefeasibility Study Oil Shale Fueled Power Generation

VWO41OFEAMI14

i

Sultani Oil Shale Analyses

Moisture

Ash (less CO 2 in CaCO 3 )

CO 2 (in CaCO 3 )

Carbon (organic)

Hydrogen

Nitrogen

Sulfur

Oxygen (by diff)

Total

High heating value BtuIb

Fischer assay oil content

bull Percent by weight

Design Basis Fuel

320

6680

1387

1132

113

048

255

065

10000

2250

840

Low High Calorific Calorific

Value Fuel Value Fuel

320 320

6730 6625

1414 1337

1020 1250

102 125

058 038

238 271

118 034

10000 10000

2000 2500

750 925

Preteasibility Study Oil Shale Fueled Power Generation

vo0N d-GEAR 1S

50 MW Oil Shale ProcessingPrototype Plant

Mlne Plant

_ 14 0 Haul0___) to Plant 1 Sorage

Portable Crusher

(-)100 mm Storage

(-) 100 mm Hopper UIU 400 th

Feed Bin

J 50

250 tvb

8 -m Circulating Load Impact3or0 0 30 0 0shy+8mm25

30 0L Sampler 0 1 30 0

p3 Day Storage

To Power Plant

Preleasibility StudyOil Shale Fueled Power Generation

17958101 SaJordanli 18 3-14-89 rsipc1

20 MW Oil Shale Demonstration Plant

Mine Plant

Haul00- 01 o

= Pb n Storage Portable _

110 mm Stora e 0

()100 mm r Hopper

U 400V

Feed Bin

CirculatingLoad3 Day Stoge

Prefea~ltSudy Shale Fueled Power Generation

179S 111p 1 11Joda3 yl 3-202-89 8vk2

I

Mine and Shale ProcessingDesign - 2050 MW Project

I Overburden removal (north pit area) 10-meter benches

- Drill and blast

- 10 m3 front-end loader

- 77-ton truck haulage

I Oil shale mining 10-meter benches

- Rippe and auger scraper

- Front-end loader

- Portable in-pit crusher

- 77-ton truck haulage

Oil shale processing

- Feed = minus 100 mm

- Product = minus 8 mm

- Capacity = 250 tph

- Reversible impactor

- Two vibrating screens

1 Prefeasibility Study Oil Shale Fueled Power Generation

V -M 1AMI1ARt46

400 MW Full-Scale Oil Shale ProcessingPlant

Feed MTnus 200 mm Samplerr

1000 bull 10000 Tonnes Live Storage Grade

200 m long(-) 200 mm -- =-- Plow Feeders

00 h 100000 Tonnes Live Storage

Stream 3 - Sampler Bin Stream 2

Stream th 31Da2000

Circulating Load 2i

NFw Feed r -17000t1 170001l 170 t 17000 t 17000 t

1000 th Silo with 7 Impactor (-1)8 mm Reapro- 3 Day Storage at Aver age Loadn

0 20 Feeders 20 m Diameter by 40 m High

JJJTHT To Power Plant

Prefeasibility Study Oil Shale Fueled Power Generation

179589 6aJordarV 1I8 3-14-89 rsipc1

Mine and Shale ProcessingDesign - 4x100 MW Project

m Overburden removal (north area) 10-meter benches

- Drill and blast

- Three 20 m3 shovels

- 136-ton truck haulage

m Oil shale mining 10-meter benches

- Two mechanical surface miners

- 136-ton trucks to pit hopper

- Belt conveyor = 2000 tph

- Traveling stacker

m Oil shale processing

- Feed = minus 200 mm

- Product = minus 8 mm

- Capacity = three 1000 tph units

Prefeasibility Study Oil Shale Fueled Power Generation

VOO79-ampGEAIAt 17

i

Steady-State Production Schedule

Overburden removal bench m3

20 MW demo project 5n MW prototype 4x100 MW full-scale plant

Oil shale mining and shale processing tonnes

20 MW project 50 MW project 4x100 MW project

HourlyDesign Capacity

282 234

1850

HourlyDesign Capacity

250 250

2000

Avg Daily Annual PEQuctiQa Production

1690 507000 4217 13 million

33333 10 million

Max Daily(a) Annual(b) Production Production

1733 390000 4324 973000

34578 78 million

(a) Based on 100 operating factor for power block

(b) Based on 75 operating factor for power block ( 20 MW project = 300 shiftsyr 50 MW project = 900 shiftsyr 400 MW project = 900 shiftsyr)

Prefeasibility Study Oil Shale Fueled Power Generation

Conceptual Power Plant Plans

m Pyroflow boiler

Power generating facilities

m Auxiliaries

S Preleasibility Study Oil ShaJe Fueled Power Generation

vo0o7dEAO 19

Pyroflow Boiler SteamConciflons

Flow rate 226700 kghr (500000 Ibhr)

Pressure 1099 kgcm2 abs (15635 psia)

Temperature 51280C (9550F)

Same for 20 50 and 100 MW designs

Prefeasibility Study Oil ShaJe Fueled Power Generation

vooGALMI 20

HtomCOPUIOTP

- 50005 5op

-- LEVAThUM ORPORAION

0

-VI

DZ 4

Power Block

Fuel handling system

- Day binsscrew feeders

Boiler

- Pyroflow circulating fluid bed combustor

Power generation

- Non reheat condensing steam turbine

- Conventional Rankin steam cycle

Ash handling system (btm ash irom combustor and flyash from bag house)

- Wetted in pug mill to add 20plusmn wt wpter

Plant service water

- Air-cooled condensors and small cooling tower from circulating trim water coolers

Plant raw water

- To cooling tower makeup

- To drinking water system

- To pump seals etc

Plant treated makeup water

- Demineralizer train

Preteasibility Study Oil Shale Fueled Power Generation

i

Onsite Infrastructure

Project office

Control house

U Maintenance shops warehouse

Laboratory

Employee service facility

Site developmentoperations service facilities

- Fire controlsecurity

- Communications

- Lighting

- Roads drainage and sewage

Prefeasibility StudyQ1I Shale Fueled Power Generation

voo4JG m 0 JV

i

BechtellPyropower50 MW Cogeneration Plant - Mt Poso California

W4t Prefeasibility Study --- 7 Oil Shale Fueled Power Generation

179586122aJordarv 118 3-14-89 rsO

Characteristics of Three Size Operations

Oil shale fuel tpy

Mine development excavation bank m3

Spent ash disposal tpy (wetted)

Water consumption 1000 m3yr

Staffing required

Community population

400 MW

20 MW 50 MW (4x1 00)

390000 973000 78 million

500000 1 million 85 million

327000 815000 61 million

538 907 1263

185 324 1046

700 1200 4000

Prefeasibility Study Oil Shale Fueled Power Generation

V000ofllAM1 23

Conceptual Designs Summary

N All BOP facilities involve conventional equipment and technology

100 MW unit operation involves boiler scale-up considerations

N Water consumption estimates

- Requirement for 4x100 MW project is 13 million m3 yr

- Water allocation of 2 million m3yr of water supports 6x100 MW

N Water availability probably limits total power generation from oil shale in Jordan

Prefeasibility Study Oil Shale Fueled Power Generation

V007041GEAOLMI

i

TECHNOLOGY RISK ASSESSMENT

Basic concepts

Key boiler scale-up design issues

Impact of scale-up

U Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Prefeasibility Study O1 Shale Fueled Power Generation

VOOh-7AEAAO 2

Basic Concepts

U CFBC is relatively new in the powerindustry

- Existing plants are small typically 20 to 50 MW

- There is limited operating experience with high-ash fuels

- Existing designs for lignite biomass and coal wastes show good plant performance

I Application of CFBC boiler design to oil shale fuel has defined risk that relates to scale-up of existing design

Similar CFBC technology is used in petroleum refining industry

- FCC cracking plant regenerators burn carbon residue off spent catalyst

- 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

FUEL ANALYSES

High Ash Fuel Projects Total Solids Input Basis

Gilberton Cambria North Branch

Carbon 4653 2749 1822 Hydrogen 153 164 160 Sulfur 073 222 234 Nitrogen 085 051 043 Oxygen 282 218 468 Moisture 1451 514 557 Ash 3303 6 0 6Z16

10000 10000 10000

HHVBtulb 7485 4809 3453

includes limestone feed a3 ash

includes CO2 in Ca~o3

CA89029 CAkw

Oil Shale

1132

113

255

048

065

320

-8062

10000

2250

Key Boiler Scale-Up DesignIssues

m Solids handling

- Feeding shale to combustor

- 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

Voo4tGEAMI 30

i

Mine and Shale Processing

U Fugitive dust emissions are controllable

- Wetting mine roads

- Enclose crushing plant equipment

Noise levels are controllable

- Enclose crushing plant equipment - Muffle truck exhausts

- Engineered waste disposal

Water effluents can be controlled

- Need good mine drainage design - Continue leachability studies on

waste dump piles

Prefeasibilily StudyOil Shale Fueled Po r Generaton

V0079OOG-4O 31

1

Power Plant

II Fugitive dust emissions are controllable

- Baghouse designoperation will minimize particulates in flue gas

- Wetting spent ash before disposal

N Gaseous emissions are controllable

- Pilot test results show acceptable SO2NOxCO in flue gas

- Develop baseline data for Sultani area

Develop air dispersion model for Sultani

Prefeasibility StudyOil Shale Fueled Power Generatio

V00 V-4GEA l32

i

Power Plant (Contd)

Noise levels are controllable

- Enclose boiler plant fans as required - Enclose turbines and pumps as

required

Water effluents are controllable

- Continue leachability studies on spent ash disposal

- Develop aquifer dispersion model

- Develop sewage and garbage disposal plan

Prefeasibility SludyOil Shale Fueled Power Generation

V00-4FAAI 33

Conclusions

No environmental constraints are anticipated on oil shale powerdevelopment

Gas effluents will meet World Bank standards

- Ash disposal is manageable

- The potential for groundwatercontamination appears low

- Water effluents will be minimal

Continued studies to develop air and groundwater baseline data are recommended

S Prefeasibility Study Oil Shale Fueled Power Generation

v0 9ampGLAMR 34

Power Demand vs SupplyAssessment

m Demand growth forecasts

Electrical generating capacity

= Power supply forecasts

= Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Preleasibility Study Oil Shaie Fuelod Power Generation

VO9- uLIROI

1

Power Demand Forecasts

Percent Annual Growth

JEA

Meta systems HaglerBailey and Bechtel National Inc

JEA Peak Demand Growth

1980 (actual) 1985 (actual) 1987 (actual) 1995 (forecast) 2005 (forecast)

1986 1990 to to

1990 2000

97 60

49 39

200 MW 475 MW 593 MW 900 MW

1400 MW

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOO-DLURO2

i

JEA ElectricityGeneratingCapacity

1987 Installed

Capacity (MW) Aqaba 260

22

Zarqa 395

Marka 102

Karak 23

Miscellaneous 67

Subtotal JEA capacity 869

Other capacity - industrial 110

Total 979

Prefeasibility Study Oi1 Shale Fueled Power Generation

V000-6O0LFJRO3 (

Forecast New Power Generating Capacity Required

Fcst 1987 Required

New Peak Available Installed

Demand Capacity Shortfall (a) Capacity (b) (MM (MW) (MW) (MW)

Assumed capacityfactor (65) (75)

1995 requirement 900 636 264 352

2005 requirement 1400 636 764 1019

(a) Excludes proposed additions and retirements (b) Excludes possible power exports or imports

Load shedding or levelizing not considered

Preteasibility Study Oil Shale Fueled Power Generation

Vflcmf-R)LLAO4

i

Supply vs Demand Evaluation

1800

1600

1400 Forecast Peak Demands

1200 -

E Installed Capacity

0 800shy75--

U) Assumed Available Calcit

a 6 Ao600 shy0 o 65

400 shy

200

I I I I I I I I I I I I I I I I I I I I I I I 1 1 1980 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958f738aIJordarV 118 3-14-89 rspCO

Conclusions

Additional power generating capacity is needed to meet forecasted 19952005demand growth

A 400 MW oil shale-to-power project at Sultani can meet a portion of this need

U A second 400 MW oil shale project maybe required if water is available

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOW0O-8LURO5

i

Economic Feasibility

N Order-of-magnitude costs

N Economic analysis

- Jordan study options

- Project size effect

m Comparison with alternative fuels

- Fuel requirement

- Project financing effect

- Alternate fuel price effect

- Estimated cost of electricity

N Summary financial analysis

bull Material was developed by Bechtel Power Company

Prefeasibility Study

go Oil Shale Fueled Power Generation VOOSO-ampDtJROh

ORDER-OF-MAGNITUDE COSTS

U Oil shale fuel

Power plant

I Integrated project- busbar

Preteasibility Study

Oil Shale Fueled Power Generation

VOO9O-ampDLUROS

Oil Shale Fuel Costs

Installed Capital Cost

Mine Development

Mine Equipment

Processing Plant

Spare Parts

Working Capital

Capitalized Interest

Total

Annual Operating Cost

Fuel Cost $UStonne

bull Based on 8020 debtequity ratio

20 MW

4900

11090

6945

1200

1200

4054

29389

5582

1431

US $1000 Factored

50 MW 4x100 MW

7833 30915

12202 66012

8388 50889

1300 5000

2200 10000

5108 39075

37031 201891

11556 53236

1188 684

Prefeasibility Study

Oil Shale Fueled Power Generation

VCO-ampDLUJ1O

Power Plant Costs

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Cost

Power faciities 57500 91800 567800

Owners cost 10200 20400 192700

Total 67700 112200 760500

Annual Operating Cost 2205 3248 17157(excluding fuel cost)

bullBased on 8020 debtequity ratio oil shale fueled

Prefeasibility Study

Oil Shale Fueled Power Generation

V00O8c4LLMO9

i

INTEGRATED PROJECT -BUSBAR COST

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Costs Mine amp shale processingPower block Waste disposal Infrastructure

29359 67700

1664 10000

37031 112200

2381 15000

201891 760500

8714 45000

TOTAL 108753 166612 1016105

Annual Operating Cost Mine amp shale processingPower block Waste disposal Infrastructure (a)

5582 2205

316

11556 3248

710

56430(b) 18186(b) 6004

Subtotal 8103 15514 80620

Capital Charges 139 9410 15596 106000

Total 17513 31110 186620

25-year levelized cost - - 218000

Busbar Cost millskWh First year 128 92 71 25-year levelized 83

(a) Housing and community facilities assumed self-liquidating(b) Includes first-year inflation adjustment

Based on 8020 debtequity ratio

Prefeasibility StudyOil Shale Fueled Power Generaion

VOOOO-8MLtROi0

ECONOMIC ANALYSIS

n Jordan study options

Project size effect

Fuel requirement

Project financing effect

Alternative fuel price effect

Estimated electricity cost

Summary financial analysis results

Prefeasibility Study

Oil Shale Fueled Powr Generation

VOOeO-BOCLLO1 I

i

Jordan Study Options

U Project size

- Demonstration = 20 MW

- Prototype = 50 MW

- Commercial = 400 MW (4x100)

Project financing

- Debtequity 8020

- Debtequity 5050

Imported alternative fuels cost assumptions

A B Crude oil $17bbl $24bbl

$120onne $170tonne

Low sulfur coal $ 50tonne $ 70tonne See Chevron forecast supporting assumptions

Prefeasibility StudyOil Shale Fueled Power Generation

VOOOO-8DLIJRO12

i

Crude Oil Price Trends

60

Source World Energy Outlook Chevron Corporation Oclober 1987

40

High trend

No Ir 20 ~~~~Arabian Light Spot I A u

IILowYUII trend

0 1970 1975 1980 1985 1990 1995

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958246aJodar 118 3-14-89 rsO

2000

Project Size Effect Shale Fuel Option

Project Size

Integrated facilities installed capital cost$ US million

Shale cost $UStonne(8020 debtequity)

Cost of power millskWh(8020 debtequity ratio)

20 MW

109

143

128

50 MW

167

118

92

400 MW (4x1 00)

1016

68

71

Prefeasibility Study Oil Sampae Fueled Power Generation

VOO O-8I0LJRO13

gt1

1

Power Block Investment Cost

3000

$2875 Excluding mining and offsite 2800

2600

2400

2200

2000

$1836 1800

$1613 1600

$1420 1400 1I 1 I

0 100 200 300 400 MWe

August 1988

Preleasibility Study OilShale Fueled Power Generation

179581147aJodar1 18 3-14-89 rspcl

Fuel Requirement - 4x100 MW Project

Coal = 12 million tpy

n Oil = 503000 tpy

Oil shale = 78 million tpy

Preleasibility Study

Oil Shale Fueled Power Generation

IO060-OLLIRO14

Financing Effect -Project

Oil Shale Fuel Option

Mine and shale processing

Power block

Waste disposal

Community facilities

Total

Coal-Fired Power Plant

Oil-Fired Power Plant

400 MW

Capital Cost ($US MM)

DebtEquity

8020 5050

202 187

760 760

9 8

45 45

1016 1000

647 647

463 463

Prefeasibility StudyOil Shale Fueled Power Generation

VOe-BD1JRO15

Financing Effect shy400 MW Project

Operating Costs ($US millionyr)

DebtEquity

8020 5050

Coal $70tonne 282 282

Oil $24bbl 254 254

Oil shale-fueled 218 236

Including fuel

Prefeasibility Study

SOil Shale Fueled Power Generaion

VOOIt JLMO I

Alternate Fuel Price Effect shy4x100 MW Project

Financing Basis DebtEquity Ratio

Alternate Fuel Price

Imported coal $50tonne $70tonne

Imported oil $17bbl ($120tonne) $24bbl ($170tonne)

Cumulative 25-yr Net Benefit

Favoring Oil Shale (US $MM) shy

8020 5050

778 315 2531 2068

(18) (506)1810 1322

Prefeasibility Study

Oil Shale Fueled Power Generation

Voo -I DLU-A 2

i

Comparison of Cumulative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

32 Pay Out Year shy

400 MW PlantOil Shale vs Imported Coal (8020 debtequty)

30

28 -Cumulative fuel cost savings forcoal $70ton

Cumulative fuel cost savings for coaJ $50ton

26---------- Cumulative Incremental capital plus OampM costs

24

22 -

18 -0

W- Cumulative net benefit for shae vs coal $50ton 2B Cumulative net benefit for shale vs coal $70ton

co16C -

14 -

12 -

10 -

09

06 -Payout inyear 1

Payout Inyear 9 for coal $50ton - -- - - -shy

02 0 I

0 1 2 3 4 5 Nowl Yewr in which sauings in fWe colsacm-ewi tat hsawinitl

ca=al wosaand OampM costs

6

_iiM

7 8

9 10

------ - -amp -

11 12 13 14Year of Operation

--

15

- - --shy

16 17

I

18

1

19

I

20

I

21

I

22

I

23

I

24 25

Prefeasibility StudyOil Shale Fueled Power Generation

17958d351aJordanr 3-14-89 rsO

118

Comparison of Cumuiative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

28 Pay Out Year shy

400 MW Plant Oil Shale vs Imported Coal (5050 debtequity)

26shy2

24-

Cumulaive fuel nst savings for coal 0 $70ton Cumulative fuel cost savings for coal $50ton Cumulative Incremental capital plus OampM corts

22 -

20 -

18 -- Cumuladve net benefit for shle vs coal $50ton B Cumuarve net benefit for sale vs coal $70ton

16 -

C 14

12

10

08 -06 - Payout In year 1for coal $50ton

04

Payout Inyear 1

for coal $70ton02~

0 0

-No

02-

1 2

Yew inrY MCM cajlaI rl

3 4 5 6

sngm inW coas 0 ort hghWcentWin

0tOM cori

7

--

8

- -

9 10 11 12 13 14

Year of Operation

15 16 17

I

18

IIII

19 20 21 22 23 24 25

Preieasibility Study Oil Shale Fueled Power Generation

17958451 bJordarV118 3-14-89 rsipcI

Estimated Cost of Power- 400 MW (4 x 100)

FUEL

ImportedCoal

$50T

$70fT

1st Year

68 88

Levelized

78 107

Sultani Oil Shale

71 83

ImportedOil

$1713

$2413

56

67

76

96

0 10 20 30 40 50

I 60

I 70

I 80

I 90 100 110 120

Mills per kWh

Prefeasibility Study Oil Shale Fueled Power Generation

179581251 cJordarVl 18 3-14-89 rspc1

Summary Financial Analysis Results

Project size

Debt equity ratio

- Investment cost

- Power cost

- 25-year net benefit

- Project implementation

Alternative fuel price

Economic Comparison

Very significant

Not significant

Not significant

Very significant

Critical

Very significant

Prefeasibility Study

Oil Shale Fueled Power Generation

VY0 tDLUAi3

i

Study Conclusions

Feasibility

Timeliness

Expansion conditions

Environmental impacts

Development advantages

Prefeasibility Study

Oil Shale Fueled Power Generation VW41-1AiUA

4

Feasibility

Oil shale fueled power generation is technically and economically justifiedunder certain conditions

N Need for additional generating capacity

exists

- 6 annual peak demand growth - Orderly retirement of olderhigh cost

generating capacity needed

U Higher costs are expected for imported fuels

- 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

-OP b i j~~4shy

-4protntiYPe 4 demo plnt orP42 t~Plant orPootypeProje(-7hould

that Rj

demo 4Therefore-44 JEA anxinus

the

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

27Pag 4- 1 2S c i n 4 4

4i2Sectjo4-18-4 Secio 4-4 014

lt th~ae hi4h -tasisso syste thrug27 ~ 04lag arstl~art-p tasforme ed 2p27132Kvdieanwhy notthroug

EAto- is protmm~~ thegnJgt~~ pracie an ect ~ platqrby

28Pg 4 s heonnenotedto~the 32K rc powr

It not8 Scection rie049teoervnrain prctc de1

rh u n trae f2V3K anerd not throughgeterAntor

27 P3e-1r p ant weung-a

-If I

2tEll10 DRWE-jOi ASOt Mint~~al d~c~e o hepwrgnrto

ELCTRInYJORD UTHORITY-

Ate~

21Pge41 ection 4 04- 5

sindicated~ t hthigh the unit outputredu f hecondenser Injengtd~ibbvePressureed incg desrin hi h riseb vmbi nt emperatureWe bel~ieve

PleaIse provide us with th rscrapcity for th-e three options n nt generating~

21-Iisidca ted that~ thediaatgeofCBi theSheavy fn oe consumnptionPlease~ providethe us withpecntgA

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

400 MW COAL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO 5050

NET GENERATION - MWe 40000 CAPACITY FACTOR - 75 ANNUAL GENERATION MKWhYR 2628 SUB TOTAL PLANT COSTS (TPC) $1000 $620000

FIXED 0 amp M COSTS MH $ MH FIRST YEAR COST$1O00

------- --------- --- ---- --- --- ------------

OPERATING LABOR 351936 $3 $1100 MAINTENANCE LABOR 4000 of 150 OF TPC 3720

MAINTENANCE MATERIAL 6000

ADMIN LABOR of 150

3000 OF TPC

OF 0 amp M LABOR 5580 1446

SUB TOTAL FIXED OampM COSTS $11846

VARIABLE 0 amp M COSTS QUANTITY UNIT COST

VARIABLE MAINTENANCE 2628 MKWh 10 MILLKWH $ 2628 PROCESS WATER 13500000 GALLON 02 SGAL $ 2700 GENERAL PLANT CHEMICALS ALLOW 50 FUEL OIL 1000000 GALLON 035 $GAL $ 350 WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290SPECIAL BOILER MAINT ALLOW 0

SUB TOTAL VARIABLE OampM COSTS $ 8018

TOTAL FIXED amp VARIABLE OampM COSTS $19864 TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $8227 $TN $99139

(INCL INFLATION ADJUSTMENT)

B DEBT EQUITY RATIO =========== 8020

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $17574

WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290

TOTAL FIXED amp VARIABLE OampM COSTS $19864TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $5877 $TN $70814

(INCL INFLATION ADJUSTMENT)

6-21

Table 612 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY

400 MW OIL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO

NET GENERATION -

CAPACITY FACTOR -

ANNUAL GENERATION SUB TOTAL PLANT COSTS (TPC)

FIXED 0 amp M COSTS

OPERATING LABOR MAINTENANCE LABOR 4000 of

MAINTENANCE MATERIAL 6000 of

ADMIN LABOR

SUB TOTAL FIXED OampM COSTS

VARIABLE 0 amp M COSTS

VARIABLE MAINTENANCE PROCESS WATER GENERAL PLANT CHEMICALS FUEL OIL WASTE DISPOSAL (Section 6027) SPECIAL BOILER MAINT

SUB TOTAL VARIABLE OampM COSTS

5050

MWe

MKWhYR $1000

MH

262080

150

150 3000

QUANTITY

2628 MKWh 13500000 GALLON

1000000 GALLON 0 TNYR

TOTAL FIXED amp VARIABLE OampM COSTS FUEL OIL 503000 TNYR

B DEBT EQUITY RATIO =8020

40000 75

268 $443000

FIRST YEAR $ MH COST$1O00

$3 $ 800

OF TPC 2658

OF TPC 3987 OF 0 amp M LABOR 1037

$ 8482

UNIT COST

05 MILLKWH $ 1314 02 $GAL $ 2700

ALLOW 50 035 $GAL $ 350

$1000 $TN $ 0 ALLOW 0

$ 4414

$12896 $19981 $TN $100502

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $12896

WASTE DISPOSAL (Section 6027) 0 TNYR $1000 $TN $ 0

TOTAL FIXED amp VARIABLE OampM COSTS $12896 FUEL OIL 503000 TNYR $14104 $TN $70943

6-23

Page 5: fo; - pdf.usaid.gov

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

Pilot Plant Test Program (Contd)

U Analyzed one blended sample of shale

- Calorific value = 532 - 597 MJkg (approx 2250 BtuIlb)

- Carbon content (dry solids) = 162 - 187 wto

- Sulfur content (dry solids) = 30 - 33 wt

- Ash content (dry solids) = 667 - 684 wt

- Shale size = minus 8 mm

Key items determined

- Combustion efficiency

- Product ash distribution

- Product gas S02NOxCO content

- Data for boiler design

- Sulfur emissions reduction by Ca in fuel

S Prefeasibility Study Oil Shale Fueled Power Generation

VOO74GEAJI 10

Pilot Plant Test Results

U Combustion efficiency exceeded 985 in all tests

Ash distribution (btm ashfly ash) was 3565 to 4753 at 100 load typically4060

Low emissions were demonstrated

Typically S02 10 to 200 ppm gt 95 removal

limestone addition not required

NOx 60 to 120 ppm lt 020 lb106 Btu

Co 10 to 90 ppm lt 50 ppm

Prefeasibility Study Oi Shale Fueled Power Generation

TITLE

Ternpe -al-CuA vs 6 Ik

00

I00

7SA-A-

Fly Ai h

0

85 e

80-

0

00

i I 800 860 oo

T-er pe -

DATE OWN APPD DCNO- ------ -

_______f - _ IPG_

Pilot Plant Test Conclusions

It is technically feasible to burn the Sultani oil shale furnished by NRA in a Pyropower boiler

A high combustion efficiency in excess of 985 was demonstrated

SO2NOxCO emissions are all acceptably low with no limestone addition required

Prefeasibility StudyO Shale Fueled Power Generation

Conceptual Design Studies Scope

m Three project sizes

- 20 MW

- 50 MW

- 400 MW (4x100) factored for power plant portion

m Open-pit mine

- Shale processing at the surface - Waste disposal system

Power block

- Boiler

- Steam turbine

- Auxiliaries

Prefeasibility Study Oil Shale Fueled Power Generation

VOn 4FAIR 1

i

Project Layout 9 fc =f4j

deg2

o r -w (031

5_7EC 45U

iPefeaibiity tud

OlSeFuedP erGr in

179581113i~o(atyvv11

n1- 14 4pc

C)

Sultani Oil Shale Reserves

North South Area Area Total

Mineable shale tonne x 106 320 658 978

Fischer assay oil content wt 744 761 765

Overburden m3 x 106 384 627 1011

Stripping ratio m3m3 2161 1711 1861

bull Based on NRA core drilling and core analysis

Prefeasibility Study Oil Shale Fueled Power Generation

VWO41OFEAMI14

i

Sultani Oil Shale Analyses

Moisture

Ash (less CO 2 in CaCO 3 )

CO 2 (in CaCO 3 )

Carbon (organic)

Hydrogen

Nitrogen

Sulfur

Oxygen (by diff)

Total

High heating value BtuIb

Fischer assay oil content

bull Percent by weight

Design Basis Fuel

320

6680

1387

1132

113

048

255

065

10000

2250

840

Low High Calorific Calorific

Value Fuel Value Fuel

320 320

6730 6625

1414 1337

1020 1250

102 125

058 038

238 271

118 034

10000 10000

2000 2500

750 925

Preteasibility Study Oil Shale Fueled Power Generation

vo0N d-GEAR 1S

50 MW Oil Shale ProcessingPrototype Plant

Mlne Plant

_ 14 0 Haul0___) to Plant 1 Sorage

Portable Crusher

(-)100 mm Storage

(-) 100 mm Hopper UIU 400 th

Feed Bin

J 50

250 tvb

8 -m Circulating Load Impact3or0 0 30 0 0shy+8mm25

30 0L Sampler 0 1 30 0

p3 Day Storage

To Power Plant

Preleasibility StudyOil Shale Fueled Power Generation

17958101 SaJordanli 18 3-14-89 rsipc1

20 MW Oil Shale Demonstration Plant

Mine Plant

Haul00- 01 o

= Pb n Storage Portable _

110 mm Stora e 0

()100 mm r Hopper

U 400V

Feed Bin

CirculatingLoad3 Day Stoge

Prefea~ltSudy Shale Fueled Power Generation

179S 111p 1 11Joda3 yl 3-202-89 8vk2

I

Mine and Shale ProcessingDesign - 2050 MW Project

I Overburden removal (north pit area) 10-meter benches

- Drill and blast

- 10 m3 front-end loader

- 77-ton truck haulage

I Oil shale mining 10-meter benches

- Rippe and auger scraper

- Front-end loader

- Portable in-pit crusher

- 77-ton truck haulage

Oil shale processing

- Feed = minus 100 mm

- Product = minus 8 mm

- Capacity = 250 tph

- Reversible impactor

- Two vibrating screens

1 Prefeasibility Study Oil Shale Fueled Power Generation

V -M 1AMI1ARt46

400 MW Full-Scale Oil Shale ProcessingPlant

Feed MTnus 200 mm Samplerr

1000 bull 10000 Tonnes Live Storage Grade

200 m long(-) 200 mm -- =-- Plow Feeders

00 h 100000 Tonnes Live Storage

Stream 3 - Sampler Bin Stream 2

Stream th 31Da2000

Circulating Load 2i

NFw Feed r -17000t1 170001l 170 t 17000 t 17000 t

1000 th Silo with 7 Impactor (-1)8 mm Reapro- 3 Day Storage at Aver age Loadn

0 20 Feeders 20 m Diameter by 40 m High

JJJTHT To Power Plant

Prefeasibility Study Oil Shale Fueled Power Generation

179589 6aJordarV 1I8 3-14-89 rsipc1

Mine and Shale ProcessingDesign - 4x100 MW Project

m Overburden removal (north area) 10-meter benches

- Drill and blast

- Three 20 m3 shovels

- 136-ton truck haulage

m Oil shale mining 10-meter benches

- Two mechanical surface miners

- 136-ton trucks to pit hopper

- Belt conveyor = 2000 tph

- Traveling stacker

m Oil shale processing

- Feed = minus 200 mm

- Product = minus 8 mm

- Capacity = three 1000 tph units

Prefeasibility Study Oil Shale Fueled Power Generation

VOO79-ampGEAIAt 17

i

Steady-State Production Schedule

Overburden removal bench m3

20 MW demo project 5n MW prototype 4x100 MW full-scale plant

Oil shale mining and shale processing tonnes

20 MW project 50 MW project 4x100 MW project

HourlyDesign Capacity

282 234

1850

HourlyDesign Capacity

250 250

2000

Avg Daily Annual PEQuctiQa Production

1690 507000 4217 13 million

33333 10 million

Max Daily(a) Annual(b) Production Production

1733 390000 4324 973000

34578 78 million

(a) Based on 100 operating factor for power block

(b) Based on 75 operating factor for power block ( 20 MW project = 300 shiftsyr 50 MW project = 900 shiftsyr 400 MW project = 900 shiftsyr)

Prefeasibility Study Oil Shale Fueled Power Generation

Conceptual Power Plant Plans

m Pyroflow boiler

Power generating facilities

m Auxiliaries

S Preleasibility Study Oil ShaJe Fueled Power Generation

vo0o7dEAO 19

Pyroflow Boiler SteamConciflons

Flow rate 226700 kghr (500000 Ibhr)

Pressure 1099 kgcm2 abs (15635 psia)

Temperature 51280C (9550F)

Same for 20 50 and 100 MW designs

Prefeasibility Study Oil ShaJe Fueled Power Generation

vooGALMI 20

HtomCOPUIOTP

- 50005 5op

-- LEVAThUM ORPORAION

0

-VI

DZ 4

Power Block

Fuel handling system

- Day binsscrew feeders

Boiler

- Pyroflow circulating fluid bed combustor

Power generation

- Non reheat condensing steam turbine

- Conventional Rankin steam cycle

Ash handling system (btm ash irom combustor and flyash from bag house)

- Wetted in pug mill to add 20plusmn wt wpter

Plant service water

- Air-cooled condensors and small cooling tower from circulating trim water coolers

Plant raw water

- To cooling tower makeup

- To drinking water system

- To pump seals etc

Plant treated makeup water

- Demineralizer train

Preteasibility Study Oil Shale Fueled Power Generation

i

Onsite Infrastructure

Project office

Control house

U Maintenance shops warehouse

Laboratory

Employee service facility

Site developmentoperations service facilities

- Fire controlsecurity

- Communications

- Lighting

- Roads drainage and sewage

Prefeasibility StudyQ1I Shale Fueled Power Generation

voo4JG m 0 JV

i

BechtellPyropower50 MW Cogeneration Plant - Mt Poso California

W4t Prefeasibility Study --- 7 Oil Shale Fueled Power Generation

179586122aJordarv 118 3-14-89 rsO

Characteristics of Three Size Operations

Oil shale fuel tpy

Mine development excavation bank m3

Spent ash disposal tpy (wetted)

Water consumption 1000 m3yr

Staffing required

Community population

400 MW

20 MW 50 MW (4x1 00)

390000 973000 78 million

500000 1 million 85 million

327000 815000 61 million

538 907 1263

185 324 1046

700 1200 4000

Prefeasibility Study Oil Shale Fueled Power Generation

V000ofllAM1 23

Conceptual Designs Summary

N All BOP facilities involve conventional equipment and technology

100 MW unit operation involves boiler scale-up considerations

N Water consumption estimates

- Requirement for 4x100 MW project is 13 million m3 yr

- Water allocation of 2 million m3yr of water supports 6x100 MW

N Water availability probably limits total power generation from oil shale in Jordan

Prefeasibility Study Oil Shale Fueled Power Generation

V007041GEAOLMI

i

TECHNOLOGY RISK ASSESSMENT

Basic concepts

Key boiler scale-up design issues

Impact of scale-up

U Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Prefeasibility Study O1 Shale Fueled Power Generation

VOOh-7AEAAO 2

Basic Concepts

U CFBC is relatively new in the powerindustry

- Existing plants are small typically 20 to 50 MW

- There is limited operating experience with high-ash fuels

- Existing designs for lignite biomass and coal wastes show good plant performance

I Application of CFBC boiler design to oil shale fuel has defined risk that relates to scale-up of existing design

Similar CFBC technology is used in petroleum refining industry

- FCC cracking plant regenerators burn carbon residue off spent catalyst

- 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

FUEL ANALYSES

High Ash Fuel Projects Total Solids Input Basis

Gilberton Cambria North Branch

Carbon 4653 2749 1822 Hydrogen 153 164 160 Sulfur 073 222 234 Nitrogen 085 051 043 Oxygen 282 218 468 Moisture 1451 514 557 Ash 3303 6 0 6Z16

10000 10000 10000

HHVBtulb 7485 4809 3453

includes limestone feed a3 ash

includes CO2 in Ca~o3

CA89029 CAkw

Oil Shale

1132

113

255

048

065

320

-8062

10000

2250

Key Boiler Scale-Up DesignIssues

m Solids handling

- Feeding shale to combustor

- 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

Voo4tGEAMI 30

i

Mine and Shale Processing

U Fugitive dust emissions are controllable

- Wetting mine roads

- Enclose crushing plant equipment

Noise levels are controllable

- Enclose crushing plant equipment - Muffle truck exhausts

- Engineered waste disposal

Water effluents can be controlled

- Need good mine drainage design - Continue leachability studies on

waste dump piles

Prefeasibilily StudyOil Shale Fueled Po r Generaton

V0079OOG-4O 31

1

Power Plant

II Fugitive dust emissions are controllable

- Baghouse designoperation will minimize particulates in flue gas

- Wetting spent ash before disposal

N Gaseous emissions are controllable

- Pilot test results show acceptable SO2NOxCO in flue gas

- Develop baseline data for Sultani area

Develop air dispersion model for Sultani

Prefeasibility StudyOil Shale Fueled Power Generatio

V00 V-4GEA l32

i

Power Plant (Contd)

Noise levels are controllable

- Enclose boiler plant fans as required - Enclose turbines and pumps as

required

Water effluents are controllable

- Continue leachability studies on spent ash disposal

- Develop aquifer dispersion model

- Develop sewage and garbage disposal plan

Prefeasibility SludyOil Shale Fueled Power Generation

V00-4FAAI 33

Conclusions

No environmental constraints are anticipated on oil shale powerdevelopment

Gas effluents will meet World Bank standards

- Ash disposal is manageable

- The potential for groundwatercontamination appears low

- Water effluents will be minimal

Continued studies to develop air and groundwater baseline data are recommended

S Prefeasibility Study Oil Shale Fueled Power Generation

v0 9ampGLAMR 34

Power Demand vs SupplyAssessment

m Demand growth forecasts

Electrical generating capacity

= Power supply forecasts

= Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Preleasibility Study Oil Shaie Fuelod Power Generation

VO9- uLIROI

1

Power Demand Forecasts

Percent Annual Growth

JEA

Meta systems HaglerBailey and Bechtel National Inc

JEA Peak Demand Growth

1980 (actual) 1985 (actual) 1987 (actual) 1995 (forecast) 2005 (forecast)

1986 1990 to to

1990 2000

97 60

49 39

200 MW 475 MW 593 MW 900 MW

1400 MW

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOO-DLURO2

i

JEA ElectricityGeneratingCapacity

1987 Installed

Capacity (MW) Aqaba 260

22

Zarqa 395

Marka 102

Karak 23

Miscellaneous 67

Subtotal JEA capacity 869

Other capacity - industrial 110

Total 979

Prefeasibility Study Oi1 Shale Fueled Power Generation

V000-6O0LFJRO3 (

Forecast New Power Generating Capacity Required

Fcst 1987 Required

New Peak Available Installed

Demand Capacity Shortfall (a) Capacity (b) (MM (MW) (MW) (MW)

Assumed capacityfactor (65) (75)

1995 requirement 900 636 264 352

2005 requirement 1400 636 764 1019

(a) Excludes proposed additions and retirements (b) Excludes possible power exports or imports

Load shedding or levelizing not considered

Preteasibility Study Oil Shale Fueled Power Generation

Vflcmf-R)LLAO4

i

Supply vs Demand Evaluation

1800

1600

1400 Forecast Peak Demands

1200 -

E Installed Capacity

0 800shy75--

U) Assumed Available Calcit

a 6 Ao600 shy0 o 65

400 shy

200

I I I I I I I I I I I I I I I I I I I I I I I 1 1 1980 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958f738aIJordarV 118 3-14-89 rspCO

Conclusions

Additional power generating capacity is needed to meet forecasted 19952005demand growth

A 400 MW oil shale-to-power project at Sultani can meet a portion of this need

U A second 400 MW oil shale project maybe required if water is available

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOW0O-8LURO5

i

Economic Feasibility

N Order-of-magnitude costs

N Economic analysis

- Jordan study options

- Project size effect

m Comparison with alternative fuels

- Fuel requirement

- Project financing effect

- Alternate fuel price effect

- Estimated cost of electricity

N Summary financial analysis

bull Material was developed by Bechtel Power Company

Prefeasibility Study

go Oil Shale Fueled Power Generation VOOSO-ampDtJROh

ORDER-OF-MAGNITUDE COSTS

U Oil shale fuel

Power plant

I Integrated project- busbar

Preteasibility Study

Oil Shale Fueled Power Generation

VOO9O-ampDLUROS

Oil Shale Fuel Costs

Installed Capital Cost

Mine Development

Mine Equipment

Processing Plant

Spare Parts

Working Capital

Capitalized Interest

Total

Annual Operating Cost

Fuel Cost $UStonne

bull Based on 8020 debtequity ratio

20 MW

4900

11090

6945

1200

1200

4054

29389

5582

1431

US $1000 Factored

50 MW 4x100 MW

7833 30915

12202 66012

8388 50889

1300 5000

2200 10000

5108 39075

37031 201891

11556 53236

1188 684

Prefeasibility Study

Oil Shale Fueled Power Generation

VCO-ampDLUJ1O

Power Plant Costs

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Cost

Power faciities 57500 91800 567800

Owners cost 10200 20400 192700

Total 67700 112200 760500

Annual Operating Cost 2205 3248 17157(excluding fuel cost)

bullBased on 8020 debtequity ratio oil shale fueled

Prefeasibility Study

Oil Shale Fueled Power Generation

V00O8c4LLMO9

i

INTEGRATED PROJECT -BUSBAR COST

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Costs Mine amp shale processingPower block Waste disposal Infrastructure

29359 67700

1664 10000

37031 112200

2381 15000

201891 760500

8714 45000

TOTAL 108753 166612 1016105

Annual Operating Cost Mine amp shale processingPower block Waste disposal Infrastructure (a)

5582 2205

316

11556 3248

710

56430(b) 18186(b) 6004

Subtotal 8103 15514 80620

Capital Charges 139 9410 15596 106000

Total 17513 31110 186620

25-year levelized cost - - 218000

Busbar Cost millskWh First year 128 92 71 25-year levelized 83

(a) Housing and community facilities assumed self-liquidating(b) Includes first-year inflation adjustment

Based on 8020 debtequity ratio

Prefeasibility StudyOil Shale Fueled Power Generaion

VOOOO-8MLtROi0

ECONOMIC ANALYSIS

n Jordan study options

Project size effect

Fuel requirement

Project financing effect

Alternative fuel price effect

Estimated electricity cost

Summary financial analysis results

Prefeasibility Study

Oil Shale Fueled Powr Generation

VOOeO-BOCLLO1 I

i

Jordan Study Options

U Project size

- Demonstration = 20 MW

- Prototype = 50 MW

- Commercial = 400 MW (4x100)

Project financing

- Debtequity 8020

- Debtequity 5050

Imported alternative fuels cost assumptions

A B Crude oil $17bbl $24bbl

$120onne $170tonne

Low sulfur coal $ 50tonne $ 70tonne See Chevron forecast supporting assumptions

Prefeasibility StudyOil Shale Fueled Power Generation

VOOOO-8DLIJRO12

i

Crude Oil Price Trends

60

Source World Energy Outlook Chevron Corporation Oclober 1987

40

High trend

No Ir 20 ~~~~Arabian Light Spot I A u

IILowYUII trend

0 1970 1975 1980 1985 1990 1995

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958246aJodar 118 3-14-89 rsO

2000

Project Size Effect Shale Fuel Option

Project Size

Integrated facilities installed capital cost$ US million

Shale cost $UStonne(8020 debtequity)

Cost of power millskWh(8020 debtequity ratio)

20 MW

109

143

128

50 MW

167

118

92

400 MW (4x1 00)

1016

68

71

Prefeasibility Study Oil Sampae Fueled Power Generation

VOO O-8I0LJRO13

gt1

1

Power Block Investment Cost

3000

$2875 Excluding mining and offsite 2800

2600

2400

2200

2000

$1836 1800

$1613 1600

$1420 1400 1I 1 I

0 100 200 300 400 MWe

August 1988

Preleasibility Study OilShale Fueled Power Generation

179581147aJodar1 18 3-14-89 rspcl

Fuel Requirement - 4x100 MW Project

Coal = 12 million tpy

n Oil = 503000 tpy

Oil shale = 78 million tpy

Preleasibility Study

Oil Shale Fueled Power Generation

IO060-OLLIRO14

Financing Effect -Project

Oil Shale Fuel Option

Mine and shale processing

Power block

Waste disposal

Community facilities

Total

Coal-Fired Power Plant

Oil-Fired Power Plant

400 MW

Capital Cost ($US MM)

DebtEquity

8020 5050

202 187

760 760

9 8

45 45

1016 1000

647 647

463 463

Prefeasibility StudyOil Shale Fueled Power Generation

VOe-BD1JRO15

Financing Effect shy400 MW Project

Operating Costs ($US millionyr)

DebtEquity

8020 5050

Coal $70tonne 282 282

Oil $24bbl 254 254

Oil shale-fueled 218 236

Including fuel

Prefeasibility Study

SOil Shale Fueled Power Generaion

VOOIt JLMO I

Alternate Fuel Price Effect shy4x100 MW Project

Financing Basis DebtEquity Ratio

Alternate Fuel Price

Imported coal $50tonne $70tonne

Imported oil $17bbl ($120tonne) $24bbl ($170tonne)

Cumulative 25-yr Net Benefit

Favoring Oil Shale (US $MM) shy

8020 5050

778 315 2531 2068

(18) (506)1810 1322

Prefeasibility Study

Oil Shale Fueled Power Generation

Voo -I DLU-A 2

i

Comparison of Cumulative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

32 Pay Out Year shy

400 MW PlantOil Shale vs Imported Coal (8020 debtequty)

30

28 -Cumulative fuel cost savings forcoal $70ton

Cumulative fuel cost savings for coaJ $50ton

26---------- Cumulative Incremental capital plus OampM costs

24

22 -

18 -0

W- Cumulative net benefit for shae vs coal $50ton 2B Cumulative net benefit for shale vs coal $70ton

co16C -

14 -

12 -

10 -

09

06 -Payout inyear 1

Payout Inyear 9 for coal $50ton - -- - - -shy

02 0 I

0 1 2 3 4 5 Nowl Yewr in which sauings in fWe colsacm-ewi tat hsawinitl

ca=al wosaand OampM costs

6

_iiM

7 8

9 10

------ - -amp -

11 12 13 14Year of Operation

--

15

- - --shy

16 17

I

18

1

19

I

20

I

21

I

22

I

23

I

24 25

Prefeasibility StudyOil Shale Fueled Power Generation

17958d351aJordanr 3-14-89 rsO

118

Comparison of Cumuiative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

28 Pay Out Year shy

400 MW Plant Oil Shale vs Imported Coal (5050 debtequity)

26shy2

24-

Cumulaive fuel nst savings for coal 0 $70ton Cumulative fuel cost savings for coal $50ton Cumulative Incremental capital plus OampM corts

22 -

20 -

18 -- Cumuladve net benefit for shle vs coal $50ton B Cumuarve net benefit for sale vs coal $70ton

16 -

C 14

12

10

08 -06 - Payout In year 1for coal $50ton

04

Payout Inyear 1

for coal $70ton02~

0 0

-No

02-

1 2

Yew inrY MCM cajlaI rl

3 4 5 6

sngm inW coas 0 ort hghWcentWin

0tOM cori

7

--

8

- -

9 10 11 12 13 14

Year of Operation

15 16 17

I

18

IIII

19 20 21 22 23 24 25

Preieasibility Study Oil Shale Fueled Power Generation

17958451 bJordarV118 3-14-89 rsipcI

Estimated Cost of Power- 400 MW (4 x 100)

FUEL

ImportedCoal

$50T

$70fT

1st Year

68 88

Levelized

78 107

Sultani Oil Shale

71 83

ImportedOil

$1713

$2413

56

67

76

96

0 10 20 30 40 50

I 60

I 70

I 80

I 90 100 110 120

Mills per kWh

Prefeasibility Study Oil Shale Fueled Power Generation

179581251 cJordarVl 18 3-14-89 rspc1

Summary Financial Analysis Results

Project size

Debt equity ratio

- Investment cost

- Power cost

- 25-year net benefit

- Project implementation

Alternative fuel price

Economic Comparison

Very significant

Not significant

Not significant

Very significant

Critical

Very significant

Prefeasibility Study

Oil Shale Fueled Power Generation

VY0 tDLUAi3

i

Study Conclusions

Feasibility

Timeliness

Expansion conditions

Environmental impacts

Development advantages

Prefeasibility Study

Oil Shale Fueled Power Generation VW41-1AiUA

4

Feasibility

Oil shale fueled power generation is technically and economically justifiedunder certain conditions

N Need for additional generating capacity

exists

- 6 annual peak demand growth - Orderly retirement of olderhigh cost

generating capacity needed

U Higher costs are expected for imported fuels

- 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

-OP b i j~~4shy

-4protntiYPe 4 demo plnt orP42 t~Plant orPootypeProje(-7hould

that Rj

demo 4Therefore-44 JEA anxinus

the

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

27Pag 4- 1 2S c i n 4 4

4i2Sectjo4-18-4 Secio 4-4 014

lt th~ae hi4h -tasisso syste thrug27 ~ 04lag arstl~art-p tasforme ed 2p27132Kvdieanwhy notthroug

EAto- is protmm~~ thegnJgt~~ pracie an ect ~ platqrby

28Pg 4 s heonnenotedto~the 32K rc powr

It not8 Scection rie049teoervnrain prctc de1

rh u n trae f2V3K anerd not throughgeterAntor

27 P3e-1r p ant weung-a

-If I

2tEll10 DRWE-jOi ASOt Mint~~al d~c~e o hepwrgnrto

ELCTRInYJORD UTHORITY-

Ate~

21Pge41 ection 4 04- 5

sindicated~ t hthigh the unit outputredu f hecondenser Injengtd~ibbvePressureed incg desrin hi h riseb vmbi nt emperatureWe bel~ieve

PleaIse provide us with th rscrapcity for th-e three options n nt generating~

21-Iisidca ted that~ thediaatgeofCBi theSheavy fn oe consumnptionPlease~ providethe us withpecntgA

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

400 MW COAL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO 5050

NET GENERATION - MWe 40000 CAPACITY FACTOR - 75 ANNUAL GENERATION MKWhYR 2628 SUB TOTAL PLANT COSTS (TPC) $1000 $620000

FIXED 0 amp M COSTS MH $ MH FIRST YEAR COST$1O00

------- --------- --- ---- --- --- ------------

OPERATING LABOR 351936 $3 $1100 MAINTENANCE LABOR 4000 of 150 OF TPC 3720

MAINTENANCE MATERIAL 6000

ADMIN LABOR of 150

3000 OF TPC

OF 0 amp M LABOR 5580 1446

SUB TOTAL FIXED OampM COSTS $11846

VARIABLE 0 amp M COSTS QUANTITY UNIT COST

VARIABLE MAINTENANCE 2628 MKWh 10 MILLKWH $ 2628 PROCESS WATER 13500000 GALLON 02 SGAL $ 2700 GENERAL PLANT CHEMICALS ALLOW 50 FUEL OIL 1000000 GALLON 035 $GAL $ 350 WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290SPECIAL BOILER MAINT ALLOW 0

SUB TOTAL VARIABLE OampM COSTS $ 8018

TOTAL FIXED amp VARIABLE OampM COSTS $19864 TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $8227 $TN $99139

(INCL INFLATION ADJUSTMENT)

B DEBT EQUITY RATIO =========== 8020

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $17574

WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290

TOTAL FIXED amp VARIABLE OampM COSTS $19864TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $5877 $TN $70814

(INCL INFLATION ADJUSTMENT)

6-21

Table 612 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY

400 MW OIL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO

NET GENERATION -

CAPACITY FACTOR -

ANNUAL GENERATION SUB TOTAL PLANT COSTS (TPC)

FIXED 0 amp M COSTS

OPERATING LABOR MAINTENANCE LABOR 4000 of

MAINTENANCE MATERIAL 6000 of

ADMIN LABOR

SUB TOTAL FIXED OampM COSTS

VARIABLE 0 amp M COSTS

VARIABLE MAINTENANCE PROCESS WATER GENERAL PLANT CHEMICALS FUEL OIL WASTE DISPOSAL (Section 6027) SPECIAL BOILER MAINT

SUB TOTAL VARIABLE OampM COSTS

5050

MWe

MKWhYR $1000

MH

262080

150

150 3000

QUANTITY

2628 MKWh 13500000 GALLON

1000000 GALLON 0 TNYR

TOTAL FIXED amp VARIABLE OampM COSTS FUEL OIL 503000 TNYR

B DEBT EQUITY RATIO =8020

40000 75

268 $443000

FIRST YEAR $ MH COST$1O00

$3 $ 800

OF TPC 2658

OF TPC 3987 OF 0 amp M LABOR 1037

$ 8482

UNIT COST

05 MILLKWH $ 1314 02 $GAL $ 2700

ALLOW 50 035 $GAL $ 350

$1000 $TN $ 0 ALLOW 0

$ 4414

$12896 $19981 $TN $100502

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $12896

WASTE DISPOSAL (Section 6027) 0 TNYR $1000 $TN $ 0

TOTAL FIXED amp VARIABLE OampM COSTS $12896 FUEL OIL 503000 TNYR $14104 $TN $70943

6-23

Page 6: fo; - pdf.usaid.gov

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

Pilot Plant Test Program (Contd)

U Analyzed one blended sample of shale

- Calorific value = 532 - 597 MJkg (approx 2250 BtuIlb)

- Carbon content (dry solids) = 162 - 187 wto

- Sulfur content (dry solids) = 30 - 33 wt

- Ash content (dry solids) = 667 - 684 wt

- Shale size = minus 8 mm

Key items determined

- Combustion efficiency

- Product ash distribution

- Product gas S02NOxCO content

- Data for boiler design

- Sulfur emissions reduction by Ca in fuel

S Prefeasibility Study Oil Shale Fueled Power Generation

VOO74GEAJI 10

Pilot Plant Test Results

U Combustion efficiency exceeded 985 in all tests

Ash distribution (btm ashfly ash) was 3565 to 4753 at 100 load typically4060

Low emissions were demonstrated

Typically S02 10 to 200 ppm gt 95 removal

limestone addition not required

NOx 60 to 120 ppm lt 020 lb106 Btu

Co 10 to 90 ppm lt 50 ppm

Prefeasibility Study Oi Shale Fueled Power Generation

TITLE

Ternpe -al-CuA vs 6 Ik

00

I00

7SA-A-

Fly Ai h

0

85 e

80-

0

00

i I 800 860 oo

T-er pe -

DATE OWN APPD DCNO- ------ -

_______f - _ IPG_

Pilot Plant Test Conclusions

It is technically feasible to burn the Sultani oil shale furnished by NRA in a Pyropower boiler

A high combustion efficiency in excess of 985 was demonstrated

SO2NOxCO emissions are all acceptably low with no limestone addition required

Prefeasibility StudyO Shale Fueled Power Generation

Conceptual Design Studies Scope

m Three project sizes

- 20 MW

- 50 MW

- 400 MW (4x100) factored for power plant portion

m Open-pit mine

- Shale processing at the surface - Waste disposal system

Power block

- Boiler

- Steam turbine

- Auxiliaries

Prefeasibility Study Oil Shale Fueled Power Generation

VOn 4FAIR 1

i

Project Layout 9 fc =f4j

deg2

o r -w (031

5_7EC 45U

iPefeaibiity tud

OlSeFuedP erGr in

179581113i~o(atyvv11

n1- 14 4pc

C)

Sultani Oil Shale Reserves

North South Area Area Total

Mineable shale tonne x 106 320 658 978

Fischer assay oil content wt 744 761 765

Overburden m3 x 106 384 627 1011

Stripping ratio m3m3 2161 1711 1861

bull Based on NRA core drilling and core analysis

Prefeasibility Study Oil Shale Fueled Power Generation

VWO41OFEAMI14

i

Sultani Oil Shale Analyses

Moisture

Ash (less CO 2 in CaCO 3 )

CO 2 (in CaCO 3 )

Carbon (organic)

Hydrogen

Nitrogen

Sulfur

Oxygen (by diff)

Total

High heating value BtuIb

Fischer assay oil content

bull Percent by weight

Design Basis Fuel

320

6680

1387

1132

113

048

255

065

10000

2250

840

Low High Calorific Calorific

Value Fuel Value Fuel

320 320

6730 6625

1414 1337

1020 1250

102 125

058 038

238 271

118 034

10000 10000

2000 2500

750 925

Preteasibility Study Oil Shale Fueled Power Generation

vo0N d-GEAR 1S

50 MW Oil Shale ProcessingPrototype Plant

Mlne Plant

_ 14 0 Haul0___) to Plant 1 Sorage

Portable Crusher

(-)100 mm Storage

(-) 100 mm Hopper UIU 400 th

Feed Bin

J 50

250 tvb

8 -m Circulating Load Impact3or0 0 30 0 0shy+8mm25

30 0L Sampler 0 1 30 0

p3 Day Storage

To Power Plant

Preleasibility StudyOil Shale Fueled Power Generation

17958101 SaJordanli 18 3-14-89 rsipc1

20 MW Oil Shale Demonstration Plant

Mine Plant

Haul00- 01 o

= Pb n Storage Portable _

110 mm Stora e 0

()100 mm r Hopper

U 400V

Feed Bin

CirculatingLoad3 Day Stoge

Prefea~ltSudy Shale Fueled Power Generation

179S 111p 1 11Joda3 yl 3-202-89 8vk2

I

Mine and Shale ProcessingDesign - 2050 MW Project

I Overburden removal (north pit area) 10-meter benches

- Drill and blast

- 10 m3 front-end loader

- 77-ton truck haulage

I Oil shale mining 10-meter benches

- Rippe and auger scraper

- Front-end loader

- Portable in-pit crusher

- 77-ton truck haulage

Oil shale processing

- Feed = minus 100 mm

- Product = minus 8 mm

- Capacity = 250 tph

- Reversible impactor

- Two vibrating screens

1 Prefeasibility Study Oil Shale Fueled Power Generation

V -M 1AMI1ARt46

400 MW Full-Scale Oil Shale ProcessingPlant

Feed MTnus 200 mm Samplerr

1000 bull 10000 Tonnes Live Storage Grade

200 m long(-) 200 mm -- =-- Plow Feeders

00 h 100000 Tonnes Live Storage

Stream 3 - Sampler Bin Stream 2

Stream th 31Da2000

Circulating Load 2i

NFw Feed r -17000t1 170001l 170 t 17000 t 17000 t

1000 th Silo with 7 Impactor (-1)8 mm Reapro- 3 Day Storage at Aver age Loadn

0 20 Feeders 20 m Diameter by 40 m High

JJJTHT To Power Plant

Prefeasibility Study Oil Shale Fueled Power Generation

179589 6aJordarV 1I8 3-14-89 rsipc1

Mine and Shale ProcessingDesign - 4x100 MW Project

m Overburden removal (north area) 10-meter benches

- Drill and blast

- Three 20 m3 shovels

- 136-ton truck haulage

m Oil shale mining 10-meter benches

- Two mechanical surface miners

- 136-ton trucks to pit hopper

- Belt conveyor = 2000 tph

- Traveling stacker

m Oil shale processing

- Feed = minus 200 mm

- Product = minus 8 mm

- Capacity = three 1000 tph units

Prefeasibility Study Oil Shale Fueled Power Generation

VOO79-ampGEAIAt 17

i

Steady-State Production Schedule

Overburden removal bench m3

20 MW demo project 5n MW prototype 4x100 MW full-scale plant

Oil shale mining and shale processing tonnes

20 MW project 50 MW project 4x100 MW project

HourlyDesign Capacity

282 234

1850

HourlyDesign Capacity

250 250

2000

Avg Daily Annual PEQuctiQa Production

1690 507000 4217 13 million

33333 10 million

Max Daily(a) Annual(b) Production Production

1733 390000 4324 973000

34578 78 million

(a) Based on 100 operating factor for power block

(b) Based on 75 operating factor for power block ( 20 MW project = 300 shiftsyr 50 MW project = 900 shiftsyr 400 MW project = 900 shiftsyr)

Prefeasibility Study Oil Shale Fueled Power Generation

Conceptual Power Plant Plans

m Pyroflow boiler

Power generating facilities

m Auxiliaries

S Preleasibility Study Oil ShaJe Fueled Power Generation

vo0o7dEAO 19

Pyroflow Boiler SteamConciflons

Flow rate 226700 kghr (500000 Ibhr)

Pressure 1099 kgcm2 abs (15635 psia)

Temperature 51280C (9550F)

Same for 20 50 and 100 MW designs

Prefeasibility Study Oil ShaJe Fueled Power Generation

vooGALMI 20

HtomCOPUIOTP

- 50005 5op

-- LEVAThUM ORPORAION

0

-VI

DZ 4

Power Block

Fuel handling system

- Day binsscrew feeders

Boiler

- Pyroflow circulating fluid bed combustor

Power generation

- Non reheat condensing steam turbine

- Conventional Rankin steam cycle

Ash handling system (btm ash irom combustor and flyash from bag house)

- Wetted in pug mill to add 20plusmn wt wpter

Plant service water

- Air-cooled condensors and small cooling tower from circulating trim water coolers

Plant raw water

- To cooling tower makeup

- To drinking water system

- To pump seals etc

Plant treated makeup water

- Demineralizer train

Preteasibility Study Oil Shale Fueled Power Generation

i

Onsite Infrastructure

Project office

Control house

U Maintenance shops warehouse

Laboratory

Employee service facility

Site developmentoperations service facilities

- Fire controlsecurity

- Communications

- Lighting

- Roads drainage and sewage

Prefeasibility StudyQ1I Shale Fueled Power Generation

voo4JG m 0 JV

i

BechtellPyropower50 MW Cogeneration Plant - Mt Poso California

W4t Prefeasibility Study --- 7 Oil Shale Fueled Power Generation

179586122aJordarv 118 3-14-89 rsO

Characteristics of Three Size Operations

Oil shale fuel tpy

Mine development excavation bank m3

Spent ash disposal tpy (wetted)

Water consumption 1000 m3yr

Staffing required

Community population

400 MW

20 MW 50 MW (4x1 00)

390000 973000 78 million

500000 1 million 85 million

327000 815000 61 million

538 907 1263

185 324 1046

700 1200 4000

Prefeasibility Study Oil Shale Fueled Power Generation

V000ofllAM1 23

Conceptual Designs Summary

N All BOP facilities involve conventional equipment and technology

100 MW unit operation involves boiler scale-up considerations

N Water consumption estimates

- Requirement for 4x100 MW project is 13 million m3 yr

- Water allocation of 2 million m3yr of water supports 6x100 MW

N Water availability probably limits total power generation from oil shale in Jordan

Prefeasibility Study Oil Shale Fueled Power Generation

V007041GEAOLMI

i

TECHNOLOGY RISK ASSESSMENT

Basic concepts

Key boiler scale-up design issues

Impact of scale-up

U Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Prefeasibility Study O1 Shale Fueled Power Generation

VOOh-7AEAAO 2

Basic Concepts

U CFBC is relatively new in the powerindustry

- Existing plants are small typically 20 to 50 MW

- There is limited operating experience with high-ash fuels

- Existing designs for lignite biomass and coal wastes show good plant performance

I Application of CFBC boiler design to oil shale fuel has defined risk that relates to scale-up of existing design

Similar CFBC technology is used in petroleum refining industry

- FCC cracking plant regenerators burn carbon residue off spent catalyst

- 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

FUEL ANALYSES

High Ash Fuel Projects Total Solids Input Basis

Gilberton Cambria North Branch

Carbon 4653 2749 1822 Hydrogen 153 164 160 Sulfur 073 222 234 Nitrogen 085 051 043 Oxygen 282 218 468 Moisture 1451 514 557 Ash 3303 6 0 6Z16

10000 10000 10000

HHVBtulb 7485 4809 3453

includes limestone feed a3 ash

includes CO2 in Ca~o3

CA89029 CAkw

Oil Shale

1132

113

255

048

065

320

-8062

10000

2250

Key Boiler Scale-Up DesignIssues

m Solids handling

- Feeding shale to combustor

- 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

Voo4tGEAMI 30

i

Mine and Shale Processing

U Fugitive dust emissions are controllable

- Wetting mine roads

- Enclose crushing plant equipment

Noise levels are controllable

- Enclose crushing plant equipment - Muffle truck exhausts

- Engineered waste disposal

Water effluents can be controlled

- Need good mine drainage design - Continue leachability studies on

waste dump piles

Prefeasibilily StudyOil Shale Fueled Po r Generaton

V0079OOG-4O 31

1

Power Plant

II Fugitive dust emissions are controllable

- Baghouse designoperation will minimize particulates in flue gas

- Wetting spent ash before disposal

N Gaseous emissions are controllable

- Pilot test results show acceptable SO2NOxCO in flue gas

- Develop baseline data for Sultani area

Develop air dispersion model for Sultani

Prefeasibility StudyOil Shale Fueled Power Generatio

V00 V-4GEA l32

i

Power Plant (Contd)

Noise levels are controllable

- Enclose boiler plant fans as required - Enclose turbines and pumps as

required

Water effluents are controllable

- Continue leachability studies on spent ash disposal

- Develop aquifer dispersion model

- Develop sewage and garbage disposal plan

Prefeasibility SludyOil Shale Fueled Power Generation

V00-4FAAI 33

Conclusions

No environmental constraints are anticipated on oil shale powerdevelopment

Gas effluents will meet World Bank standards

- Ash disposal is manageable

- The potential for groundwatercontamination appears low

- Water effluents will be minimal

Continued studies to develop air and groundwater baseline data are recommended

S Prefeasibility Study Oil Shale Fueled Power Generation

v0 9ampGLAMR 34

Power Demand vs SupplyAssessment

m Demand growth forecasts

Electrical generating capacity

= Power supply forecasts

= Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Preleasibility Study Oil Shaie Fuelod Power Generation

VO9- uLIROI

1

Power Demand Forecasts

Percent Annual Growth

JEA

Meta systems HaglerBailey and Bechtel National Inc

JEA Peak Demand Growth

1980 (actual) 1985 (actual) 1987 (actual) 1995 (forecast) 2005 (forecast)

1986 1990 to to

1990 2000

97 60

49 39

200 MW 475 MW 593 MW 900 MW

1400 MW

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOO-DLURO2

i

JEA ElectricityGeneratingCapacity

1987 Installed

Capacity (MW) Aqaba 260

22

Zarqa 395

Marka 102

Karak 23

Miscellaneous 67

Subtotal JEA capacity 869

Other capacity - industrial 110

Total 979

Prefeasibility Study Oi1 Shale Fueled Power Generation

V000-6O0LFJRO3 (

Forecast New Power Generating Capacity Required

Fcst 1987 Required

New Peak Available Installed

Demand Capacity Shortfall (a) Capacity (b) (MM (MW) (MW) (MW)

Assumed capacityfactor (65) (75)

1995 requirement 900 636 264 352

2005 requirement 1400 636 764 1019

(a) Excludes proposed additions and retirements (b) Excludes possible power exports or imports

Load shedding or levelizing not considered

Preteasibility Study Oil Shale Fueled Power Generation

Vflcmf-R)LLAO4

i

Supply vs Demand Evaluation

1800

1600

1400 Forecast Peak Demands

1200 -

E Installed Capacity

0 800shy75--

U) Assumed Available Calcit

a 6 Ao600 shy0 o 65

400 shy

200

I I I I I I I I I I I I I I I I I I I I I I I 1 1 1980 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958f738aIJordarV 118 3-14-89 rspCO

Conclusions

Additional power generating capacity is needed to meet forecasted 19952005demand growth

A 400 MW oil shale-to-power project at Sultani can meet a portion of this need

U A second 400 MW oil shale project maybe required if water is available

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOW0O-8LURO5

i

Economic Feasibility

N Order-of-magnitude costs

N Economic analysis

- Jordan study options

- Project size effect

m Comparison with alternative fuels

- Fuel requirement

- Project financing effect

- Alternate fuel price effect

- Estimated cost of electricity

N Summary financial analysis

bull Material was developed by Bechtel Power Company

Prefeasibility Study

go Oil Shale Fueled Power Generation VOOSO-ampDtJROh

ORDER-OF-MAGNITUDE COSTS

U Oil shale fuel

Power plant

I Integrated project- busbar

Preteasibility Study

Oil Shale Fueled Power Generation

VOO9O-ampDLUROS

Oil Shale Fuel Costs

Installed Capital Cost

Mine Development

Mine Equipment

Processing Plant

Spare Parts

Working Capital

Capitalized Interest

Total

Annual Operating Cost

Fuel Cost $UStonne

bull Based on 8020 debtequity ratio

20 MW

4900

11090

6945

1200

1200

4054

29389

5582

1431

US $1000 Factored

50 MW 4x100 MW

7833 30915

12202 66012

8388 50889

1300 5000

2200 10000

5108 39075

37031 201891

11556 53236

1188 684

Prefeasibility Study

Oil Shale Fueled Power Generation

VCO-ampDLUJ1O

Power Plant Costs

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Cost

Power faciities 57500 91800 567800

Owners cost 10200 20400 192700

Total 67700 112200 760500

Annual Operating Cost 2205 3248 17157(excluding fuel cost)

bullBased on 8020 debtequity ratio oil shale fueled

Prefeasibility Study

Oil Shale Fueled Power Generation

V00O8c4LLMO9

i

INTEGRATED PROJECT -BUSBAR COST

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Costs Mine amp shale processingPower block Waste disposal Infrastructure

29359 67700

1664 10000

37031 112200

2381 15000

201891 760500

8714 45000

TOTAL 108753 166612 1016105

Annual Operating Cost Mine amp shale processingPower block Waste disposal Infrastructure (a)

5582 2205

316

11556 3248

710

56430(b) 18186(b) 6004

Subtotal 8103 15514 80620

Capital Charges 139 9410 15596 106000

Total 17513 31110 186620

25-year levelized cost - - 218000

Busbar Cost millskWh First year 128 92 71 25-year levelized 83

(a) Housing and community facilities assumed self-liquidating(b) Includes first-year inflation adjustment

Based on 8020 debtequity ratio

Prefeasibility StudyOil Shale Fueled Power Generaion

VOOOO-8MLtROi0

ECONOMIC ANALYSIS

n Jordan study options

Project size effect

Fuel requirement

Project financing effect

Alternative fuel price effect

Estimated electricity cost

Summary financial analysis results

Prefeasibility Study

Oil Shale Fueled Powr Generation

VOOeO-BOCLLO1 I

i

Jordan Study Options

U Project size

- Demonstration = 20 MW

- Prototype = 50 MW

- Commercial = 400 MW (4x100)

Project financing

- Debtequity 8020

- Debtequity 5050

Imported alternative fuels cost assumptions

A B Crude oil $17bbl $24bbl

$120onne $170tonne

Low sulfur coal $ 50tonne $ 70tonne See Chevron forecast supporting assumptions

Prefeasibility StudyOil Shale Fueled Power Generation

VOOOO-8DLIJRO12

i

Crude Oil Price Trends

60

Source World Energy Outlook Chevron Corporation Oclober 1987

40

High trend

No Ir 20 ~~~~Arabian Light Spot I A u

IILowYUII trend

0 1970 1975 1980 1985 1990 1995

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958246aJodar 118 3-14-89 rsO

2000

Project Size Effect Shale Fuel Option

Project Size

Integrated facilities installed capital cost$ US million

Shale cost $UStonne(8020 debtequity)

Cost of power millskWh(8020 debtequity ratio)

20 MW

109

143

128

50 MW

167

118

92

400 MW (4x1 00)

1016

68

71

Prefeasibility Study Oil Sampae Fueled Power Generation

VOO O-8I0LJRO13

gt1

1

Power Block Investment Cost

3000

$2875 Excluding mining and offsite 2800

2600

2400

2200

2000

$1836 1800

$1613 1600

$1420 1400 1I 1 I

0 100 200 300 400 MWe

August 1988

Preleasibility Study OilShale Fueled Power Generation

179581147aJodar1 18 3-14-89 rspcl

Fuel Requirement - 4x100 MW Project

Coal = 12 million tpy

n Oil = 503000 tpy

Oil shale = 78 million tpy

Preleasibility Study

Oil Shale Fueled Power Generation

IO060-OLLIRO14

Financing Effect -Project

Oil Shale Fuel Option

Mine and shale processing

Power block

Waste disposal

Community facilities

Total

Coal-Fired Power Plant

Oil-Fired Power Plant

400 MW

Capital Cost ($US MM)

DebtEquity

8020 5050

202 187

760 760

9 8

45 45

1016 1000

647 647

463 463

Prefeasibility StudyOil Shale Fueled Power Generation

VOe-BD1JRO15

Financing Effect shy400 MW Project

Operating Costs ($US millionyr)

DebtEquity

8020 5050

Coal $70tonne 282 282

Oil $24bbl 254 254

Oil shale-fueled 218 236

Including fuel

Prefeasibility Study

SOil Shale Fueled Power Generaion

VOOIt JLMO I

Alternate Fuel Price Effect shy4x100 MW Project

Financing Basis DebtEquity Ratio

Alternate Fuel Price

Imported coal $50tonne $70tonne

Imported oil $17bbl ($120tonne) $24bbl ($170tonne)

Cumulative 25-yr Net Benefit

Favoring Oil Shale (US $MM) shy

8020 5050

778 315 2531 2068

(18) (506)1810 1322

Prefeasibility Study

Oil Shale Fueled Power Generation

Voo -I DLU-A 2

i

Comparison of Cumulative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

32 Pay Out Year shy

400 MW PlantOil Shale vs Imported Coal (8020 debtequty)

30

28 -Cumulative fuel cost savings forcoal $70ton

Cumulative fuel cost savings for coaJ $50ton

26---------- Cumulative Incremental capital plus OampM costs

24

22 -

18 -0

W- Cumulative net benefit for shae vs coal $50ton 2B Cumulative net benefit for shale vs coal $70ton

co16C -

14 -

12 -

10 -

09

06 -Payout inyear 1

Payout Inyear 9 for coal $50ton - -- - - -shy

02 0 I

0 1 2 3 4 5 Nowl Yewr in which sauings in fWe colsacm-ewi tat hsawinitl

ca=al wosaand OampM costs

6

_iiM

7 8

9 10

------ - -amp -

11 12 13 14Year of Operation

--

15

- - --shy

16 17

I

18

1

19

I

20

I

21

I

22

I

23

I

24 25

Prefeasibility StudyOil Shale Fueled Power Generation

17958d351aJordanr 3-14-89 rsO

118

Comparison of Cumuiative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

28 Pay Out Year shy

400 MW Plant Oil Shale vs Imported Coal (5050 debtequity)

26shy2

24-

Cumulaive fuel nst savings for coal 0 $70ton Cumulative fuel cost savings for coal $50ton Cumulative Incremental capital plus OampM corts

22 -

20 -

18 -- Cumuladve net benefit for shle vs coal $50ton B Cumuarve net benefit for sale vs coal $70ton

16 -

C 14

12

10

08 -06 - Payout In year 1for coal $50ton

04

Payout Inyear 1

for coal $70ton02~

0 0

-No

02-

1 2

Yew inrY MCM cajlaI rl

3 4 5 6

sngm inW coas 0 ort hghWcentWin

0tOM cori

7

--

8

- -

9 10 11 12 13 14

Year of Operation

15 16 17

I

18

IIII

19 20 21 22 23 24 25

Preieasibility Study Oil Shale Fueled Power Generation

17958451 bJordarV118 3-14-89 rsipcI

Estimated Cost of Power- 400 MW (4 x 100)

FUEL

ImportedCoal

$50T

$70fT

1st Year

68 88

Levelized

78 107

Sultani Oil Shale

71 83

ImportedOil

$1713

$2413

56

67

76

96

0 10 20 30 40 50

I 60

I 70

I 80

I 90 100 110 120

Mills per kWh

Prefeasibility Study Oil Shale Fueled Power Generation

179581251 cJordarVl 18 3-14-89 rspc1

Summary Financial Analysis Results

Project size

Debt equity ratio

- Investment cost

- Power cost

- 25-year net benefit

- Project implementation

Alternative fuel price

Economic Comparison

Very significant

Not significant

Not significant

Very significant

Critical

Very significant

Prefeasibility Study

Oil Shale Fueled Power Generation

VY0 tDLUAi3

i

Study Conclusions

Feasibility

Timeliness

Expansion conditions

Environmental impacts

Development advantages

Prefeasibility Study

Oil Shale Fueled Power Generation VW41-1AiUA

4

Feasibility

Oil shale fueled power generation is technically and economically justifiedunder certain conditions

N Need for additional generating capacity

exists

- 6 annual peak demand growth - Orderly retirement of olderhigh cost

generating capacity needed

U Higher costs are expected for imported fuels

- 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

-OP b i j~~4shy

-4protntiYPe 4 demo plnt orP42 t~Plant orPootypeProje(-7hould

that Rj

demo 4Therefore-44 JEA anxinus

the

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

27Pag 4- 1 2S c i n 4 4

4i2Sectjo4-18-4 Secio 4-4 014

lt th~ae hi4h -tasisso syste thrug27 ~ 04lag arstl~art-p tasforme ed 2p27132Kvdieanwhy notthroug

EAto- is protmm~~ thegnJgt~~ pracie an ect ~ platqrby

28Pg 4 s heonnenotedto~the 32K rc powr

It not8 Scection rie049teoervnrain prctc de1

rh u n trae f2V3K anerd not throughgeterAntor

27 P3e-1r p ant weung-a

-If I

2tEll10 DRWE-jOi ASOt Mint~~al d~c~e o hepwrgnrto

ELCTRInYJORD UTHORITY-

Ate~

21Pge41 ection 4 04- 5

sindicated~ t hthigh the unit outputredu f hecondenser Injengtd~ibbvePressureed incg desrin hi h riseb vmbi nt emperatureWe bel~ieve

PleaIse provide us with th rscrapcity for th-e three options n nt generating~

21-Iisidca ted that~ thediaatgeofCBi theSheavy fn oe consumnptionPlease~ providethe us withpecntgA

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

400 MW COAL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO 5050

NET GENERATION - MWe 40000 CAPACITY FACTOR - 75 ANNUAL GENERATION MKWhYR 2628 SUB TOTAL PLANT COSTS (TPC) $1000 $620000

FIXED 0 amp M COSTS MH $ MH FIRST YEAR COST$1O00

------- --------- --- ---- --- --- ------------

OPERATING LABOR 351936 $3 $1100 MAINTENANCE LABOR 4000 of 150 OF TPC 3720

MAINTENANCE MATERIAL 6000

ADMIN LABOR of 150

3000 OF TPC

OF 0 amp M LABOR 5580 1446

SUB TOTAL FIXED OampM COSTS $11846

VARIABLE 0 amp M COSTS QUANTITY UNIT COST

VARIABLE MAINTENANCE 2628 MKWh 10 MILLKWH $ 2628 PROCESS WATER 13500000 GALLON 02 SGAL $ 2700 GENERAL PLANT CHEMICALS ALLOW 50 FUEL OIL 1000000 GALLON 035 $GAL $ 350 WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290SPECIAL BOILER MAINT ALLOW 0

SUB TOTAL VARIABLE OampM COSTS $ 8018

TOTAL FIXED amp VARIABLE OampM COSTS $19864 TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $8227 $TN $99139

(INCL INFLATION ADJUSTMENT)

B DEBT EQUITY RATIO =========== 8020

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $17574

WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290

TOTAL FIXED amp VARIABLE OampM COSTS $19864TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $5877 $TN $70814

(INCL INFLATION ADJUSTMENT)

6-21

Table 612 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY

400 MW OIL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO

NET GENERATION -

CAPACITY FACTOR -

ANNUAL GENERATION SUB TOTAL PLANT COSTS (TPC)

FIXED 0 amp M COSTS

OPERATING LABOR MAINTENANCE LABOR 4000 of

MAINTENANCE MATERIAL 6000 of

ADMIN LABOR

SUB TOTAL FIXED OampM COSTS

VARIABLE 0 amp M COSTS

VARIABLE MAINTENANCE PROCESS WATER GENERAL PLANT CHEMICALS FUEL OIL WASTE DISPOSAL (Section 6027) SPECIAL BOILER MAINT

SUB TOTAL VARIABLE OampM COSTS

5050

MWe

MKWhYR $1000

MH

262080

150

150 3000

QUANTITY

2628 MKWh 13500000 GALLON

1000000 GALLON 0 TNYR

TOTAL FIXED amp VARIABLE OampM COSTS FUEL OIL 503000 TNYR

B DEBT EQUITY RATIO =8020

40000 75

268 $443000

FIRST YEAR $ MH COST$1O00

$3 $ 800

OF TPC 2658

OF TPC 3987 OF 0 amp M LABOR 1037

$ 8482

UNIT COST

05 MILLKWH $ 1314 02 $GAL $ 2700

ALLOW 50 035 $GAL $ 350

$1000 $TN $ 0 ALLOW 0

$ 4414

$12896 $19981 $TN $100502

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $12896

WASTE DISPOSAL (Section 6027) 0 TNYR $1000 $TN $ 0

TOTAL FIXED amp VARIABLE OampM COSTS $12896 FUEL OIL 503000 TNYR $14104 $TN $70943

6-23

Page 7: fo; - pdf.usaid.gov

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

Pilot Plant Test Program (Contd)

U Analyzed one blended sample of shale

- Calorific value = 532 - 597 MJkg (approx 2250 BtuIlb)

- Carbon content (dry solids) = 162 - 187 wto

- Sulfur content (dry solids) = 30 - 33 wt

- Ash content (dry solids) = 667 - 684 wt

- Shale size = minus 8 mm

Key items determined

- Combustion efficiency

- Product ash distribution

- Product gas S02NOxCO content

- Data for boiler design

- Sulfur emissions reduction by Ca in fuel

S Prefeasibility Study Oil Shale Fueled Power Generation

VOO74GEAJI 10

Pilot Plant Test Results

U Combustion efficiency exceeded 985 in all tests

Ash distribution (btm ashfly ash) was 3565 to 4753 at 100 load typically4060

Low emissions were demonstrated

Typically S02 10 to 200 ppm gt 95 removal

limestone addition not required

NOx 60 to 120 ppm lt 020 lb106 Btu

Co 10 to 90 ppm lt 50 ppm

Prefeasibility Study Oi Shale Fueled Power Generation

TITLE

Ternpe -al-CuA vs 6 Ik

00

I00

7SA-A-

Fly Ai h

0

85 e

80-

0

00

i I 800 860 oo

T-er pe -

DATE OWN APPD DCNO- ------ -

_______f - _ IPG_

Pilot Plant Test Conclusions

It is technically feasible to burn the Sultani oil shale furnished by NRA in a Pyropower boiler

A high combustion efficiency in excess of 985 was demonstrated

SO2NOxCO emissions are all acceptably low with no limestone addition required

Prefeasibility StudyO Shale Fueled Power Generation

Conceptual Design Studies Scope

m Three project sizes

- 20 MW

- 50 MW

- 400 MW (4x100) factored for power plant portion

m Open-pit mine

- Shale processing at the surface - Waste disposal system

Power block

- Boiler

- Steam turbine

- Auxiliaries

Prefeasibility Study Oil Shale Fueled Power Generation

VOn 4FAIR 1

i

Project Layout 9 fc =f4j

deg2

o r -w (031

5_7EC 45U

iPefeaibiity tud

OlSeFuedP erGr in

179581113i~o(atyvv11

n1- 14 4pc

C)

Sultani Oil Shale Reserves

North South Area Area Total

Mineable shale tonne x 106 320 658 978

Fischer assay oil content wt 744 761 765

Overburden m3 x 106 384 627 1011

Stripping ratio m3m3 2161 1711 1861

bull Based on NRA core drilling and core analysis

Prefeasibility Study Oil Shale Fueled Power Generation

VWO41OFEAMI14

i

Sultani Oil Shale Analyses

Moisture

Ash (less CO 2 in CaCO 3 )

CO 2 (in CaCO 3 )

Carbon (organic)

Hydrogen

Nitrogen

Sulfur

Oxygen (by diff)

Total

High heating value BtuIb

Fischer assay oil content

bull Percent by weight

Design Basis Fuel

320

6680

1387

1132

113

048

255

065

10000

2250

840

Low High Calorific Calorific

Value Fuel Value Fuel

320 320

6730 6625

1414 1337

1020 1250

102 125

058 038

238 271

118 034

10000 10000

2000 2500

750 925

Preteasibility Study Oil Shale Fueled Power Generation

vo0N d-GEAR 1S

50 MW Oil Shale ProcessingPrototype Plant

Mlne Plant

_ 14 0 Haul0___) to Plant 1 Sorage

Portable Crusher

(-)100 mm Storage

(-) 100 mm Hopper UIU 400 th

Feed Bin

J 50

250 tvb

8 -m Circulating Load Impact3or0 0 30 0 0shy+8mm25

30 0L Sampler 0 1 30 0

p3 Day Storage

To Power Plant

Preleasibility StudyOil Shale Fueled Power Generation

17958101 SaJordanli 18 3-14-89 rsipc1

20 MW Oil Shale Demonstration Plant

Mine Plant

Haul00- 01 o

= Pb n Storage Portable _

110 mm Stora e 0

()100 mm r Hopper

U 400V

Feed Bin

CirculatingLoad3 Day Stoge

Prefea~ltSudy Shale Fueled Power Generation

179S 111p 1 11Joda3 yl 3-202-89 8vk2

I

Mine and Shale ProcessingDesign - 2050 MW Project

I Overburden removal (north pit area) 10-meter benches

- Drill and blast

- 10 m3 front-end loader

- 77-ton truck haulage

I Oil shale mining 10-meter benches

- Rippe and auger scraper

- Front-end loader

- Portable in-pit crusher

- 77-ton truck haulage

Oil shale processing

- Feed = minus 100 mm

- Product = minus 8 mm

- Capacity = 250 tph

- Reversible impactor

- Two vibrating screens

1 Prefeasibility Study Oil Shale Fueled Power Generation

V -M 1AMI1ARt46

400 MW Full-Scale Oil Shale ProcessingPlant

Feed MTnus 200 mm Samplerr

1000 bull 10000 Tonnes Live Storage Grade

200 m long(-) 200 mm -- =-- Plow Feeders

00 h 100000 Tonnes Live Storage

Stream 3 - Sampler Bin Stream 2

Stream th 31Da2000

Circulating Load 2i

NFw Feed r -17000t1 170001l 170 t 17000 t 17000 t

1000 th Silo with 7 Impactor (-1)8 mm Reapro- 3 Day Storage at Aver age Loadn

0 20 Feeders 20 m Diameter by 40 m High

JJJTHT To Power Plant

Prefeasibility Study Oil Shale Fueled Power Generation

179589 6aJordarV 1I8 3-14-89 rsipc1

Mine and Shale ProcessingDesign - 4x100 MW Project

m Overburden removal (north area) 10-meter benches

- Drill and blast

- Three 20 m3 shovels

- 136-ton truck haulage

m Oil shale mining 10-meter benches

- Two mechanical surface miners

- 136-ton trucks to pit hopper

- Belt conveyor = 2000 tph

- Traveling stacker

m Oil shale processing

- Feed = minus 200 mm

- Product = minus 8 mm

- Capacity = three 1000 tph units

Prefeasibility Study Oil Shale Fueled Power Generation

VOO79-ampGEAIAt 17

i

Steady-State Production Schedule

Overburden removal bench m3

20 MW demo project 5n MW prototype 4x100 MW full-scale plant

Oil shale mining and shale processing tonnes

20 MW project 50 MW project 4x100 MW project

HourlyDesign Capacity

282 234

1850

HourlyDesign Capacity

250 250

2000

Avg Daily Annual PEQuctiQa Production

1690 507000 4217 13 million

33333 10 million

Max Daily(a) Annual(b) Production Production

1733 390000 4324 973000

34578 78 million

(a) Based on 100 operating factor for power block

(b) Based on 75 operating factor for power block ( 20 MW project = 300 shiftsyr 50 MW project = 900 shiftsyr 400 MW project = 900 shiftsyr)

Prefeasibility Study Oil Shale Fueled Power Generation

Conceptual Power Plant Plans

m Pyroflow boiler

Power generating facilities

m Auxiliaries

S Preleasibility Study Oil ShaJe Fueled Power Generation

vo0o7dEAO 19

Pyroflow Boiler SteamConciflons

Flow rate 226700 kghr (500000 Ibhr)

Pressure 1099 kgcm2 abs (15635 psia)

Temperature 51280C (9550F)

Same for 20 50 and 100 MW designs

Prefeasibility Study Oil ShaJe Fueled Power Generation

vooGALMI 20

HtomCOPUIOTP

- 50005 5op

-- LEVAThUM ORPORAION

0

-VI

DZ 4

Power Block

Fuel handling system

- Day binsscrew feeders

Boiler

- Pyroflow circulating fluid bed combustor

Power generation

- Non reheat condensing steam turbine

- Conventional Rankin steam cycle

Ash handling system (btm ash irom combustor and flyash from bag house)

- Wetted in pug mill to add 20plusmn wt wpter

Plant service water

- Air-cooled condensors and small cooling tower from circulating trim water coolers

Plant raw water

- To cooling tower makeup

- To drinking water system

- To pump seals etc

Plant treated makeup water

- Demineralizer train

Preteasibility Study Oil Shale Fueled Power Generation

i

Onsite Infrastructure

Project office

Control house

U Maintenance shops warehouse

Laboratory

Employee service facility

Site developmentoperations service facilities

- Fire controlsecurity

- Communications

- Lighting

- Roads drainage and sewage

Prefeasibility StudyQ1I Shale Fueled Power Generation

voo4JG m 0 JV

i

BechtellPyropower50 MW Cogeneration Plant - Mt Poso California

W4t Prefeasibility Study --- 7 Oil Shale Fueled Power Generation

179586122aJordarv 118 3-14-89 rsO

Characteristics of Three Size Operations

Oil shale fuel tpy

Mine development excavation bank m3

Spent ash disposal tpy (wetted)

Water consumption 1000 m3yr

Staffing required

Community population

400 MW

20 MW 50 MW (4x1 00)

390000 973000 78 million

500000 1 million 85 million

327000 815000 61 million

538 907 1263

185 324 1046

700 1200 4000

Prefeasibility Study Oil Shale Fueled Power Generation

V000ofllAM1 23

Conceptual Designs Summary

N All BOP facilities involve conventional equipment and technology

100 MW unit operation involves boiler scale-up considerations

N Water consumption estimates

- Requirement for 4x100 MW project is 13 million m3 yr

- Water allocation of 2 million m3yr of water supports 6x100 MW

N Water availability probably limits total power generation from oil shale in Jordan

Prefeasibility Study Oil Shale Fueled Power Generation

V007041GEAOLMI

i

TECHNOLOGY RISK ASSESSMENT

Basic concepts

Key boiler scale-up design issues

Impact of scale-up

U Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Prefeasibility Study O1 Shale Fueled Power Generation

VOOh-7AEAAO 2

Basic Concepts

U CFBC is relatively new in the powerindustry

- Existing plants are small typically 20 to 50 MW

- There is limited operating experience with high-ash fuels

- Existing designs for lignite biomass and coal wastes show good plant performance

I Application of CFBC boiler design to oil shale fuel has defined risk that relates to scale-up of existing design

Similar CFBC technology is used in petroleum refining industry

- FCC cracking plant regenerators burn carbon residue off spent catalyst

- 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

FUEL ANALYSES

High Ash Fuel Projects Total Solids Input Basis

Gilberton Cambria North Branch

Carbon 4653 2749 1822 Hydrogen 153 164 160 Sulfur 073 222 234 Nitrogen 085 051 043 Oxygen 282 218 468 Moisture 1451 514 557 Ash 3303 6 0 6Z16

10000 10000 10000

HHVBtulb 7485 4809 3453

includes limestone feed a3 ash

includes CO2 in Ca~o3

CA89029 CAkw

Oil Shale

1132

113

255

048

065

320

-8062

10000

2250

Key Boiler Scale-Up DesignIssues

m Solids handling

- Feeding shale to combustor

- 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

Voo4tGEAMI 30

i

Mine and Shale Processing

U Fugitive dust emissions are controllable

- Wetting mine roads

- Enclose crushing plant equipment

Noise levels are controllable

- Enclose crushing plant equipment - Muffle truck exhausts

- Engineered waste disposal

Water effluents can be controlled

- Need good mine drainage design - Continue leachability studies on

waste dump piles

Prefeasibilily StudyOil Shale Fueled Po r Generaton

V0079OOG-4O 31

1

Power Plant

II Fugitive dust emissions are controllable

- Baghouse designoperation will minimize particulates in flue gas

- Wetting spent ash before disposal

N Gaseous emissions are controllable

- Pilot test results show acceptable SO2NOxCO in flue gas

- Develop baseline data for Sultani area

Develop air dispersion model for Sultani

Prefeasibility StudyOil Shale Fueled Power Generatio

V00 V-4GEA l32

i

Power Plant (Contd)

Noise levels are controllable

- Enclose boiler plant fans as required - Enclose turbines and pumps as

required

Water effluents are controllable

- Continue leachability studies on spent ash disposal

- Develop aquifer dispersion model

- Develop sewage and garbage disposal plan

Prefeasibility SludyOil Shale Fueled Power Generation

V00-4FAAI 33

Conclusions

No environmental constraints are anticipated on oil shale powerdevelopment

Gas effluents will meet World Bank standards

- Ash disposal is manageable

- The potential for groundwatercontamination appears low

- Water effluents will be minimal

Continued studies to develop air and groundwater baseline data are recommended

S Prefeasibility Study Oil Shale Fueled Power Generation

v0 9ampGLAMR 34

Power Demand vs SupplyAssessment

m Demand growth forecasts

Electrical generating capacity

= Power supply forecasts

= Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Preleasibility Study Oil Shaie Fuelod Power Generation

VO9- uLIROI

1

Power Demand Forecasts

Percent Annual Growth

JEA

Meta systems HaglerBailey and Bechtel National Inc

JEA Peak Demand Growth

1980 (actual) 1985 (actual) 1987 (actual) 1995 (forecast) 2005 (forecast)

1986 1990 to to

1990 2000

97 60

49 39

200 MW 475 MW 593 MW 900 MW

1400 MW

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOO-DLURO2

i

JEA ElectricityGeneratingCapacity

1987 Installed

Capacity (MW) Aqaba 260

22

Zarqa 395

Marka 102

Karak 23

Miscellaneous 67

Subtotal JEA capacity 869

Other capacity - industrial 110

Total 979

Prefeasibility Study Oi1 Shale Fueled Power Generation

V000-6O0LFJRO3 (

Forecast New Power Generating Capacity Required

Fcst 1987 Required

New Peak Available Installed

Demand Capacity Shortfall (a) Capacity (b) (MM (MW) (MW) (MW)

Assumed capacityfactor (65) (75)

1995 requirement 900 636 264 352

2005 requirement 1400 636 764 1019

(a) Excludes proposed additions and retirements (b) Excludes possible power exports or imports

Load shedding or levelizing not considered

Preteasibility Study Oil Shale Fueled Power Generation

Vflcmf-R)LLAO4

i

Supply vs Demand Evaluation

1800

1600

1400 Forecast Peak Demands

1200 -

E Installed Capacity

0 800shy75--

U) Assumed Available Calcit

a 6 Ao600 shy0 o 65

400 shy

200

I I I I I I I I I I I I I I I I I I I I I I I 1 1 1980 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958f738aIJordarV 118 3-14-89 rspCO

Conclusions

Additional power generating capacity is needed to meet forecasted 19952005demand growth

A 400 MW oil shale-to-power project at Sultani can meet a portion of this need

U A second 400 MW oil shale project maybe required if water is available

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOW0O-8LURO5

i

Economic Feasibility

N Order-of-magnitude costs

N Economic analysis

- Jordan study options

- Project size effect

m Comparison with alternative fuels

- Fuel requirement

- Project financing effect

- Alternate fuel price effect

- Estimated cost of electricity

N Summary financial analysis

bull Material was developed by Bechtel Power Company

Prefeasibility Study

go Oil Shale Fueled Power Generation VOOSO-ampDtJROh

ORDER-OF-MAGNITUDE COSTS

U Oil shale fuel

Power plant

I Integrated project- busbar

Preteasibility Study

Oil Shale Fueled Power Generation

VOO9O-ampDLUROS

Oil Shale Fuel Costs

Installed Capital Cost

Mine Development

Mine Equipment

Processing Plant

Spare Parts

Working Capital

Capitalized Interest

Total

Annual Operating Cost

Fuel Cost $UStonne

bull Based on 8020 debtequity ratio

20 MW

4900

11090

6945

1200

1200

4054

29389

5582

1431

US $1000 Factored

50 MW 4x100 MW

7833 30915

12202 66012

8388 50889

1300 5000

2200 10000

5108 39075

37031 201891

11556 53236

1188 684

Prefeasibility Study

Oil Shale Fueled Power Generation

VCO-ampDLUJ1O

Power Plant Costs

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Cost

Power faciities 57500 91800 567800

Owners cost 10200 20400 192700

Total 67700 112200 760500

Annual Operating Cost 2205 3248 17157(excluding fuel cost)

bullBased on 8020 debtequity ratio oil shale fueled

Prefeasibility Study

Oil Shale Fueled Power Generation

V00O8c4LLMO9

i

INTEGRATED PROJECT -BUSBAR COST

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Costs Mine amp shale processingPower block Waste disposal Infrastructure

29359 67700

1664 10000

37031 112200

2381 15000

201891 760500

8714 45000

TOTAL 108753 166612 1016105

Annual Operating Cost Mine amp shale processingPower block Waste disposal Infrastructure (a)

5582 2205

316

11556 3248

710

56430(b) 18186(b) 6004

Subtotal 8103 15514 80620

Capital Charges 139 9410 15596 106000

Total 17513 31110 186620

25-year levelized cost - - 218000

Busbar Cost millskWh First year 128 92 71 25-year levelized 83

(a) Housing and community facilities assumed self-liquidating(b) Includes first-year inflation adjustment

Based on 8020 debtequity ratio

Prefeasibility StudyOil Shale Fueled Power Generaion

VOOOO-8MLtROi0

ECONOMIC ANALYSIS

n Jordan study options

Project size effect

Fuel requirement

Project financing effect

Alternative fuel price effect

Estimated electricity cost

Summary financial analysis results

Prefeasibility Study

Oil Shale Fueled Powr Generation

VOOeO-BOCLLO1 I

i

Jordan Study Options

U Project size

- Demonstration = 20 MW

- Prototype = 50 MW

- Commercial = 400 MW (4x100)

Project financing

- Debtequity 8020

- Debtequity 5050

Imported alternative fuels cost assumptions

A B Crude oil $17bbl $24bbl

$120onne $170tonne

Low sulfur coal $ 50tonne $ 70tonne See Chevron forecast supporting assumptions

Prefeasibility StudyOil Shale Fueled Power Generation

VOOOO-8DLIJRO12

i

Crude Oil Price Trends

60

Source World Energy Outlook Chevron Corporation Oclober 1987

40

High trend

No Ir 20 ~~~~Arabian Light Spot I A u

IILowYUII trend

0 1970 1975 1980 1985 1990 1995

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958246aJodar 118 3-14-89 rsO

2000

Project Size Effect Shale Fuel Option

Project Size

Integrated facilities installed capital cost$ US million

Shale cost $UStonne(8020 debtequity)

Cost of power millskWh(8020 debtequity ratio)

20 MW

109

143

128

50 MW

167

118

92

400 MW (4x1 00)

1016

68

71

Prefeasibility Study Oil Sampae Fueled Power Generation

VOO O-8I0LJRO13

gt1

1

Power Block Investment Cost

3000

$2875 Excluding mining and offsite 2800

2600

2400

2200

2000

$1836 1800

$1613 1600

$1420 1400 1I 1 I

0 100 200 300 400 MWe

August 1988

Preleasibility Study OilShale Fueled Power Generation

179581147aJodar1 18 3-14-89 rspcl

Fuel Requirement - 4x100 MW Project

Coal = 12 million tpy

n Oil = 503000 tpy

Oil shale = 78 million tpy

Preleasibility Study

Oil Shale Fueled Power Generation

IO060-OLLIRO14

Financing Effect -Project

Oil Shale Fuel Option

Mine and shale processing

Power block

Waste disposal

Community facilities

Total

Coal-Fired Power Plant

Oil-Fired Power Plant

400 MW

Capital Cost ($US MM)

DebtEquity

8020 5050

202 187

760 760

9 8

45 45

1016 1000

647 647

463 463

Prefeasibility StudyOil Shale Fueled Power Generation

VOe-BD1JRO15

Financing Effect shy400 MW Project

Operating Costs ($US millionyr)

DebtEquity

8020 5050

Coal $70tonne 282 282

Oil $24bbl 254 254

Oil shale-fueled 218 236

Including fuel

Prefeasibility Study

SOil Shale Fueled Power Generaion

VOOIt JLMO I

Alternate Fuel Price Effect shy4x100 MW Project

Financing Basis DebtEquity Ratio

Alternate Fuel Price

Imported coal $50tonne $70tonne

Imported oil $17bbl ($120tonne) $24bbl ($170tonne)

Cumulative 25-yr Net Benefit

Favoring Oil Shale (US $MM) shy

8020 5050

778 315 2531 2068

(18) (506)1810 1322

Prefeasibility Study

Oil Shale Fueled Power Generation

Voo -I DLU-A 2

i

Comparison of Cumulative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

32 Pay Out Year shy

400 MW PlantOil Shale vs Imported Coal (8020 debtequty)

30

28 -Cumulative fuel cost savings forcoal $70ton

Cumulative fuel cost savings for coaJ $50ton

26---------- Cumulative Incremental capital plus OampM costs

24

22 -

18 -0

W- Cumulative net benefit for shae vs coal $50ton 2B Cumulative net benefit for shale vs coal $70ton

co16C -

14 -

12 -

10 -

09

06 -Payout inyear 1

Payout Inyear 9 for coal $50ton - -- - - -shy

02 0 I

0 1 2 3 4 5 Nowl Yewr in which sauings in fWe colsacm-ewi tat hsawinitl

ca=al wosaand OampM costs

6

_iiM

7 8

9 10

------ - -amp -

11 12 13 14Year of Operation

--

15

- - --shy

16 17

I

18

1

19

I

20

I

21

I

22

I

23

I

24 25

Prefeasibility StudyOil Shale Fueled Power Generation

17958d351aJordanr 3-14-89 rsO

118

Comparison of Cumuiative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

28 Pay Out Year shy

400 MW Plant Oil Shale vs Imported Coal (5050 debtequity)

26shy2

24-

Cumulaive fuel nst savings for coal 0 $70ton Cumulative fuel cost savings for coal $50ton Cumulative Incremental capital plus OampM corts

22 -

20 -

18 -- Cumuladve net benefit for shle vs coal $50ton B Cumuarve net benefit for sale vs coal $70ton

16 -

C 14

12

10

08 -06 - Payout In year 1for coal $50ton

04

Payout Inyear 1

for coal $70ton02~

0 0

-No

02-

1 2

Yew inrY MCM cajlaI rl

3 4 5 6

sngm inW coas 0 ort hghWcentWin

0tOM cori

7

--

8

- -

9 10 11 12 13 14

Year of Operation

15 16 17

I

18

IIII

19 20 21 22 23 24 25

Preieasibility Study Oil Shale Fueled Power Generation

17958451 bJordarV118 3-14-89 rsipcI

Estimated Cost of Power- 400 MW (4 x 100)

FUEL

ImportedCoal

$50T

$70fT

1st Year

68 88

Levelized

78 107

Sultani Oil Shale

71 83

ImportedOil

$1713

$2413

56

67

76

96

0 10 20 30 40 50

I 60

I 70

I 80

I 90 100 110 120

Mills per kWh

Prefeasibility Study Oil Shale Fueled Power Generation

179581251 cJordarVl 18 3-14-89 rspc1

Summary Financial Analysis Results

Project size

Debt equity ratio

- Investment cost

- Power cost

- 25-year net benefit

- Project implementation

Alternative fuel price

Economic Comparison

Very significant

Not significant

Not significant

Very significant

Critical

Very significant

Prefeasibility Study

Oil Shale Fueled Power Generation

VY0 tDLUAi3

i

Study Conclusions

Feasibility

Timeliness

Expansion conditions

Environmental impacts

Development advantages

Prefeasibility Study

Oil Shale Fueled Power Generation VW41-1AiUA

4

Feasibility

Oil shale fueled power generation is technically and economically justifiedunder certain conditions

N Need for additional generating capacity

exists

- 6 annual peak demand growth - Orderly retirement of olderhigh cost

generating capacity needed

U Higher costs are expected for imported fuels

- 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

-OP b i j~~4shy

-4protntiYPe 4 demo plnt orP42 t~Plant orPootypeProje(-7hould

that Rj

demo 4Therefore-44 JEA anxinus

the

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

27Pag 4- 1 2S c i n 4 4

4i2Sectjo4-18-4 Secio 4-4 014

lt th~ae hi4h -tasisso syste thrug27 ~ 04lag arstl~art-p tasforme ed 2p27132Kvdieanwhy notthroug

EAto- is protmm~~ thegnJgt~~ pracie an ect ~ platqrby

28Pg 4 s heonnenotedto~the 32K rc powr

It not8 Scection rie049teoervnrain prctc de1

rh u n trae f2V3K anerd not throughgeterAntor

27 P3e-1r p ant weung-a

-If I

2tEll10 DRWE-jOi ASOt Mint~~al d~c~e o hepwrgnrto

ELCTRInYJORD UTHORITY-

Ate~

21Pge41 ection 4 04- 5

sindicated~ t hthigh the unit outputredu f hecondenser Injengtd~ibbvePressureed incg desrin hi h riseb vmbi nt emperatureWe bel~ieve

PleaIse provide us with th rscrapcity for th-e three options n nt generating~

21-Iisidca ted that~ thediaatgeofCBi theSheavy fn oe consumnptionPlease~ providethe us withpecntgA

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

400 MW COAL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO 5050

NET GENERATION - MWe 40000 CAPACITY FACTOR - 75 ANNUAL GENERATION MKWhYR 2628 SUB TOTAL PLANT COSTS (TPC) $1000 $620000

FIXED 0 amp M COSTS MH $ MH FIRST YEAR COST$1O00

------- --------- --- ---- --- --- ------------

OPERATING LABOR 351936 $3 $1100 MAINTENANCE LABOR 4000 of 150 OF TPC 3720

MAINTENANCE MATERIAL 6000

ADMIN LABOR of 150

3000 OF TPC

OF 0 amp M LABOR 5580 1446

SUB TOTAL FIXED OampM COSTS $11846

VARIABLE 0 amp M COSTS QUANTITY UNIT COST

VARIABLE MAINTENANCE 2628 MKWh 10 MILLKWH $ 2628 PROCESS WATER 13500000 GALLON 02 SGAL $ 2700 GENERAL PLANT CHEMICALS ALLOW 50 FUEL OIL 1000000 GALLON 035 $GAL $ 350 WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290SPECIAL BOILER MAINT ALLOW 0

SUB TOTAL VARIABLE OampM COSTS $ 8018

TOTAL FIXED amp VARIABLE OampM COSTS $19864 TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $8227 $TN $99139

(INCL INFLATION ADJUSTMENT)

B DEBT EQUITY RATIO =========== 8020

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $17574

WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290

TOTAL FIXED amp VARIABLE OampM COSTS $19864TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $5877 $TN $70814

(INCL INFLATION ADJUSTMENT)

6-21

Table 612 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY

400 MW OIL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO

NET GENERATION -

CAPACITY FACTOR -

ANNUAL GENERATION SUB TOTAL PLANT COSTS (TPC)

FIXED 0 amp M COSTS

OPERATING LABOR MAINTENANCE LABOR 4000 of

MAINTENANCE MATERIAL 6000 of

ADMIN LABOR

SUB TOTAL FIXED OampM COSTS

VARIABLE 0 amp M COSTS

VARIABLE MAINTENANCE PROCESS WATER GENERAL PLANT CHEMICALS FUEL OIL WASTE DISPOSAL (Section 6027) SPECIAL BOILER MAINT

SUB TOTAL VARIABLE OampM COSTS

5050

MWe

MKWhYR $1000

MH

262080

150

150 3000

QUANTITY

2628 MKWh 13500000 GALLON

1000000 GALLON 0 TNYR

TOTAL FIXED amp VARIABLE OampM COSTS FUEL OIL 503000 TNYR

B DEBT EQUITY RATIO =8020

40000 75

268 $443000

FIRST YEAR $ MH COST$1O00

$3 $ 800

OF TPC 2658

OF TPC 3987 OF 0 amp M LABOR 1037

$ 8482

UNIT COST

05 MILLKWH $ 1314 02 $GAL $ 2700

ALLOW 50 035 $GAL $ 350

$1000 $TN $ 0 ALLOW 0

$ 4414

$12896 $19981 $TN $100502

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $12896

WASTE DISPOSAL (Section 6027) 0 TNYR $1000 $TN $ 0

TOTAL FIXED amp VARIABLE OampM COSTS $12896 FUEL OIL 503000 TNYR $14104 $TN $70943

6-23

Page 8: fo; - pdf.usaid.gov

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

Pilot Plant Test Program (Contd)

U Analyzed one blended sample of shale

- Calorific value = 532 - 597 MJkg (approx 2250 BtuIlb)

- Carbon content (dry solids) = 162 - 187 wto

- Sulfur content (dry solids) = 30 - 33 wt

- Ash content (dry solids) = 667 - 684 wt

- Shale size = minus 8 mm

Key items determined

- Combustion efficiency

- Product ash distribution

- Product gas S02NOxCO content

- Data for boiler design

- Sulfur emissions reduction by Ca in fuel

S Prefeasibility Study Oil Shale Fueled Power Generation

VOO74GEAJI 10

Pilot Plant Test Results

U Combustion efficiency exceeded 985 in all tests

Ash distribution (btm ashfly ash) was 3565 to 4753 at 100 load typically4060

Low emissions were demonstrated

Typically S02 10 to 200 ppm gt 95 removal

limestone addition not required

NOx 60 to 120 ppm lt 020 lb106 Btu

Co 10 to 90 ppm lt 50 ppm

Prefeasibility Study Oi Shale Fueled Power Generation

TITLE

Ternpe -al-CuA vs 6 Ik

00

I00

7SA-A-

Fly Ai h

0

85 e

80-

0

00

i I 800 860 oo

T-er pe -

DATE OWN APPD DCNO- ------ -

_______f - _ IPG_

Pilot Plant Test Conclusions

It is technically feasible to burn the Sultani oil shale furnished by NRA in a Pyropower boiler

A high combustion efficiency in excess of 985 was demonstrated

SO2NOxCO emissions are all acceptably low with no limestone addition required

Prefeasibility StudyO Shale Fueled Power Generation

Conceptual Design Studies Scope

m Three project sizes

- 20 MW

- 50 MW

- 400 MW (4x100) factored for power plant portion

m Open-pit mine

- Shale processing at the surface - Waste disposal system

Power block

- Boiler

- Steam turbine

- Auxiliaries

Prefeasibility Study Oil Shale Fueled Power Generation

VOn 4FAIR 1

i

Project Layout 9 fc =f4j

deg2

o r -w (031

5_7EC 45U

iPefeaibiity tud

OlSeFuedP erGr in

179581113i~o(atyvv11

n1- 14 4pc

C)

Sultani Oil Shale Reserves

North South Area Area Total

Mineable shale tonne x 106 320 658 978

Fischer assay oil content wt 744 761 765

Overburden m3 x 106 384 627 1011

Stripping ratio m3m3 2161 1711 1861

bull Based on NRA core drilling and core analysis

Prefeasibility Study Oil Shale Fueled Power Generation

VWO41OFEAMI14

i

Sultani Oil Shale Analyses

Moisture

Ash (less CO 2 in CaCO 3 )

CO 2 (in CaCO 3 )

Carbon (organic)

Hydrogen

Nitrogen

Sulfur

Oxygen (by diff)

Total

High heating value BtuIb

Fischer assay oil content

bull Percent by weight

Design Basis Fuel

320

6680

1387

1132

113

048

255

065

10000

2250

840

Low High Calorific Calorific

Value Fuel Value Fuel

320 320

6730 6625

1414 1337

1020 1250

102 125

058 038

238 271

118 034

10000 10000

2000 2500

750 925

Preteasibility Study Oil Shale Fueled Power Generation

vo0N d-GEAR 1S

50 MW Oil Shale ProcessingPrototype Plant

Mlne Plant

_ 14 0 Haul0___) to Plant 1 Sorage

Portable Crusher

(-)100 mm Storage

(-) 100 mm Hopper UIU 400 th

Feed Bin

J 50

250 tvb

8 -m Circulating Load Impact3or0 0 30 0 0shy+8mm25

30 0L Sampler 0 1 30 0

p3 Day Storage

To Power Plant

Preleasibility StudyOil Shale Fueled Power Generation

17958101 SaJordanli 18 3-14-89 rsipc1

20 MW Oil Shale Demonstration Plant

Mine Plant

Haul00- 01 o

= Pb n Storage Portable _

110 mm Stora e 0

()100 mm r Hopper

U 400V

Feed Bin

CirculatingLoad3 Day Stoge

Prefea~ltSudy Shale Fueled Power Generation

179S 111p 1 11Joda3 yl 3-202-89 8vk2

I

Mine and Shale ProcessingDesign - 2050 MW Project

I Overburden removal (north pit area) 10-meter benches

- Drill and blast

- 10 m3 front-end loader

- 77-ton truck haulage

I Oil shale mining 10-meter benches

- Rippe and auger scraper

- Front-end loader

- Portable in-pit crusher

- 77-ton truck haulage

Oil shale processing

- Feed = minus 100 mm

- Product = minus 8 mm

- Capacity = 250 tph

- Reversible impactor

- Two vibrating screens

1 Prefeasibility Study Oil Shale Fueled Power Generation

V -M 1AMI1ARt46

400 MW Full-Scale Oil Shale ProcessingPlant

Feed MTnus 200 mm Samplerr

1000 bull 10000 Tonnes Live Storage Grade

200 m long(-) 200 mm -- =-- Plow Feeders

00 h 100000 Tonnes Live Storage

Stream 3 - Sampler Bin Stream 2

Stream th 31Da2000

Circulating Load 2i

NFw Feed r -17000t1 170001l 170 t 17000 t 17000 t

1000 th Silo with 7 Impactor (-1)8 mm Reapro- 3 Day Storage at Aver age Loadn

0 20 Feeders 20 m Diameter by 40 m High

JJJTHT To Power Plant

Prefeasibility Study Oil Shale Fueled Power Generation

179589 6aJordarV 1I8 3-14-89 rsipc1

Mine and Shale ProcessingDesign - 4x100 MW Project

m Overburden removal (north area) 10-meter benches

- Drill and blast

- Three 20 m3 shovels

- 136-ton truck haulage

m Oil shale mining 10-meter benches

- Two mechanical surface miners

- 136-ton trucks to pit hopper

- Belt conveyor = 2000 tph

- Traveling stacker

m Oil shale processing

- Feed = minus 200 mm

- Product = minus 8 mm

- Capacity = three 1000 tph units

Prefeasibility Study Oil Shale Fueled Power Generation

VOO79-ampGEAIAt 17

i

Steady-State Production Schedule

Overburden removal bench m3

20 MW demo project 5n MW prototype 4x100 MW full-scale plant

Oil shale mining and shale processing tonnes

20 MW project 50 MW project 4x100 MW project

HourlyDesign Capacity

282 234

1850

HourlyDesign Capacity

250 250

2000

Avg Daily Annual PEQuctiQa Production

1690 507000 4217 13 million

33333 10 million

Max Daily(a) Annual(b) Production Production

1733 390000 4324 973000

34578 78 million

(a) Based on 100 operating factor for power block

(b) Based on 75 operating factor for power block ( 20 MW project = 300 shiftsyr 50 MW project = 900 shiftsyr 400 MW project = 900 shiftsyr)

Prefeasibility Study Oil Shale Fueled Power Generation

Conceptual Power Plant Plans

m Pyroflow boiler

Power generating facilities

m Auxiliaries

S Preleasibility Study Oil ShaJe Fueled Power Generation

vo0o7dEAO 19

Pyroflow Boiler SteamConciflons

Flow rate 226700 kghr (500000 Ibhr)

Pressure 1099 kgcm2 abs (15635 psia)

Temperature 51280C (9550F)

Same for 20 50 and 100 MW designs

Prefeasibility Study Oil ShaJe Fueled Power Generation

vooGALMI 20

HtomCOPUIOTP

- 50005 5op

-- LEVAThUM ORPORAION

0

-VI

DZ 4

Power Block

Fuel handling system

- Day binsscrew feeders

Boiler

- Pyroflow circulating fluid bed combustor

Power generation

- Non reheat condensing steam turbine

- Conventional Rankin steam cycle

Ash handling system (btm ash irom combustor and flyash from bag house)

- Wetted in pug mill to add 20plusmn wt wpter

Plant service water

- Air-cooled condensors and small cooling tower from circulating trim water coolers

Plant raw water

- To cooling tower makeup

- To drinking water system

- To pump seals etc

Plant treated makeup water

- Demineralizer train

Preteasibility Study Oil Shale Fueled Power Generation

i

Onsite Infrastructure

Project office

Control house

U Maintenance shops warehouse

Laboratory

Employee service facility

Site developmentoperations service facilities

- Fire controlsecurity

- Communications

- Lighting

- Roads drainage and sewage

Prefeasibility StudyQ1I Shale Fueled Power Generation

voo4JG m 0 JV

i

BechtellPyropower50 MW Cogeneration Plant - Mt Poso California

W4t Prefeasibility Study --- 7 Oil Shale Fueled Power Generation

179586122aJordarv 118 3-14-89 rsO

Characteristics of Three Size Operations

Oil shale fuel tpy

Mine development excavation bank m3

Spent ash disposal tpy (wetted)

Water consumption 1000 m3yr

Staffing required

Community population

400 MW

20 MW 50 MW (4x1 00)

390000 973000 78 million

500000 1 million 85 million

327000 815000 61 million

538 907 1263

185 324 1046

700 1200 4000

Prefeasibility Study Oil Shale Fueled Power Generation

V000ofllAM1 23

Conceptual Designs Summary

N All BOP facilities involve conventional equipment and technology

100 MW unit operation involves boiler scale-up considerations

N Water consumption estimates

- Requirement for 4x100 MW project is 13 million m3 yr

- Water allocation of 2 million m3yr of water supports 6x100 MW

N Water availability probably limits total power generation from oil shale in Jordan

Prefeasibility Study Oil Shale Fueled Power Generation

V007041GEAOLMI

i

TECHNOLOGY RISK ASSESSMENT

Basic concepts

Key boiler scale-up design issues

Impact of scale-up

U Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Prefeasibility Study O1 Shale Fueled Power Generation

VOOh-7AEAAO 2

Basic Concepts

U CFBC is relatively new in the powerindustry

- Existing plants are small typically 20 to 50 MW

- There is limited operating experience with high-ash fuels

- Existing designs for lignite biomass and coal wastes show good plant performance

I Application of CFBC boiler design to oil shale fuel has defined risk that relates to scale-up of existing design

Similar CFBC technology is used in petroleum refining industry

- FCC cracking plant regenerators burn carbon residue off spent catalyst

- 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

FUEL ANALYSES

High Ash Fuel Projects Total Solids Input Basis

Gilberton Cambria North Branch

Carbon 4653 2749 1822 Hydrogen 153 164 160 Sulfur 073 222 234 Nitrogen 085 051 043 Oxygen 282 218 468 Moisture 1451 514 557 Ash 3303 6 0 6Z16

10000 10000 10000

HHVBtulb 7485 4809 3453

includes limestone feed a3 ash

includes CO2 in Ca~o3

CA89029 CAkw

Oil Shale

1132

113

255

048

065

320

-8062

10000

2250

Key Boiler Scale-Up DesignIssues

m Solids handling

- Feeding shale to combustor

- 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

Voo4tGEAMI 30

i

Mine and Shale Processing

U Fugitive dust emissions are controllable

- Wetting mine roads

- Enclose crushing plant equipment

Noise levels are controllable

- Enclose crushing plant equipment - Muffle truck exhausts

- Engineered waste disposal

Water effluents can be controlled

- Need good mine drainage design - Continue leachability studies on

waste dump piles

Prefeasibilily StudyOil Shale Fueled Po r Generaton

V0079OOG-4O 31

1

Power Plant

II Fugitive dust emissions are controllable

- Baghouse designoperation will minimize particulates in flue gas

- Wetting spent ash before disposal

N Gaseous emissions are controllable

- Pilot test results show acceptable SO2NOxCO in flue gas

- Develop baseline data for Sultani area

Develop air dispersion model for Sultani

Prefeasibility StudyOil Shale Fueled Power Generatio

V00 V-4GEA l32

i

Power Plant (Contd)

Noise levels are controllable

- Enclose boiler plant fans as required - Enclose turbines and pumps as

required

Water effluents are controllable

- Continue leachability studies on spent ash disposal

- Develop aquifer dispersion model

- Develop sewage and garbage disposal plan

Prefeasibility SludyOil Shale Fueled Power Generation

V00-4FAAI 33

Conclusions

No environmental constraints are anticipated on oil shale powerdevelopment

Gas effluents will meet World Bank standards

- Ash disposal is manageable

- The potential for groundwatercontamination appears low

- Water effluents will be minimal

Continued studies to develop air and groundwater baseline data are recommended

S Prefeasibility Study Oil Shale Fueled Power Generation

v0 9ampGLAMR 34

Power Demand vs SupplyAssessment

m Demand growth forecasts

Electrical generating capacity

= Power supply forecasts

= Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Preleasibility Study Oil Shaie Fuelod Power Generation

VO9- uLIROI

1

Power Demand Forecasts

Percent Annual Growth

JEA

Meta systems HaglerBailey and Bechtel National Inc

JEA Peak Demand Growth

1980 (actual) 1985 (actual) 1987 (actual) 1995 (forecast) 2005 (forecast)

1986 1990 to to

1990 2000

97 60

49 39

200 MW 475 MW 593 MW 900 MW

1400 MW

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOO-DLURO2

i

JEA ElectricityGeneratingCapacity

1987 Installed

Capacity (MW) Aqaba 260

22

Zarqa 395

Marka 102

Karak 23

Miscellaneous 67

Subtotal JEA capacity 869

Other capacity - industrial 110

Total 979

Prefeasibility Study Oi1 Shale Fueled Power Generation

V000-6O0LFJRO3 (

Forecast New Power Generating Capacity Required

Fcst 1987 Required

New Peak Available Installed

Demand Capacity Shortfall (a) Capacity (b) (MM (MW) (MW) (MW)

Assumed capacityfactor (65) (75)

1995 requirement 900 636 264 352

2005 requirement 1400 636 764 1019

(a) Excludes proposed additions and retirements (b) Excludes possible power exports or imports

Load shedding or levelizing not considered

Preteasibility Study Oil Shale Fueled Power Generation

Vflcmf-R)LLAO4

i

Supply vs Demand Evaluation

1800

1600

1400 Forecast Peak Demands

1200 -

E Installed Capacity

0 800shy75--

U) Assumed Available Calcit

a 6 Ao600 shy0 o 65

400 shy

200

I I I I I I I I I I I I I I I I I I I I I I I 1 1 1980 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958f738aIJordarV 118 3-14-89 rspCO

Conclusions

Additional power generating capacity is needed to meet forecasted 19952005demand growth

A 400 MW oil shale-to-power project at Sultani can meet a portion of this need

U A second 400 MW oil shale project maybe required if water is available

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOW0O-8LURO5

i

Economic Feasibility

N Order-of-magnitude costs

N Economic analysis

- Jordan study options

- Project size effect

m Comparison with alternative fuels

- Fuel requirement

- Project financing effect

- Alternate fuel price effect

- Estimated cost of electricity

N Summary financial analysis

bull Material was developed by Bechtel Power Company

Prefeasibility Study

go Oil Shale Fueled Power Generation VOOSO-ampDtJROh

ORDER-OF-MAGNITUDE COSTS

U Oil shale fuel

Power plant

I Integrated project- busbar

Preteasibility Study

Oil Shale Fueled Power Generation

VOO9O-ampDLUROS

Oil Shale Fuel Costs

Installed Capital Cost

Mine Development

Mine Equipment

Processing Plant

Spare Parts

Working Capital

Capitalized Interest

Total

Annual Operating Cost

Fuel Cost $UStonne

bull Based on 8020 debtequity ratio

20 MW

4900

11090

6945

1200

1200

4054

29389

5582

1431

US $1000 Factored

50 MW 4x100 MW

7833 30915

12202 66012

8388 50889

1300 5000

2200 10000

5108 39075

37031 201891

11556 53236

1188 684

Prefeasibility Study

Oil Shale Fueled Power Generation

VCO-ampDLUJ1O

Power Plant Costs

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Cost

Power faciities 57500 91800 567800

Owners cost 10200 20400 192700

Total 67700 112200 760500

Annual Operating Cost 2205 3248 17157(excluding fuel cost)

bullBased on 8020 debtequity ratio oil shale fueled

Prefeasibility Study

Oil Shale Fueled Power Generation

V00O8c4LLMO9

i

INTEGRATED PROJECT -BUSBAR COST

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Costs Mine amp shale processingPower block Waste disposal Infrastructure

29359 67700

1664 10000

37031 112200

2381 15000

201891 760500

8714 45000

TOTAL 108753 166612 1016105

Annual Operating Cost Mine amp shale processingPower block Waste disposal Infrastructure (a)

5582 2205

316

11556 3248

710

56430(b) 18186(b) 6004

Subtotal 8103 15514 80620

Capital Charges 139 9410 15596 106000

Total 17513 31110 186620

25-year levelized cost - - 218000

Busbar Cost millskWh First year 128 92 71 25-year levelized 83

(a) Housing and community facilities assumed self-liquidating(b) Includes first-year inflation adjustment

Based on 8020 debtequity ratio

Prefeasibility StudyOil Shale Fueled Power Generaion

VOOOO-8MLtROi0

ECONOMIC ANALYSIS

n Jordan study options

Project size effect

Fuel requirement

Project financing effect

Alternative fuel price effect

Estimated electricity cost

Summary financial analysis results

Prefeasibility Study

Oil Shale Fueled Powr Generation

VOOeO-BOCLLO1 I

i

Jordan Study Options

U Project size

- Demonstration = 20 MW

- Prototype = 50 MW

- Commercial = 400 MW (4x100)

Project financing

- Debtequity 8020

- Debtequity 5050

Imported alternative fuels cost assumptions

A B Crude oil $17bbl $24bbl

$120onne $170tonne

Low sulfur coal $ 50tonne $ 70tonne See Chevron forecast supporting assumptions

Prefeasibility StudyOil Shale Fueled Power Generation

VOOOO-8DLIJRO12

i

Crude Oil Price Trends

60

Source World Energy Outlook Chevron Corporation Oclober 1987

40

High trend

No Ir 20 ~~~~Arabian Light Spot I A u

IILowYUII trend

0 1970 1975 1980 1985 1990 1995

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958246aJodar 118 3-14-89 rsO

2000

Project Size Effect Shale Fuel Option

Project Size

Integrated facilities installed capital cost$ US million

Shale cost $UStonne(8020 debtequity)

Cost of power millskWh(8020 debtequity ratio)

20 MW

109

143

128

50 MW

167

118

92

400 MW (4x1 00)

1016

68

71

Prefeasibility Study Oil Sampae Fueled Power Generation

VOO O-8I0LJRO13

gt1

1

Power Block Investment Cost

3000

$2875 Excluding mining and offsite 2800

2600

2400

2200

2000

$1836 1800

$1613 1600

$1420 1400 1I 1 I

0 100 200 300 400 MWe

August 1988

Preleasibility Study OilShale Fueled Power Generation

179581147aJodar1 18 3-14-89 rspcl

Fuel Requirement - 4x100 MW Project

Coal = 12 million tpy

n Oil = 503000 tpy

Oil shale = 78 million tpy

Preleasibility Study

Oil Shale Fueled Power Generation

IO060-OLLIRO14

Financing Effect -Project

Oil Shale Fuel Option

Mine and shale processing

Power block

Waste disposal

Community facilities

Total

Coal-Fired Power Plant

Oil-Fired Power Plant

400 MW

Capital Cost ($US MM)

DebtEquity

8020 5050

202 187

760 760

9 8

45 45

1016 1000

647 647

463 463

Prefeasibility StudyOil Shale Fueled Power Generation

VOe-BD1JRO15

Financing Effect shy400 MW Project

Operating Costs ($US millionyr)

DebtEquity

8020 5050

Coal $70tonne 282 282

Oil $24bbl 254 254

Oil shale-fueled 218 236

Including fuel

Prefeasibility Study

SOil Shale Fueled Power Generaion

VOOIt JLMO I

Alternate Fuel Price Effect shy4x100 MW Project

Financing Basis DebtEquity Ratio

Alternate Fuel Price

Imported coal $50tonne $70tonne

Imported oil $17bbl ($120tonne) $24bbl ($170tonne)

Cumulative 25-yr Net Benefit

Favoring Oil Shale (US $MM) shy

8020 5050

778 315 2531 2068

(18) (506)1810 1322

Prefeasibility Study

Oil Shale Fueled Power Generation

Voo -I DLU-A 2

i

Comparison of Cumulative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

32 Pay Out Year shy

400 MW PlantOil Shale vs Imported Coal (8020 debtequty)

30

28 -Cumulative fuel cost savings forcoal $70ton

Cumulative fuel cost savings for coaJ $50ton

26---------- Cumulative Incremental capital plus OampM costs

24

22 -

18 -0

W- Cumulative net benefit for shae vs coal $50ton 2B Cumulative net benefit for shale vs coal $70ton

co16C -

14 -

12 -

10 -

09

06 -Payout inyear 1

Payout Inyear 9 for coal $50ton - -- - - -shy

02 0 I

0 1 2 3 4 5 Nowl Yewr in which sauings in fWe colsacm-ewi tat hsawinitl

ca=al wosaand OampM costs

6

_iiM

7 8

9 10

------ - -amp -

11 12 13 14Year of Operation

--

15

- - --shy

16 17

I

18

1

19

I

20

I

21

I

22

I

23

I

24 25

Prefeasibility StudyOil Shale Fueled Power Generation

17958d351aJordanr 3-14-89 rsO

118

Comparison of Cumuiative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

28 Pay Out Year shy

400 MW Plant Oil Shale vs Imported Coal (5050 debtequity)

26shy2

24-

Cumulaive fuel nst savings for coal 0 $70ton Cumulative fuel cost savings for coal $50ton Cumulative Incremental capital plus OampM corts

22 -

20 -

18 -- Cumuladve net benefit for shle vs coal $50ton B Cumuarve net benefit for sale vs coal $70ton

16 -

C 14

12

10

08 -06 - Payout In year 1for coal $50ton

04

Payout Inyear 1

for coal $70ton02~

0 0

-No

02-

1 2

Yew inrY MCM cajlaI rl

3 4 5 6

sngm inW coas 0 ort hghWcentWin

0tOM cori

7

--

8

- -

9 10 11 12 13 14

Year of Operation

15 16 17

I

18

IIII

19 20 21 22 23 24 25

Preieasibility Study Oil Shale Fueled Power Generation

17958451 bJordarV118 3-14-89 rsipcI

Estimated Cost of Power- 400 MW (4 x 100)

FUEL

ImportedCoal

$50T

$70fT

1st Year

68 88

Levelized

78 107

Sultani Oil Shale

71 83

ImportedOil

$1713

$2413

56

67

76

96

0 10 20 30 40 50

I 60

I 70

I 80

I 90 100 110 120

Mills per kWh

Prefeasibility Study Oil Shale Fueled Power Generation

179581251 cJordarVl 18 3-14-89 rspc1

Summary Financial Analysis Results

Project size

Debt equity ratio

- Investment cost

- Power cost

- 25-year net benefit

- Project implementation

Alternative fuel price

Economic Comparison

Very significant

Not significant

Not significant

Very significant

Critical

Very significant

Prefeasibility Study

Oil Shale Fueled Power Generation

VY0 tDLUAi3

i

Study Conclusions

Feasibility

Timeliness

Expansion conditions

Environmental impacts

Development advantages

Prefeasibility Study

Oil Shale Fueled Power Generation VW41-1AiUA

4

Feasibility

Oil shale fueled power generation is technically and economically justifiedunder certain conditions

N Need for additional generating capacity

exists

- 6 annual peak demand growth - Orderly retirement of olderhigh cost

generating capacity needed

U Higher costs are expected for imported fuels

- 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

-OP b i j~~4shy

-4protntiYPe 4 demo plnt orP42 t~Plant orPootypeProje(-7hould

that Rj

demo 4Therefore-44 JEA anxinus

the

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

27Pag 4- 1 2S c i n 4 4

4i2Sectjo4-18-4 Secio 4-4 014

lt th~ae hi4h -tasisso syste thrug27 ~ 04lag arstl~art-p tasforme ed 2p27132Kvdieanwhy notthroug

EAto- is protmm~~ thegnJgt~~ pracie an ect ~ platqrby

28Pg 4 s heonnenotedto~the 32K rc powr

It not8 Scection rie049teoervnrain prctc de1

rh u n trae f2V3K anerd not throughgeterAntor

27 P3e-1r p ant weung-a

-If I

2tEll10 DRWE-jOi ASOt Mint~~al d~c~e o hepwrgnrto

ELCTRInYJORD UTHORITY-

Ate~

21Pge41 ection 4 04- 5

sindicated~ t hthigh the unit outputredu f hecondenser Injengtd~ibbvePressureed incg desrin hi h riseb vmbi nt emperatureWe bel~ieve

PleaIse provide us with th rscrapcity for th-e three options n nt generating~

21-Iisidca ted that~ thediaatgeofCBi theSheavy fn oe consumnptionPlease~ providethe us withpecntgA

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

400 MW COAL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO 5050

NET GENERATION - MWe 40000 CAPACITY FACTOR - 75 ANNUAL GENERATION MKWhYR 2628 SUB TOTAL PLANT COSTS (TPC) $1000 $620000

FIXED 0 amp M COSTS MH $ MH FIRST YEAR COST$1O00

------- --------- --- ---- --- --- ------------

OPERATING LABOR 351936 $3 $1100 MAINTENANCE LABOR 4000 of 150 OF TPC 3720

MAINTENANCE MATERIAL 6000

ADMIN LABOR of 150

3000 OF TPC

OF 0 amp M LABOR 5580 1446

SUB TOTAL FIXED OampM COSTS $11846

VARIABLE 0 amp M COSTS QUANTITY UNIT COST

VARIABLE MAINTENANCE 2628 MKWh 10 MILLKWH $ 2628 PROCESS WATER 13500000 GALLON 02 SGAL $ 2700 GENERAL PLANT CHEMICALS ALLOW 50 FUEL OIL 1000000 GALLON 035 $GAL $ 350 WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290SPECIAL BOILER MAINT ALLOW 0

SUB TOTAL VARIABLE OampM COSTS $ 8018

TOTAL FIXED amp VARIABLE OampM COSTS $19864 TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $8227 $TN $99139

(INCL INFLATION ADJUSTMENT)

B DEBT EQUITY RATIO =========== 8020

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $17574

WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290

TOTAL FIXED amp VARIABLE OampM COSTS $19864TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $5877 $TN $70814

(INCL INFLATION ADJUSTMENT)

6-21

Table 612 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY

400 MW OIL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO

NET GENERATION -

CAPACITY FACTOR -

ANNUAL GENERATION SUB TOTAL PLANT COSTS (TPC)

FIXED 0 amp M COSTS

OPERATING LABOR MAINTENANCE LABOR 4000 of

MAINTENANCE MATERIAL 6000 of

ADMIN LABOR

SUB TOTAL FIXED OampM COSTS

VARIABLE 0 amp M COSTS

VARIABLE MAINTENANCE PROCESS WATER GENERAL PLANT CHEMICALS FUEL OIL WASTE DISPOSAL (Section 6027) SPECIAL BOILER MAINT

SUB TOTAL VARIABLE OampM COSTS

5050

MWe

MKWhYR $1000

MH

262080

150

150 3000

QUANTITY

2628 MKWh 13500000 GALLON

1000000 GALLON 0 TNYR

TOTAL FIXED amp VARIABLE OampM COSTS FUEL OIL 503000 TNYR

B DEBT EQUITY RATIO =8020

40000 75

268 $443000

FIRST YEAR $ MH COST$1O00

$3 $ 800

OF TPC 2658

OF TPC 3987 OF 0 amp M LABOR 1037

$ 8482

UNIT COST

05 MILLKWH $ 1314 02 $GAL $ 2700

ALLOW 50 035 $GAL $ 350

$1000 $TN $ 0 ALLOW 0

$ 4414

$12896 $19981 $TN $100502

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $12896

WASTE DISPOSAL (Section 6027) 0 TNYR $1000 $TN $ 0

TOTAL FIXED amp VARIABLE OampM COSTS $12896 FUEL OIL 503000 TNYR $14104 $TN $70943

6-23

Page 9: fo; - pdf.usaid.gov

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

Pilot Plant Test Program (Contd)

U Analyzed one blended sample of shale

- Calorific value = 532 - 597 MJkg (approx 2250 BtuIlb)

- Carbon content (dry solids) = 162 - 187 wto

- Sulfur content (dry solids) = 30 - 33 wt

- Ash content (dry solids) = 667 - 684 wt

- Shale size = minus 8 mm

Key items determined

- Combustion efficiency

- Product ash distribution

- Product gas S02NOxCO content

- Data for boiler design

- Sulfur emissions reduction by Ca in fuel

S Prefeasibility Study Oil Shale Fueled Power Generation

VOO74GEAJI 10

Pilot Plant Test Results

U Combustion efficiency exceeded 985 in all tests

Ash distribution (btm ashfly ash) was 3565 to 4753 at 100 load typically4060

Low emissions were demonstrated

Typically S02 10 to 200 ppm gt 95 removal

limestone addition not required

NOx 60 to 120 ppm lt 020 lb106 Btu

Co 10 to 90 ppm lt 50 ppm

Prefeasibility Study Oi Shale Fueled Power Generation

TITLE

Ternpe -al-CuA vs 6 Ik

00

I00

7SA-A-

Fly Ai h

0

85 e

80-

0

00

i I 800 860 oo

T-er pe -

DATE OWN APPD DCNO- ------ -

_______f - _ IPG_

Pilot Plant Test Conclusions

It is technically feasible to burn the Sultani oil shale furnished by NRA in a Pyropower boiler

A high combustion efficiency in excess of 985 was demonstrated

SO2NOxCO emissions are all acceptably low with no limestone addition required

Prefeasibility StudyO Shale Fueled Power Generation

Conceptual Design Studies Scope

m Three project sizes

- 20 MW

- 50 MW

- 400 MW (4x100) factored for power plant portion

m Open-pit mine

- Shale processing at the surface - Waste disposal system

Power block

- Boiler

- Steam turbine

- Auxiliaries

Prefeasibility Study Oil Shale Fueled Power Generation

VOn 4FAIR 1

i

Project Layout 9 fc =f4j

deg2

o r -w (031

5_7EC 45U

iPefeaibiity tud

OlSeFuedP erGr in

179581113i~o(atyvv11

n1- 14 4pc

C)

Sultani Oil Shale Reserves

North South Area Area Total

Mineable shale tonne x 106 320 658 978

Fischer assay oil content wt 744 761 765

Overburden m3 x 106 384 627 1011

Stripping ratio m3m3 2161 1711 1861

bull Based on NRA core drilling and core analysis

Prefeasibility Study Oil Shale Fueled Power Generation

VWO41OFEAMI14

i

Sultani Oil Shale Analyses

Moisture

Ash (less CO 2 in CaCO 3 )

CO 2 (in CaCO 3 )

Carbon (organic)

Hydrogen

Nitrogen

Sulfur

Oxygen (by diff)

Total

High heating value BtuIb

Fischer assay oil content

bull Percent by weight

Design Basis Fuel

320

6680

1387

1132

113

048

255

065

10000

2250

840

Low High Calorific Calorific

Value Fuel Value Fuel

320 320

6730 6625

1414 1337

1020 1250

102 125

058 038

238 271

118 034

10000 10000

2000 2500

750 925

Preteasibility Study Oil Shale Fueled Power Generation

vo0N d-GEAR 1S

50 MW Oil Shale ProcessingPrototype Plant

Mlne Plant

_ 14 0 Haul0___) to Plant 1 Sorage

Portable Crusher

(-)100 mm Storage

(-) 100 mm Hopper UIU 400 th

Feed Bin

J 50

250 tvb

8 -m Circulating Load Impact3or0 0 30 0 0shy+8mm25

30 0L Sampler 0 1 30 0

p3 Day Storage

To Power Plant

Preleasibility StudyOil Shale Fueled Power Generation

17958101 SaJordanli 18 3-14-89 rsipc1

20 MW Oil Shale Demonstration Plant

Mine Plant

Haul00- 01 o

= Pb n Storage Portable _

110 mm Stora e 0

()100 mm r Hopper

U 400V

Feed Bin

CirculatingLoad3 Day Stoge

Prefea~ltSudy Shale Fueled Power Generation

179S 111p 1 11Joda3 yl 3-202-89 8vk2

I

Mine and Shale ProcessingDesign - 2050 MW Project

I Overburden removal (north pit area) 10-meter benches

- Drill and blast

- 10 m3 front-end loader

- 77-ton truck haulage

I Oil shale mining 10-meter benches

- Rippe and auger scraper

- Front-end loader

- Portable in-pit crusher

- 77-ton truck haulage

Oil shale processing

- Feed = minus 100 mm

- Product = minus 8 mm

- Capacity = 250 tph

- Reversible impactor

- Two vibrating screens

1 Prefeasibility Study Oil Shale Fueled Power Generation

V -M 1AMI1ARt46

400 MW Full-Scale Oil Shale ProcessingPlant

Feed MTnus 200 mm Samplerr

1000 bull 10000 Tonnes Live Storage Grade

200 m long(-) 200 mm -- =-- Plow Feeders

00 h 100000 Tonnes Live Storage

Stream 3 - Sampler Bin Stream 2

Stream th 31Da2000

Circulating Load 2i

NFw Feed r -17000t1 170001l 170 t 17000 t 17000 t

1000 th Silo with 7 Impactor (-1)8 mm Reapro- 3 Day Storage at Aver age Loadn

0 20 Feeders 20 m Diameter by 40 m High

JJJTHT To Power Plant

Prefeasibility Study Oil Shale Fueled Power Generation

179589 6aJordarV 1I8 3-14-89 rsipc1

Mine and Shale ProcessingDesign - 4x100 MW Project

m Overburden removal (north area) 10-meter benches

- Drill and blast

- Three 20 m3 shovels

- 136-ton truck haulage

m Oil shale mining 10-meter benches

- Two mechanical surface miners

- 136-ton trucks to pit hopper

- Belt conveyor = 2000 tph

- Traveling stacker

m Oil shale processing

- Feed = minus 200 mm

- Product = minus 8 mm

- Capacity = three 1000 tph units

Prefeasibility Study Oil Shale Fueled Power Generation

VOO79-ampGEAIAt 17

i

Steady-State Production Schedule

Overburden removal bench m3

20 MW demo project 5n MW prototype 4x100 MW full-scale plant

Oil shale mining and shale processing tonnes

20 MW project 50 MW project 4x100 MW project

HourlyDesign Capacity

282 234

1850

HourlyDesign Capacity

250 250

2000

Avg Daily Annual PEQuctiQa Production

1690 507000 4217 13 million

33333 10 million

Max Daily(a) Annual(b) Production Production

1733 390000 4324 973000

34578 78 million

(a) Based on 100 operating factor for power block

(b) Based on 75 operating factor for power block ( 20 MW project = 300 shiftsyr 50 MW project = 900 shiftsyr 400 MW project = 900 shiftsyr)

Prefeasibility Study Oil Shale Fueled Power Generation

Conceptual Power Plant Plans

m Pyroflow boiler

Power generating facilities

m Auxiliaries

S Preleasibility Study Oil ShaJe Fueled Power Generation

vo0o7dEAO 19

Pyroflow Boiler SteamConciflons

Flow rate 226700 kghr (500000 Ibhr)

Pressure 1099 kgcm2 abs (15635 psia)

Temperature 51280C (9550F)

Same for 20 50 and 100 MW designs

Prefeasibility Study Oil ShaJe Fueled Power Generation

vooGALMI 20

HtomCOPUIOTP

- 50005 5op

-- LEVAThUM ORPORAION

0

-VI

DZ 4

Power Block

Fuel handling system

- Day binsscrew feeders

Boiler

- Pyroflow circulating fluid bed combustor

Power generation

- Non reheat condensing steam turbine

- Conventional Rankin steam cycle

Ash handling system (btm ash irom combustor and flyash from bag house)

- Wetted in pug mill to add 20plusmn wt wpter

Plant service water

- Air-cooled condensors and small cooling tower from circulating trim water coolers

Plant raw water

- To cooling tower makeup

- To drinking water system

- To pump seals etc

Plant treated makeup water

- Demineralizer train

Preteasibility Study Oil Shale Fueled Power Generation

i

Onsite Infrastructure

Project office

Control house

U Maintenance shops warehouse

Laboratory

Employee service facility

Site developmentoperations service facilities

- Fire controlsecurity

- Communications

- Lighting

- Roads drainage and sewage

Prefeasibility StudyQ1I Shale Fueled Power Generation

voo4JG m 0 JV

i

BechtellPyropower50 MW Cogeneration Plant - Mt Poso California

W4t Prefeasibility Study --- 7 Oil Shale Fueled Power Generation

179586122aJordarv 118 3-14-89 rsO

Characteristics of Three Size Operations

Oil shale fuel tpy

Mine development excavation bank m3

Spent ash disposal tpy (wetted)

Water consumption 1000 m3yr

Staffing required

Community population

400 MW

20 MW 50 MW (4x1 00)

390000 973000 78 million

500000 1 million 85 million

327000 815000 61 million

538 907 1263

185 324 1046

700 1200 4000

Prefeasibility Study Oil Shale Fueled Power Generation

V000ofllAM1 23

Conceptual Designs Summary

N All BOP facilities involve conventional equipment and technology

100 MW unit operation involves boiler scale-up considerations

N Water consumption estimates

- Requirement for 4x100 MW project is 13 million m3 yr

- Water allocation of 2 million m3yr of water supports 6x100 MW

N Water availability probably limits total power generation from oil shale in Jordan

Prefeasibility Study Oil Shale Fueled Power Generation

V007041GEAOLMI

i

TECHNOLOGY RISK ASSESSMENT

Basic concepts

Key boiler scale-up design issues

Impact of scale-up

U Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Prefeasibility Study O1 Shale Fueled Power Generation

VOOh-7AEAAO 2

Basic Concepts

U CFBC is relatively new in the powerindustry

- Existing plants are small typically 20 to 50 MW

- There is limited operating experience with high-ash fuels

- Existing designs for lignite biomass and coal wastes show good plant performance

I Application of CFBC boiler design to oil shale fuel has defined risk that relates to scale-up of existing design

Similar CFBC technology is used in petroleum refining industry

- FCC cracking plant regenerators burn carbon residue off spent catalyst

- 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

FUEL ANALYSES

High Ash Fuel Projects Total Solids Input Basis

Gilberton Cambria North Branch

Carbon 4653 2749 1822 Hydrogen 153 164 160 Sulfur 073 222 234 Nitrogen 085 051 043 Oxygen 282 218 468 Moisture 1451 514 557 Ash 3303 6 0 6Z16

10000 10000 10000

HHVBtulb 7485 4809 3453

includes limestone feed a3 ash

includes CO2 in Ca~o3

CA89029 CAkw

Oil Shale

1132

113

255

048

065

320

-8062

10000

2250

Key Boiler Scale-Up DesignIssues

m Solids handling

- Feeding shale to combustor

- 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

Voo4tGEAMI 30

i

Mine and Shale Processing

U Fugitive dust emissions are controllable

- Wetting mine roads

- Enclose crushing plant equipment

Noise levels are controllable

- Enclose crushing plant equipment - Muffle truck exhausts

- Engineered waste disposal

Water effluents can be controlled

- Need good mine drainage design - Continue leachability studies on

waste dump piles

Prefeasibilily StudyOil Shale Fueled Po r Generaton

V0079OOG-4O 31

1

Power Plant

II Fugitive dust emissions are controllable

- Baghouse designoperation will minimize particulates in flue gas

- Wetting spent ash before disposal

N Gaseous emissions are controllable

- Pilot test results show acceptable SO2NOxCO in flue gas

- Develop baseline data for Sultani area

Develop air dispersion model for Sultani

Prefeasibility StudyOil Shale Fueled Power Generatio

V00 V-4GEA l32

i

Power Plant (Contd)

Noise levels are controllable

- Enclose boiler plant fans as required - Enclose turbines and pumps as

required

Water effluents are controllable

- Continue leachability studies on spent ash disposal

- Develop aquifer dispersion model

- Develop sewage and garbage disposal plan

Prefeasibility SludyOil Shale Fueled Power Generation

V00-4FAAI 33

Conclusions

No environmental constraints are anticipated on oil shale powerdevelopment

Gas effluents will meet World Bank standards

- Ash disposal is manageable

- The potential for groundwatercontamination appears low

- Water effluents will be minimal

Continued studies to develop air and groundwater baseline data are recommended

S Prefeasibility Study Oil Shale Fueled Power Generation

v0 9ampGLAMR 34

Power Demand vs SupplyAssessment

m Demand growth forecasts

Electrical generating capacity

= Power supply forecasts

= Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Preleasibility Study Oil Shaie Fuelod Power Generation

VO9- uLIROI

1

Power Demand Forecasts

Percent Annual Growth

JEA

Meta systems HaglerBailey and Bechtel National Inc

JEA Peak Demand Growth

1980 (actual) 1985 (actual) 1987 (actual) 1995 (forecast) 2005 (forecast)

1986 1990 to to

1990 2000

97 60

49 39

200 MW 475 MW 593 MW 900 MW

1400 MW

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOO-DLURO2

i

JEA ElectricityGeneratingCapacity

1987 Installed

Capacity (MW) Aqaba 260

22

Zarqa 395

Marka 102

Karak 23

Miscellaneous 67

Subtotal JEA capacity 869

Other capacity - industrial 110

Total 979

Prefeasibility Study Oi1 Shale Fueled Power Generation

V000-6O0LFJRO3 (

Forecast New Power Generating Capacity Required

Fcst 1987 Required

New Peak Available Installed

Demand Capacity Shortfall (a) Capacity (b) (MM (MW) (MW) (MW)

Assumed capacityfactor (65) (75)

1995 requirement 900 636 264 352

2005 requirement 1400 636 764 1019

(a) Excludes proposed additions and retirements (b) Excludes possible power exports or imports

Load shedding or levelizing not considered

Preteasibility Study Oil Shale Fueled Power Generation

Vflcmf-R)LLAO4

i

Supply vs Demand Evaluation

1800

1600

1400 Forecast Peak Demands

1200 -

E Installed Capacity

0 800shy75--

U) Assumed Available Calcit

a 6 Ao600 shy0 o 65

400 shy

200

I I I I I I I I I I I I I I I I I I I I I I I 1 1 1980 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958f738aIJordarV 118 3-14-89 rspCO

Conclusions

Additional power generating capacity is needed to meet forecasted 19952005demand growth

A 400 MW oil shale-to-power project at Sultani can meet a portion of this need

U A second 400 MW oil shale project maybe required if water is available

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOW0O-8LURO5

i

Economic Feasibility

N Order-of-magnitude costs

N Economic analysis

- Jordan study options

- Project size effect

m Comparison with alternative fuels

- Fuel requirement

- Project financing effect

- Alternate fuel price effect

- Estimated cost of electricity

N Summary financial analysis

bull Material was developed by Bechtel Power Company

Prefeasibility Study

go Oil Shale Fueled Power Generation VOOSO-ampDtJROh

ORDER-OF-MAGNITUDE COSTS

U Oil shale fuel

Power plant

I Integrated project- busbar

Preteasibility Study

Oil Shale Fueled Power Generation

VOO9O-ampDLUROS

Oil Shale Fuel Costs

Installed Capital Cost

Mine Development

Mine Equipment

Processing Plant

Spare Parts

Working Capital

Capitalized Interest

Total

Annual Operating Cost

Fuel Cost $UStonne

bull Based on 8020 debtequity ratio

20 MW

4900

11090

6945

1200

1200

4054

29389

5582

1431

US $1000 Factored

50 MW 4x100 MW

7833 30915

12202 66012

8388 50889

1300 5000

2200 10000

5108 39075

37031 201891

11556 53236

1188 684

Prefeasibility Study

Oil Shale Fueled Power Generation

VCO-ampDLUJ1O

Power Plant Costs

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Cost

Power faciities 57500 91800 567800

Owners cost 10200 20400 192700

Total 67700 112200 760500

Annual Operating Cost 2205 3248 17157(excluding fuel cost)

bullBased on 8020 debtequity ratio oil shale fueled

Prefeasibility Study

Oil Shale Fueled Power Generation

V00O8c4LLMO9

i

INTEGRATED PROJECT -BUSBAR COST

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Costs Mine amp shale processingPower block Waste disposal Infrastructure

29359 67700

1664 10000

37031 112200

2381 15000

201891 760500

8714 45000

TOTAL 108753 166612 1016105

Annual Operating Cost Mine amp shale processingPower block Waste disposal Infrastructure (a)

5582 2205

316

11556 3248

710

56430(b) 18186(b) 6004

Subtotal 8103 15514 80620

Capital Charges 139 9410 15596 106000

Total 17513 31110 186620

25-year levelized cost - - 218000

Busbar Cost millskWh First year 128 92 71 25-year levelized 83

(a) Housing and community facilities assumed self-liquidating(b) Includes first-year inflation adjustment

Based on 8020 debtequity ratio

Prefeasibility StudyOil Shale Fueled Power Generaion

VOOOO-8MLtROi0

ECONOMIC ANALYSIS

n Jordan study options

Project size effect

Fuel requirement

Project financing effect

Alternative fuel price effect

Estimated electricity cost

Summary financial analysis results

Prefeasibility Study

Oil Shale Fueled Powr Generation

VOOeO-BOCLLO1 I

i

Jordan Study Options

U Project size

- Demonstration = 20 MW

- Prototype = 50 MW

- Commercial = 400 MW (4x100)

Project financing

- Debtequity 8020

- Debtequity 5050

Imported alternative fuels cost assumptions

A B Crude oil $17bbl $24bbl

$120onne $170tonne

Low sulfur coal $ 50tonne $ 70tonne See Chevron forecast supporting assumptions

Prefeasibility StudyOil Shale Fueled Power Generation

VOOOO-8DLIJRO12

i

Crude Oil Price Trends

60

Source World Energy Outlook Chevron Corporation Oclober 1987

40

High trend

No Ir 20 ~~~~Arabian Light Spot I A u

IILowYUII trend

0 1970 1975 1980 1985 1990 1995

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958246aJodar 118 3-14-89 rsO

2000

Project Size Effect Shale Fuel Option

Project Size

Integrated facilities installed capital cost$ US million

Shale cost $UStonne(8020 debtequity)

Cost of power millskWh(8020 debtequity ratio)

20 MW

109

143

128

50 MW

167

118

92

400 MW (4x1 00)

1016

68

71

Prefeasibility Study Oil Sampae Fueled Power Generation

VOO O-8I0LJRO13

gt1

1

Power Block Investment Cost

3000

$2875 Excluding mining and offsite 2800

2600

2400

2200

2000

$1836 1800

$1613 1600

$1420 1400 1I 1 I

0 100 200 300 400 MWe

August 1988

Preleasibility Study OilShale Fueled Power Generation

179581147aJodar1 18 3-14-89 rspcl

Fuel Requirement - 4x100 MW Project

Coal = 12 million tpy

n Oil = 503000 tpy

Oil shale = 78 million tpy

Preleasibility Study

Oil Shale Fueled Power Generation

IO060-OLLIRO14

Financing Effect -Project

Oil Shale Fuel Option

Mine and shale processing

Power block

Waste disposal

Community facilities

Total

Coal-Fired Power Plant

Oil-Fired Power Plant

400 MW

Capital Cost ($US MM)

DebtEquity

8020 5050

202 187

760 760

9 8

45 45

1016 1000

647 647

463 463

Prefeasibility StudyOil Shale Fueled Power Generation

VOe-BD1JRO15

Financing Effect shy400 MW Project

Operating Costs ($US millionyr)

DebtEquity

8020 5050

Coal $70tonne 282 282

Oil $24bbl 254 254

Oil shale-fueled 218 236

Including fuel

Prefeasibility Study

SOil Shale Fueled Power Generaion

VOOIt JLMO I

Alternate Fuel Price Effect shy4x100 MW Project

Financing Basis DebtEquity Ratio

Alternate Fuel Price

Imported coal $50tonne $70tonne

Imported oil $17bbl ($120tonne) $24bbl ($170tonne)

Cumulative 25-yr Net Benefit

Favoring Oil Shale (US $MM) shy

8020 5050

778 315 2531 2068

(18) (506)1810 1322

Prefeasibility Study

Oil Shale Fueled Power Generation

Voo -I DLU-A 2

i

Comparison of Cumulative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

32 Pay Out Year shy

400 MW PlantOil Shale vs Imported Coal (8020 debtequty)

30

28 -Cumulative fuel cost savings forcoal $70ton

Cumulative fuel cost savings for coaJ $50ton

26---------- Cumulative Incremental capital plus OampM costs

24

22 -

18 -0

W- Cumulative net benefit for shae vs coal $50ton 2B Cumulative net benefit for shale vs coal $70ton

co16C -

14 -

12 -

10 -

09

06 -Payout inyear 1

Payout Inyear 9 for coal $50ton - -- - - -shy

02 0 I

0 1 2 3 4 5 Nowl Yewr in which sauings in fWe colsacm-ewi tat hsawinitl

ca=al wosaand OampM costs

6

_iiM

7 8

9 10

------ - -amp -

11 12 13 14Year of Operation

--

15

- - --shy

16 17

I

18

1

19

I

20

I

21

I

22

I

23

I

24 25

Prefeasibility StudyOil Shale Fueled Power Generation

17958d351aJordanr 3-14-89 rsO

118

Comparison of Cumuiative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

28 Pay Out Year shy

400 MW Plant Oil Shale vs Imported Coal (5050 debtequity)

26shy2

24-

Cumulaive fuel nst savings for coal 0 $70ton Cumulative fuel cost savings for coal $50ton Cumulative Incremental capital plus OampM corts

22 -

20 -

18 -- Cumuladve net benefit for shle vs coal $50ton B Cumuarve net benefit for sale vs coal $70ton

16 -

C 14

12

10

08 -06 - Payout In year 1for coal $50ton

04

Payout Inyear 1

for coal $70ton02~

0 0

-No

02-

1 2

Yew inrY MCM cajlaI rl

3 4 5 6

sngm inW coas 0 ort hghWcentWin

0tOM cori

7

--

8

- -

9 10 11 12 13 14

Year of Operation

15 16 17

I

18

IIII

19 20 21 22 23 24 25

Preieasibility Study Oil Shale Fueled Power Generation

17958451 bJordarV118 3-14-89 rsipcI

Estimated Cost of Power- 400 MW (4 x 100)

FUEL

ImportedCoal

$50T

$70fT

1st Year

68 88

Levelized

78 107

Sultani Oil Shale

71 83

ImportedOil

$1713

$2413

56

67

76

96

0 10 20 30 40 50

I 60

I 70

I 80

I 90 100 110 120

Mills per kWh

Prefeasibility Study Oil Shale Fueled Power Generation

179581251 cJordarVl 18 3-14-89 rspc1

Summary Financial Analysis Results

Project size

Debt equity ratio

- Investment cost

- Power cost

- 25-year net benefit

- Project implementation

Alternative fuel price

Economic Comparison

Very significant

Not significant

Not significant

Very significant

Critical

Very significant

Prefeasibility Study

Oil Shale Fueled Power Generation

VY0 tDLUAi3

i

Study Conclusions

Feasibility

Timeliness

Expansion conditions

Environmental impacts

Development advantages

Prefeasibility Study

Oil Shale Fueled Power Generation VW41-1AiUA

4

Feasibility

Oil shale fueled power generation is technically and economically justifiedunder certain conditions

N Need for additional generating capacity

exists

- 6 annual peak demand growth - Orderly retirement of olderhigh cost

generating capacity needed

U Higher costs are expected for imported fuels

- 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

-OP b i j~~4shy

-4protntiYPe 4 demo plnt orP42 t~Plant orPootypeProje(-7hould

that Rj

demo 4Therefore-44 JEA anxinus

the

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

27Pag 4- 1 2S c i n 4 4

4i2Sectjo4-18-4 Secio 4-4 014

lt th~ae hi4h -tasisso syste thrug27 ~ 04lag arstl~art-p tasforme ed 2p27132Kvdieanwhy notthroug

EAto- is protmm~~ thegnJgt~~ pracie an ect ~ platqrby

28Pg 4 s heonnenotedto~the 32K rc powr

It not8 Scection rie049teoervnrain prctc de1

rh u n trae f2V3K anerd not throughgeterAntor

27 P3e-1r p ant weung-a

-If I

2tEll10 DRWE-jOi ASOt Mint~~al d~c~e o hepwrgnrto

ELCTRInYJORD UTHORITY-

Ate~

21Pge41 ection 4 04- 5

sindicated~ t hthigh the unit outputredu f hecondenser Injengtd~ibbvePressureed incg desrin hi h riseb vmbi nt emperatureWe bel~ieve

PleaIse provide us with th rscrapcity for th-e three options n nt generating~

21-Iisidca ted that~ thediaatgeofCBi theSheavy fn oe consumnptionPlease~ providethe us withpecntgA

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

400 MW COAL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO 5050

NET GENERATION - MWe 40000 CAPACITY FACTOR - 75 ANNUAL GENERATION MKWhYR 2628 SUB TOTAL PLANT COSTS (TPC) $1000 $620000

FIXED 0 amp M COSTS MH $ MH FIRST YEAR COST$1O00

------- --------- --- ---- --- --- ------------

OPERATING LABOR 351936 $3 $1100 MAINTENANCE LABOR 4000 of 150 OF TPC 3720

MAINTENANCE MATERIAL 6000

ADMIN LABOR of 150

3000 OF TPC

OF 0 amp M LABOR 5580 1446

SUB TOTAL FIXED OampM COSTS $11846

VARIABLE 0 amp M COSTS QUANTITY UNIT COST

VARIABLE MAINTENANCE 2628 MKWh 10 MILLKWH $ 2628 PROCESS WATER 13500000 GALLON 02 SGAL $ 2700 GENERAL PLANT CHEMICALS ALLOW 50 FUEL OIL 1000000 GALLON 035 $GAL $ 350 WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290SPECIAL BOILER MAINT ALLOW 0

SUB TOTAL VARIABLE OampM COSTS $ 8018

TOTAL FIXED amp VARIABLE OampM COSTS $19864 TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $8227 $TN $99139

(INCL INFLATION ADJUSTMENT)

B DEBT EQUITY RATIO =========== 8020

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $17574

WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290

TOTAL FIXED amp VARIABLE OampM COSTS $19864TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $5877 $TN $70814

(INCL INFLATION ADJUSTMENT)

6-21

Table 612 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY

400 MW OIL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO

NET GENERATION -

CAPACITY FACTOR -

ANNUAL GENERATION SUB TOTAL PLANT COSTS (TPC)

FIXED 0 amp M COSTS

OPERATING LABOR MAINTENANCE LABOR 4000 of

MAINTENANCE MATERIAL 6000 of

ADMIN LABOR

SUB TOTAL FIXED OampM COSTS

VARIABLE 0 amp M COSTS

VARIABLE MAINTENANCE PROCESS WATER GENERAL PLANT CHEMICALS FUEL OIL WASTE DISPOSAL (Section 6027) SPECIAL BOILER MAINT

SUB TOTAL VARIABLE OampM COSTS

5050

MWe

MKWhYR $1000

MH

262080

150

150 3000

QUANTITY

2628 MKWh 13500000 GALLON

1000000 GALLON 0 TNYR

TOTAL FIXED amp VARIABLE OampM COSTS FUEL OIL 503000 TNYR

B DEBT EQUITY RATIO =8020

40000 75

268 $443000

FIRST YEAR $ MH COST$1O00

$3 $ 800

OF TPC 2658

OF TPC 3987 OF 0 amp M LABOR 1037

$ 8482

UNIT COST

05 MILLKWH $ 1314 02 $GAL $ 2700

ALLOW 50 035 $GAL $ 350

$1000 $TN $ 0 ALLOW 0

$ 4414

$12896 $19981 $TN $100502

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $12896

WASTE DISPOSAL (Section 6027) 0 TNYR $1000 $TN $ 0

TOTAL FIXED amp VARIABLE OampM COSTS $12896 FUEL OIL 503000 TNYR $14104 $TN $70943

6-23

Page 10: fo; - pdf.usaid.gov

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

Pilot Plant Test Program (Contd)

U Analyzed one blended sample of shale

- Calorific value = 532 - 597 MJkg (approx 2250 BtuIlb)

- Carbon content (dry solids) = 162 - 187 wto

- Sulfur content (dry solids) = 30 - 33 wt

- Ash content (dry solids) = 667 - 684 wt

- Shale size = minus 8 mm

Key items determined

- Combustion efficiency

- Product ash distribution

- Product gas S02NOxCO content

- Data for boiler design

- Sulfur emissions reduction by Ca in fuel

S Prefeasibility Study Oil Shale Fueled Power Generation

VOO74GEAJI 10

Pilot Plant Test Results

U Combustion efficiency exceeded 985 in all tests

Ash distribution (btm ashfly ash) was 3565 to 4753 at 100 load typically4060

Low emissions were demonstrated

Typically S02 10 to 200 ppm gt 95 removal

limestone addition not required

NOx 60 to 120 ppm lt 020 lb106 Btu

Co 10 to 90 ppm lt 50 ppm

Prefeasibility Study Oi Shale Fueled Power Generation

TITLE

Ternpe -al-CuA vs 6 Ik

00

I00

7SA-A-

Fly Ai h

0

85 e

80-

0

00

i I 800 860 oo

T-er pe -

DATE OWN APPD DCNO- ------ -

_______f - _ IPG_

Pilot Plant Test Conclusions

It is technically feasible to burn the Sultani oil shale furnished by NRA in a Pyropower boiler

A high combustion efficiency in excess of 985 was demonstrated

SO2NOxCO emissions are all acceptably low with no limestone addition required

Prefeasibility StudyO Shale Fueled Power Generation

Conceptual Design Studies Scope

m Three project sizes

- 20 MW

- 50 MW

- 400 MW (4x100) factored for power plant portion

m Open-pit mine

- Shale processing at the surface - Waste disposal system

Power block

- Boiler

- Steam turbine

- Auxiliaries

Prefeasibility Study Oil Shale Fueled Power Generation

VOn 4FAIR 1

i

Project Layout 9 fc =f4j

deg2

o r -w (031

5_7EC 45U

iPefeaibiity tud

OlSeFuedP erGr in

179581113i~o(atyvv11

n1- 14 4pc

C)

Sultani Oil Shale Reserves

North South Area Area Total

Mineable shale tonne x 106 320 658 978

Fischer assay oil content wt 744 761 765

Overburden m3 x 106 384 627 1011

Stripping ratio m3m3 2161 1711 1861

bull Based on NRA core drilling and core analysis

Prefeasibility Study Oil Shale Fueled Power Generation

VWO41OFEAMI14

i

Sultani Oil Shale Analyses

Moisture

Ash (less CO 2 in CaCO 3 )

CO 2 (in CaCO 3 )

Carbon (organic)

Hydrogen

Nitrogen

Sulfur

Oxygen (by diff)

Total

High heating value BtuIb

Fischer assay oil content

bull Percent by weight

Design Basis Fuel

320

6680

1387

1132

113

048

255

065

10000

2250

840

Low High Calorific Calorific

Value Fuel Value Fuel

320 320

6730 6625

1414 1337

1020 1250

102 125

058 038

238 271

118 034

10000 10000

2000 2500

750 925

Preteasibility Study Oil Shale Fueled Power Generation

vo0N d-GEAR 1S

50 MW Oil Shale ProcessingPrototype Plant

Mlne Plant

_ 14 0 Haul0___) to Plant 1 Sorage

Portable Crusher

(-)100 mm Storage

(-) 100 mm Hopper UIU 400 th

Feed Bin

J 50

250 tvb

8 -m Circulating Load Impact3or0 0 30 0 0shy+8mm25

30 0L Sampler 0 1 30 0

p3 Day Storage

To Power Plant

Preleasibility StudyOil Shale Fueled Power Generation

17958101 SaJordanli 18 3-14-89 rsipc1

20 MW Oil Shale Demonstration Plant

Mine Plant

Haul00- 01 o

= Pb n Storage Portable _

110 mm Stora e 0

()100 mm r Hopper

U 400V

Feed Bin

CirculatingLoad3 Day Stoge

Prefea~ltSudy Shale Fueled Power Generation

179S 111p 1 11Joda3 yl 3-202-89 8vk2

I

Mine and Shale ProcessingDesign - 2050 MW Project

I Overburden removal (north pit area) 10-meter benches

- Drill and blast

- 10 m3 front-end loader

- 77-ton truck haulage

I Oil shale mining 10-meter benches

- Rippe and auger scraper

- Front-end loader

- Portable in-pit crusher

- 77-ton truck haulage

Oil shale processing

- Feed = minus 100 mm

- Product = minus 8 mm

- Capacity = 250 tph

- Reversible impactor

- Two vibrating screens

1 Prefeasibility Study Oil Shale Fueled Power Generation

V -M 1AMI1ARt46

400 MW Full-Scale Oil Shale ProcessingPlant

Feed MTnus 200 mm Samplerr

1000 bull 10000 Tonnes Live Storage Grade

200 m long(-) 200 mm -- =-- Plow Feeders

00 h 100000 Tonnes Live Storage

Stream 3 - Sampler Bin Stream 2

Stream th 31Da2000

Circulating Load 2i

NFw Feed r -17000t1 170001l 170 t 17000 t 17000 t

1000 th Silo with 7 Impactor (-1)8 mm Reapro- 3 Day Storage at Aver age Loadn

0 20 Feeders 20 m Diameter by 40 m High

JJJTHT To Power Plant

Prefeasibility Study Oil Shale Fueled Power Generation

179589 6aJordarV 1I8 3-14-89 rsipc1

Mine and Shale ProcessingDesign - 4x100 MW Project

m Overburden removal (north area) 10-meter benches

- Drill and blast

- Three 20 m3 shovels

- 136-ton truck haulage

m Oil shale mining 10-meter benches

- Two mechanical surface miners

- 136-ton trucks to pit hopper

- Belt conveyor = 2000 tph

- Traveling stacker

m Oil shale processing

- Feed = minus 200 mm

- Product = minus 8 mm

- Capacity = three 1000 tph units

Prefeasibility Study Oil Shale Fueled Power Generation

VOO79-ampGEAIAt 17

i

Steady-State Production Schedule

Overburden removal bench m3

20 MW demo project 5n MW prototype 4x100 MW full-scale plant

Oil shale mining and shale processing tonnes

20 MW project 50 MW project 4x100 MW project

HourlyDesign Capacity

282 234

1850

HourlyDesign Capacity

250 250

2000

Avg Daily Annual PEQuctiQa Production

1690 507000 4217 13 million

33333 10 million

Max Daily(a) Annual(b) Production Production

1733 390000 4324 973000

34578 78 million

(a) Based on 100 operating factor for power block

(b) Based on 75 operating factor for power block ( 20 MW project = 300 shiftsyr 50 MW project = 900 shiftsyr 400 MW project = 900 shiftsyr)

Prefeasibility Study Oil Shale Fueled Power Generation

Conceptual Power Plant Plans

m Pyroflow boiler

Power generating facilities

m Auxiliaries

S Preleasibility Study Oil ShaJe Fueled Power Generation

vo0o7dEAO 19

Pyroflow Boiler SteamConciflons

Flow rate 226700 kghr (500000 Ibhr)

Pressure 1099 kgcm2 abs (15635 psia)

Temperature 51280C (9550F)

Same for 20 50 and 100 MW designs

Prefeasibility Study Oil ShaJe Fueled Power Generation

vooGALMI 20

HtomCOPUIOTP

- 50005 5op

-- LEVAThUM ORPORAION

0

-VI

DZ 4

Power Block

Fuel handling system

- Day binsscrew feeders

Boiler

- Pyroflow circulating fluid bed combustor

Power generation

- Non reheat condensing steam turbine

- Conventional Rankin steam cycle

Ash handling system (btm ash irom combustor and flyash from bag house)

- Wetted in pug mill to add 20plusmn wt wpter

Plant service water

- Air-cooled condensors and small cooling tower from circulating trim water coolers

Plant raw water

- To cooling tower makeup

- To drinking water system

- To pump seals etc

Plant treated makeup water

- Demineralizer train

Preteasibility Study Oil Shale Fueled Power Generation

i

Onsite Infrastructure

Project office

Control house

U Maintenance shops warehouse

Laboratory

Employee service facility

Site developmentoperations service facilities

- Fire controlsecurity

- Communications

- Lighting

- Roads drainage and sewage

Prefeasibility StudyQ1I Shale Fueled Power Generation

voo4JG m 0 JV

i

BechtellPyropower50 MW Cogeneration Plant - Mt Poso California

W4t Prefeasibility Study --- 7 Oil Shale Fueled Power Generation

179586122aJordarv 118 3-14-89 rsO

Characteristics of Three Size Operations

Oil shale fuel tpy

Mine development excavation bank m3

Spent ash disposal tpy (wetted)

Water consumption 1000 m3yr

Staffing required

Community population

400 MW

20 MW 50 MW (4x1 00)

390000 973000 78 million

500000 1 million 85 million

327000 815000 61 million

538 907 1263

185 324 1046

700 1200 4000

Prefeasibility Study Oil Shale Fueled Power Generation

V000ofllAM1 23

Conceptual Designs Summary

N All BOP facilities involve conventional equipment and technology

100 MW unit operation involves boiler scale-up considerations

N Water consumption estimates

- Requirement for 4x100 MW project is 13 million m3 yr

- Water allocation of 2 million m3yr of water supports 6x100 MW

N Water availability probably limits total power generation from oil shale in Jordan

Prefeasibility Study Oil Shale Fueled Power Generation

V007041GEAOLMI

i

TECHNOLOGY RISK ASSESSMENT

Basic concepts

Key boiler scale-up design issues

Impact of scale-up

U Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Prefeasibility Study O1 Shale Fueled Power Generation

VOOh-7AEAAO 2

Basic Concepts

U CFBC is relatively new in the powerindustry

- Existing plants are small typically 20 to 50 MW

- There is limited operating experience with high-ash fuels

- Existing designs for lignite biomass and coal wastes show good plant performance

I Application of CFBC boiler design to oil shale fuel has defined risk that relates to scale-up of existing design

Similar CFBC technology is used in petroleum refining industry

- FCC cracking plant regenerators burn carbon residue off spent catalyst

- 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

FUEL ANALYSES

High Ash Fuel Projects Total Solids Input Basis

Gilberton Cambria North Branch

Carbon 4653 2749 1822 Hydrogen 153 164 160 Sulfur 073 222 234 Nitrogen 085 051 043 Oxygen 282 218 468 Moisture 1451 514 557 Ash 3303 6 0 6Z16

10000 10000 10000

HHVBtulb 7485 4809 3453

includes limestone feed a3 ash

includes CO2 in Ca~o3

CA89029 CAkw

Oil Shale

1132

113

255

048

065

320

-8062

10000

2250

Key Boiler Scale-Up DesignIssues

m Solids handling

- Feeding shale to combustor

- 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

Voo4tGEAMI 30

i

Mine and Shale Processing

U Fugitive dust emissions are controllable

- Wetting mine roads

- Enclose crushing plant equipment

Noise levels are controllable

- Enclose crushing plant equipment - Muffle truck exhausts

- Engineered waste disposal

Water effluents can be controlled

- Need good mine drainage design - Continue leachability studies on

waste dump piles

Prefeasibilily StudyOil Shale Fueled Po r Generaton

V0079OOG-4O 31

1

Power Plant

II Fugitive dust emissions are controllable

- Baghouse designoperation will minimize particulates in flue gas

- Wetting spent ash before disposal

N Gaseous emissions are controllable

- Pilot test results show acceptable SO2NOxCO in flue gas

- Develop baseline data for Sultani area

Develop air dispersion model for Sultani

Prefeasibility StudyOil Shale Fueled Power Generatio

V00 V-4GEA l32

i

Power Plant (Contd)

Noise levels are controllable

- Enclose boiler plant fans as required - Enclose turbines and pumps as

required

Water effluents are controllable

- Continue leachability studies on spent ash disposal

- Develop aquifer dispersion model

- Develop sewage and garbage disposal plan

Prefeasibility SludyOil Shale Fueled Power Generation

V00-4FAAI 33

Conclusions

No environmental constraints are anticipated on oil shale powerdevelopment

Gas effluents will meet World Bank standards

- Ash disposal is manageable

- The potential for groundwatercontamination appears low

- Water effluents will be minimal

Continued studies to develop air and groundwater baseline data are recommended

S Prefeasibility Study Oil Shale Fueled Power Generation

v0 9ampGLAMR 34

Power Demand vs SupplyAssessment

m Demand growth forecasts

Electrical generating capacity

= Power supply forecasts

= Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Preleasibility Study Oil Shaie Fuelod Power Generation

VO9- uLIROI

1

Power Demand Forecasts

Percent Annual Growth

JEA

Meta systems HaglerBailey and Bechtel National Inc

JEA Peak Demand Growth

1980 (actual) 1985 (actual) 1987 (actual) 1995 (forecast) 2005 (forecast)

1986 1990 to to

1990 2000

97 60

49 39

200 MW 475 MW 593 MW 900 MW

1400 MW

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOO-DLURO2

i

JEA ElectricityGeneratingCapacity

1987 Installed

Capacity (MW) Aqaba 260

22

Zarqa 395

Marka 102

Karak 23

Miscellaneous 67

Subtotal JEA capacity 869

Other capacity - industrial 110

Total 979

Prefeasibility Study Oi1 Shale Fueled Power Generation

V000-6O0LFJRO3 (

Forecast New Power Generating Capacity Required

Fcst 1987 Required

New Peak Available Installed

Demand Capacity Shortfall (a) Capacity (b) (MM (MW) (MW) (MW)

Assumed capacityfactor (65) (75)

1995 requirement 900 636 264 352

2005 requirement 1400 636 764 1019

(a) Excludes proposed additions and retirements (b) Excludes possible power exports or imports

Load shedding or levelizing not considered

Preteasibility Study Oil Shale Fueled Power Generation

Vflcmf-R)LLAO4

i

Supply vs Demand Evaluation

1800

1600

1400 Forecast Peak Demands

1200 -

E Installed Capacity

0 800shy75--

U) Assumed Available Calcit

a 6 Ao600 shy0 o 65

400 shy

200

I I I I I I I I I I I I I I I I I I I I I I I 1 1 1980 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958f738aIJordarV 118 3-14-89 rspCO

Conclusions

Additional power generating capacity is needed to meet forecasted 19952005demand growth

A 400 MW oil shale-to-power project at Sultani can meet a portion of this need

U A second 400 MW oil shale project maybe required if water is available

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOW0O-8LURO5

i

Economic Feasibility

N Order-of-magnitude costs

N Economic analysis

- Jordan study options

- Project size effect

m Comparison with alternative fuels

- Fuel requirement

- Project financing effect

- Alternate fuel price effect

- Estimated cost of electricity

N Summary financial analysis

bull Material was developed by Bechtel Power Company

Prefeasibility Study

go Oil Shale Fueled Power Generation VOOSO-ampDtJROh

ORDER-OF-MAGNITUDE COSTS

U Oil shale fuel

Power plant

I Integrated project- busbar

Preteasibility Study

Oil Shale Fueled Power Generation

VOO9O-ampDLUROS

Oil Shale Fuel Costs

Installed Capital Cost

Mine Development

Mine Equipment

Processing Plant

Spare Parts

Working Capital

Capitalized Interest

Total

Annual Operating Cost

Fuel Cost $UStonne

bull Based on 8020 debtequity ratio

20 MW

4900

11090

6945

1200

1200

4054

29389

5582

1431

US $1000 Factored

50 MW 4x100 MW

7833 30915

12202 66012

8388 50889

1300 5000

2200 10000

5108 39075

37031 201891

11556 53236

1188 684

Prefeasibility Study

Oil Shale Fueled Power Generation

VCO-ampDLUJ1O

Power Plant Costs

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Cost

Power faciities 57500 91800 567800

Owners cost 10200 20400 192700

Total 67700 112200 760500

Annual Operating Cost 2205 3248 17157(excluding fuel cost)

bullBased on 8020 debtequity ratio oil shale fueled

Prefeasibility Study

Oil Shale Fueled Power Generation

V00O8c4LLMO9

i

INTEGRATED PROJECT -BUSBAR COST

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Costs Mine amp shale processingPower block Waste disposal Infrastructure

29359 67700

1664 10000

37031 112200

2381 15000

201891 760500

8714 45000

TOTAL 108753 166612 1016105

Annual Operating Cost Mine amp shale processingPower block Waste disposal Infrastructure (a)

5582 2205

316

11556 3248

710

56430(b) 18186(b) 6004

Subtotal 8103 15514 80620

Capital Charges 139 9410 15596 106000

Total 17513 31110 186620

25-year levelized cost - - 218000

Busbar Cost millskWh First year 128 92 71 25-year levelized 83

(a) Housing and community facilities assumed self-liquidating(b) Includes first-year inflation adjustment

Based on 8020 debtequity ratio

Prefeasibility StudyOil Shale Fueled Power Generaion

VOOOO-8MLtROi0

ECONOMIC ANALYSIS

n Jordan study options

Project size effect

Fuel requirement

Project financing effect

Alternative fuel price effect

Estimated electricity cost

Summary financial analysis results

Prefeasibility Study

Oil Shale Fueled Powr Generation

VOOeO-BOCLLO1 I

i

Jordan Study Options

U Project size

- Demonstration = 20 MW

- Prototype = 50 MW

- Commercial = 400 MW (4x100)

Project financing

- Debtequity 8020

- Debtequity 5050

Imported alternative fuels cost assumptions

A B Crude oil $17bbl $24bbl

$120onne $170tonne

Low sulfur coal $ 50tonne $ 70tonne See Chevron forecast supporting assumptions

Prefeasibility StudyOil Shale Fueled Power Generation

VOOOO-8DLIJRO12

i

Crude Oil Price Trends

60

Source World Energy Outlook Chevron Corporation Oclober 1987

40

High trend

No Ir 20 ~~~~Arabian Light Spot I A u

IILowYUII trend

0 1970 1975 1980 1985 1990 1995

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958246aJodar 118 3-14-89 rsO

2000

Project Size Effect Shale Fuel Option

Project Size

Integrated facilities installed capital cost$ US million

Shale cost $UStonne(8020 debtequity)

Cost of power millskWh(8020 debtequity ratio)

20 MW

109

143

128

50 MW

167

118

92

400 MW (4x1 00)

1016

68

71

Prefeasibility Study Oil Sampae Fueled Power Generation

VOO O-8I0LJRO13

gt1

1

Power Block Investment Cost

3000

$2875 Excluding mining and offsite 2800

2600

2400

2200

2000

$1836 1800

$1613 1600

$1420 1400 1I 1 I

0 100 200 300 400 MWe

August 1988

Preleasibility Study OilShale Fueled Power Generation

179581147aJodar1 18 3-14-89 rspcl

Fuel Requirement - 4x100 MW Project

Coal = 12 million tpy

n Oil = 503000 tpy

Oil shale = 78 million tpy

Preleasibility Study

Oil Shale Fueled Power Generation

IO060-OLLIRO14

Financing Effect -Project

Oil Shale Fuel Option

Mine and shale processing

Power block

Waste disposal

Community facilities

Total

Coal-Fired Power Plant

Oil-Fired Power Plant

400 MW

Capital Cost ($US MM)

DebtEquity

8020 5050

202 187

760 760

9 8

45 45

1016 1000

647 647

463 463

Prefeasibility StudyOil Shale Fueled Power Generation

VOe-BD1JRO15

Financing Effect shy400 MW Project

Operating Costs ($US millionyr)

DebtEquity

8020 5050

Coal $70tonne 282 282

Oil $24bbl 254 254

Oil shale-fueled 218 236

Including fuel

Prefeasibility Study

SOil Shale Fueled Power Generaion

VOOIt JLMO I

Alternate Fuel Price Effect shy4x100 MW Project

Financing Basis DebtEquity Ratio

Alternate Fuel Price

Imported coal $50tonne $70tonne

Imported oil $17bbl ($120tonne) $24bbl ($170tonne)

Cumulative 25-yr Net Benefit

Favoring Oil Shale (US $MM) shy

8020 5050

778 315 2531 2068

(18) (506)1810 1322

Prefeasibility Study

Oil Shale Fueled Power Generation

Voo -I DLU-A 2

i

Comparison of Cumulative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

32 Pay Out Year shy

400 MW PlantOil Shale vs Imported Coal (8020 debtequty)

30

28 -Cumulative fuel cost savings forcoal $70ton

Cumulative fuel cost savings for coaJ $50ton

26---------- Cumulative Incremental capital plus OampM costs

24

22 -

18 -0

W- Cumulative net benefit for shae vs coal $50ton 2B Cumulative net benefit for shale vs coal $70ton

co16C -

14 -

12 -

10 -

09

06 -Payout inyear 1

Payout Inyear 9 for coal $50ton - -- - - -shy

02 0 I

0 1 2 3 4 5 Nowl Yewr in which sauings in fWe colsacm-ewi tat hsawinitl

ca=al wosaand OampM costs

6

_iiM

7 8

9 10

------ - -amp -

11 12 13 14Year of Operation

--

15

- - --shy

16 17

I

18

1

19

I

20

I

21

I

22

I

23

I

24 25

Prefeasibility StudyOil Shale Fueled Power Generation

17958d351aJordanr 3-14-89 rsO

118

Comparison of Cumuiative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

28 Pay Out Year shy

400 MW Plant Oil Shale vs Imported Coal (5050 debtequity)

26shy2

24-

Cumulaive fuel nst savings for coal 0 $70ton Cumulative fuel cost savings for coal $50ton Cumulative Incremental capital plus OampM corts

22 -

20 -

18 -- Cumuladve net benefit for shle vs coal $50ton B Cumuarve net benefit for sale vs coal $70ton

16 -

C 14

12

10

08 -06 - Payout In year 1for coal $50ton

04

Payout Inyear 1

for coal $70ton02~

0 0

-No

02-

1 2

Yew inrY MCM cajlaI rl

3 4 5 6

sngm inW coas 0 ort hghWcentWin

0tOM cori

7

--

8

- -

9 10 11 12 13 14

Year of Operation

15 16 17

I

18

IIII

19 20 21 22 23 24 25

Preieasibility Study Oil Shale Fueled Power Generation

17958451 bJordarV118 3-14-89 rsipcI

Estimated Cost of Power- 400 MW (4 x 100)

FUEL

ImportedCoal

$50T

$70fT

1st Year

68 88

Levelized

78 107

Sultani Oil Shale

71 83

ImportedOil

$1713

$2413

56

67

76

96

0 10 20 30 40 50

I 60

I 70

I 80

I 90 100 110 120

Mills per kWh

Prefeasibility Study Oil Shale Fueled Power Generation

179581251 cJordarVl 18 3-14-89 rspc1

Summary Financial Analysis Results

Project size

Debt equity ratio

- Investment cost

- Power cost

- 25-year net benefit

- Project implementation

Alternative fuel price

Economic Comparison

Very significant

Not significant

Not significant

Very significant

Critical

Very significant

Prefeasibility Study

Oil Shale Fueled Power Generation

VY0 tDLUAi3

i

Study Conclusions

Feasibility

Timeliness

Expansion conditions

Environmental impacts

Development advantages

Prefeasibility Study

Oil Shale Fueled Power Generation VW41-1AiUA

4

Feasibility

Oil shale fueled power generation is technically and economically justifiedunder certain conditions

N Need for additional generating capacity

exists

- 6 annual peak demand growth - Orderly retirement of olderhigh cost

generating capacity needed

U Higher costs are expected for imported fuels

- 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

-OP b i j~~4shy

-4protntiYPe 4 demo plnt orP42 t~Plant orPootypeProje(-7hould

that Rj

demo 4Therefore-44 JEA anxinus

the

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

27Pag 4- 1 2S c i n 4 4

4i2Sectjo4-18-4 Secio 4-4 014

lt th~ae hi4h -tasisso syste thrug27 ~ 04lag arstl~art-p tasforme ed 2p27132Kvdieanwhy notthroug

EAto- is protmm~~ thegnJgt~~ pracie an ect ~ platqrby

28Pg 4 s heonnenotedto~the 32K rc powr

It not8 Scection rie049teoervnrain prctc de1

rh u n trae f2V3K anerd not throughgeterAntor

27 P3e-1r p ant weung-a

-If I

2tEll10 DRWE-jOi ASOt Mint~~al d~c~e o hepwrgnrto

ELCTRInYJORD UTHORITY-

Ate~

21Pge41 ection 4 04- 5

sindicated~ t hthigh the unit outputredu f hecondenser Injengtd~ibbvePressureed incg desrin hi h riseb vmbi nt emperatureWe bel~ieve

PleaIse provide us with th rscrapcity for th-e three options n nt generating~

21-Iisidca ted that~ thediaatgeofCBi theSheavy fn oe consumnptionPlease~ providethe us withpecntgA

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

400 MW COAL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO 5050

NET GENERATION - MWe 40000 CAPACITY FACTOR - 75 ANNUAL GENERATION MKWhYR 2628 SUB TOTAL PLANT COSTS (TPC) $1000 $620000

FIXED 0 amp M COSTS MH $ MH FIRST YEAR COST$1O00

------- --------- --- ---- --- --- ------------

OPERATING LABOR 351936 $3 $1100 MAINTENANCE LABOR 4000 of 150 OF TPC 3720

MAINTENANCE MATERIAL 6000

ADMIN LABOR of 150

3000 OF TPC

OF 0 amp M LABOR 5580 1446

SUB TOTAL FIXED OampM COSTS $11846

VARIABLE 0 amp M COSTS QUANTITY UNIT COST

VARIABLE MAINTENANCE 2628 MKWh 10 MILLKWH $ 2628 PROCESS WATER 13500000 GALLON 02 SGAL $ 2700 GENERAL PLANT CHEMICALS ALLOW 50 FUEL OIL 1000000 GALLON 035 $GAL $ 350 WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290SPECIAL BOILER MAINT ALLOW 0

SUB TOTAL VARIABLE OampM COSTS $ 8018

TOTAL FIXED amp VARIABLE OampM COSTS $19864 TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $8227 $TN $99139

(INCL INFLATION ADJUSTMENT)

B DEBT EQUITY RATIO =========== 8020

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $17574

WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290

TOTAL FIXED amp VARIABLE OampM COSTS $19864TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $5877 $TN $70814

(INCL INFLATION ADJUSTMENT)

6-21

Table 612 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY

400 MW OIL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO

NET GENERATION -

CAPACITY FACTOR -

ANNUAL GENERATION SUB TOTAL PLANT COSTS (TPC)

FIXED 0 amp M COSTS

OPERATING LABOR MAINTENANCE LABOR 4000 of

MAINTENANCE MATERIAL 6000 of

ADMIN LABOR

SUB TOTAL FIXED OampM COSTS

VARIABLE 0 amp M COSTS

VARIABLE MAINTENANCE PROCESS WATER GENERAL PLANT CHEMICALS FUEL OIL WASTE DISPOSAL (Section 6027) SPECIAL BOILER MAINT

SUB TOTAL VARIABLE OampM COSTS

5050

MWe

MKWhYR $1000

MH

262080

150

150 3000

QUANTITY

2628 MKWh 13500000 GALLON

1000000 GALLON 0 TNYR

TOTAL FIXED amp VARIABLE OampM COSTS FUEL OIL 503000 TNYR

B DEBT EQUITY RATIO =8020

40000 75

268 $443000

FIRST YEAR $ MH COST$1O00

$3 $ 800

OF TPC 2658

OF TPC 3987 OF 0 amp M LABOR 1037

$ 8482

UNIT COST

05 MILLKWH $ 1314 02 $GAL $ 2700

ALLOW 50 035 $GAL $ 350

$1000 $TN $ 0 ALLOW 0

$ 4414

$12896 $19981 $TN $100502

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $12896

WASTE DISPOSAL (Section 6027) 0 TNYR $1000 $TN $ 0

TOTAL FIXED amp VARIABLE OampM COSTS $12896 FUEL OIL 503000 TNYR $14104 $TN $70943

6-23

Page 11: fo; - pdf.usaid.gov

_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

Pilot Plant Test Program (Contd)

U Analyzed one blended sample of shale

- Calorific value = 532 - 597 MJkg (approx 2250 BtuIlb)

- Carbon content (dry solids) = 162 - 187 wto

- Sulfur content (dry solids) = 30 - 33 wt

- Ash content (dry solids) = 667 - 684 wt

- Shale size = minus 8 mm

Key items determined

- Combustion efficiency

- Product ash distribution

- Product gas S02NOxCO content

- Data for boiler design

- Sulfur emissions reduction by Ca in fuel

S Prefeasibility Study Oil Shale Fueled Power Generation

VOO74GEAJI 10

Pilot Plant Test Results

U Combustion efficiency exceeded 985 in all tests

Ash distribution (btm ashfly ash) was 3565 to 4753 at 100 load typically4060

Low emissions were demonstrated

Typically S02 10 to 200 ppm gt 95 removal

limestone addition not required

NOx 60 to 120 ppm lt 020 lb106 Btu

Co 10 to 90 ppm lt 50 ppm

Prefeasibility Study Oi Shale Fueled Power Generation

TITLE

Ternpe -al-CuA vs 6 Ik

00

I00

7SA-A-

Fly Ai h

0

85 e

80-

0

00

i I 800 860 oo

T-er pe -

DATE OWN APPD DCNO- ------ -

_______f - _ IPG_

Pilot Plant Test Conclusions

It is technically feasible to burn the Sultani oil shale furnished by NRA in a Pyropower boiler

A high combustion efficiency in excess of 985 was demonstrated

SO2NOxCO emissions are all acceptably low with no limestone addition required

Prefeasibility StudyO Shale Fueled Power Generation

Conceptual Design Studies Scope

m Three project sizes

- 20 MW

- 50 MW

- 400 MW (4x100) factored for power plant portion

m Open-pit mine

- Shale processing at the surface - Waste disposal system

Power block

- Boiler

- Steam turbine

- Auxiliaries

Prefeasibility Study Oil Shale Fueled Power Generation

VOn 4FAIR 1

i

Project Layout 9 fc =f4j

deg2

o r -w (031

5_7EC 45U

iPefeaibiity tud

OlSeFuedP erGr in

179581113i~o(atyvv11

n1- 14 4pc

C)

Sultani Oil Shale Reserves

North South Area Area Total

Mineable shale tonne x 106 320 658 978

Fischer assay oil content wt 744 761 765

Overburden m3 x 106 384 627 1011

Stripping ratio m3m3 2161 1711 1861

bull Based on NRA core drilling and core analysis

Prefeasibility Study Oil Shale Fueled Power Generation

VWO41OFEAMI14

i

Sultani Oil Shale Analyses

Moisture

Ash (less CO 2 in CaCO 3 )

CO 2 (in CaCO 3 )

Carbon (organic)

Hydrogen

Nitrogen

Sulfur

Oxygen (by diff)

Total

High heating value BtuIb

Fischer assay oil content

bull Percent by weight

Design Basis Fuel

320

6680

1387

1132

113

048

255

065

10000

2250

840

Low High Calorific Calorific

Value Fuel Value Fuel

320 320

6730 6625

1414 1337

1020 1250

102 125

058 038

238 271

118 034

10000 10000

2000 2500

750 925

Preteasibility Study Oil Shale Fueled Power Generation

vo0N d-GEAR 1S

50 MW Oil Shale ProcessingPrototype Plant

Mlne Plant

_ 14 0 Haul0___) to Plant 1 Sorage

Portable Crusher

(-)100 mm Storage

(-) 100 mm Hopper UIU 400 th

Feed Bin

J 50

250 tvb

8 -m Circulating Load Impact3or0 0 30 0 0shy+8mm25

30 0L Sampler 0 1 30 0

p3 Day Storage

To Power Plant

Preleasibility StudyOil Shale Fueled Power Generation

17958101 SaJordanli 18 3-14-89 rsipc1

20 MW Oil Shale Demonstration Plant

Mine Plant

Haul00- 01 o

= Pb n Storage Portable _

110 mm Stora e 0

()100 mm r Hopper

U 400V

Feed Bin

CirculatingLoad3 Day Stoge

Prefea~ltSudy Shale Fueled Power Generation

179S 111p 1 11Joda3 yl 3-202-89 8vk2

I

Mine and Shale ProcessingDesign - 2050 MW Project

I Overburden removal (north pit area) 10-meter benches

- Drill and blast

- 10 m3 front-end loader

- 77-ton truck haulage

I Oil shale mining 10-meter benches

- Rippe and auger scraper

- Front-end loader

- Portable in-pit crusher

- 77-ton truck haulage

Oil shale processing

- Feed = minus 100 mm

- Product = minus 8 mm

- Capacity = 250 tph

- Reversible impactor

- Two vibrating screens

1 Prefeasibility Study Oil Shale Fueled Power Generation

V -M 1AMI1ARt46

400 MW Full-Scale Oil Shale ProcessingPlant

Feed MTnus 200 mm Samplerr

1000 bull 10000 Tonnes Live Storage Grade

200 m long(-) 200 mm -- =-- Plow Feeders

00 h 100000 Tonnes Live Storage

Stream 3 - Sampler Bin Stream 2

Stream th 31Da2000

Circulating Load 2i

NFw Feed r -17000t1 170001l 170 t 17000 t 17000 t

1000 th Silo with 7 Impactor (-1)8 mm Reapro- 3 Day Storage at Aver age Loadn

0 20 Feeders 20 m Diameter by 40 m High

JJJTHT To Power Plant

Prefeasibility Study Oil Shale Fueled Power Generation

179589 6aJordarV 1I8 3-14-89 rsipc1

Mine and Shale ProcessingDesign - 4x100 MW Project

m Overburden removal (north area) 10-meter benches

- Drill and blast

- Three 20 m3 shovels

- 136-ton truck haulage

m Oil shale mining 10-meter benches

- Two mechanical surface miners

- 136-ton trucks to pit hopper

- Belt conveyor = 2000 tph

- Traveling stacker

m Oil shale processing

- Feed = minus 200 mm

- Product = minus 8 mm

- Capacity = three 1000 tph units

Prefeasibility Study Oil Shale Fueled Power Generation

VOO79-ampGEAIAt 17

i

Steady-State Production Schedule

Overburden removal bench m3

20 MW demo project 5n MW prototype 4x100 MW full-scale plant

Oil shale mining and shale processing tonnes

20 MW project 50 MW project 4x100 MW project

HourlyDesign Capacity

282 234

1850

HourlyDesign Capacity

250 250

2000

Avg Daily Annual PEQuctiQa Production

1690 507000 4217 13 million

33333 10 million

Max Daily(a) Annual(b) Production Production

1733 390000 4324 973000

34578 78 million

(a) Based on 100 operating factor for power block

(b) Based on 75 operating factor for power block ( 20 MW project = 300 shiftsyr 50 MW project = 900 shiftsyr 400 MW project = 900 shiftsyr)

Prefeasibility Study Oil Shale Fueled Power Generation

Conceptual Power Plant Plans

m Pyroflow boiler

Power generating facilities

m Auxiliaries

S Preleasibility Study Oil ShaJe Fueled Power Generation

vo0o7dEAO 19

Pyroflow Boiler SteamConciflons

Flow rate 226700 kghr (500000 Ibhr)

Pressure 1099 kgcm2 abs (15635 psia)

Temperature 51280C (9550F)

Same for 20 50 and 100 MW designs

Prefeasibility Study Oil ShaJe Fueled Power Generation

vooGALMI 20

HtomCOPUIOTP

- 50005 5op

-- LEVAThUM ORPORAION

0

-VI

DZ 4

Power Block

Fuel handling system

- Day binsscrew feeders

Boiler

- Pyroflow circulating fluid bed combustor

Power generation

- Non reheat condensing steam turbine

- Conventional Rankin steam cycle

Ash handling system (btm ash irom combustor and flyash from bag house)

- Wetted in pug mill to add 20plusmn wt wpter

Plant service water

- Air-cooled condensors and small cooling tower from circulating trim water coolers

Plant raw water

- To cooling tower makeup

- To drinking water system

- To pump seals etc

Plant treated makeup water

- Demineralizer train

Preteasibility Study Oil Shale Fueled Power Generation

i

Onsite Infrastructure

Project office

Control house

U Maintenance shops warehouse

Laboratory

Employee service facility

Site developmentoperations service facilities

- Fire controlsecurity

- Communications

- Lighting

- Roads drainage and sewage

Prefeasibility StudyQ1I Shale Fueled Power Generation

voo4JG m 0 JV

i

BechtellPyropower50 MW Cogeneration Plant - Mt Poso California

W4t Prefeasibility Study --- 7 Oil Shale Fueled Power Generation

179586122aJordarv 118 3-14-89 rsO

Characteristics of Three Size Operations

Oil shale fuel tpy

Mine development excavation bank m3

Spent ash disposal tpy (wetted)

Water consumption 1000 m3yr

Staffing required

Community population

400 MW

20 MW 50 MW (4x1 00)

390000 973000 78 million

500000 1 million 85 million

327000 815000 61 million

538 907 1263

185 324 1046

700 1200 4000

Prefeasibility Study Oil Shale Fueled Power Generation

V000ofllAM1 23

Conceptual Designs Summary

N All BOP facilities involve conventional equipment and technology

100 MW unit operation involves boiler scale-up considerations

N Water consumption estimates

- Requirement for 4x100 MW project is 13 million m3 yr

- Water allocation of 2 million m3yr of water supports 6x100 MW

N Water availability probably limits total power generation from oil shale in Jordan

Prefeasibility Study Oil Shale Fueled Power Generation

V007041GEAOLMI

i

TECHNOLOGY RISK ASSESSMENT

Basic concepts

Key boiler scale-up design issues

Impact of scale-up

U Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Prefeasibility Study O1 Shale Fueled Power Generation

VOOh-7AEAAO 2

Basic Concepts

U CFBC is relatively new in the powerindustry

- Existing plants are small typically 20 to 50 MW

- There is limited operating experience with high-ash fuels

- Existing designs for lignite biomass and coal wastes show good plant performance

I Application of CFBC boiler design to oil shale fuel has defined risk that relates to scale-up of existing design

Similar CFBC technology is used in petroleum refining industry

- FCC cracking plant regenerators burn carbon residue off spent catalyst

- 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

FUEL ANALYSES

High Ash Fuel Projects Total Solids Input Basis

Gilberton Cambria North Branch

Carbon 4653 2749 1822 Hydrogen 153 164 160 Sulfur 073 222 234 Nitrogen 085 051 043 Oxygen 282 218 468 Moisture 1451 514 557 Ash 3303 6 0 6Z16

10000 10000 10000

HHVBtulb 7485 4809 3453

includes limestone feed a3 ash

includes CO2 in Ca~o3

CA89029 CAkw

Oil Shale

1132

113

255

048

065

320

-8062

10000

2250

Key Boiler Scale-Up DesignIssues

m Solids handling

- Feeding shale to combustor

- 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

Voo4tGEAMI 30

i

Mine and Shale Processing

U Fugitive dust emissions are controllable

- Wetting mine roads

- Enclose crushing plant equipment

Noise levels are controllable

- Enclose crushing plant equipment - Muffle truck exhausts

- Engineered waste disposal

Water effluents can be controlled

- Need good mine drainage design - Continue leachability studies on

waste dump piles

Prefeasibilily StudyOil Shale Fueled Po r Generaton

V0079OOG-4O 31

1

Power Plant

II Fugitive dust emissions are controllable

- Baghouse designoperation will minimize particulates in flue gas

- Wetting spent ash before disposal

N Gaseous emissions are controllable

- Pilot test results show acceptable SO2NOxCO in flue gas

- Develop baseline data for Sultani area

Develop air dispersion model for Sultani

Prefeasibility StudyOil Shale Fueled Power Generatio

V00 V-4GEA l32

i

Power Plant (Contd)

Noise levels are controllable

- Enclose boiler plant fans as required - Enclose turbines and pumps as

required

Water effluents are controllable

- Continue leachability studies on spent ash disposal

- Develop aquifer dispersion model

- Develop sewage and garbage disposal plan

Prefeasibility SludyOil Shale Fueled Power Generation

V00-4FAAI 33

Conclusions

No environmental constraints are anticipated on oil shale powerdevelopment

Gas effluents will meet World Bank standards

- Ash disposal is manageable

- The potential for groundwatercontamination appears low

- Water effluents will be minimal

Continued studies to develop air and groundwater baseline data are recommended

S Prefeasibility Study Oil Shale Fueled Power Generation

v0 9ampGLAMR 34

Power Demand vs SupplyAssessment

m Demand growth forecasts

Electrical generating capacity

= Power supply forecasts

= Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Preleasibility Study Oil Shaie Fuelod Power Generation

VO9- uLIROI

1

Power Demand Forecasts

Percent Annual Growth

JEA

Meta systems HaglerBailey and Bechtel National Inc

JEA Peak Demand Growth

1980 (actual) 1985 (actual) 1987 (actual) 1995 (forecast) 2005 (forecast)

1986 1990 to to

1990 2000

97 60

49 39

200 MW 475 MW 593 MW 900 MW

1400 MW

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOO-DLURO2

i

JEA ElectricityGeneratingCapacity

1987 Installed

Capacity (MW) Aqaba 260

22

Zarqa 395

Marka 102

Karak 23

Miscellaneous 67

Subtotal JEA capacity 869

Other capacity - industrial 110

Total 979

Prefeasibility Study Oi1 Shale Fueled Power Generation

V000-6O0LFJRO3 (

Forecast New Power Generating Capacity Required

Fcst 1987 Required

New Peak Available Installed

Demand Capacity Shortfall (a) Capacity (b) (MM (MW) (MW) (MW)

Assumed capacityfactor (65) (75)

1995 requirement 900 636 264 352

2005 requirement 1400 636 764 1019

(a) Excludes proposed additions and retirements (b) Excludes possible power exports or imports

Load shedding or levelizing not considered

Preteasibility Study Oil Shale Fueled Power Generation

Vflcmf-R)LLAO4

i

Supply vs Demand Evaluation

1800

1600

1400 Forecast Peak Demands

1200 -

E Installed Capacity

0 800shy75--

U) Assumed Available Calcit

a 6 Ao600 shy0 o 65

400 shy

200

I I I I I I I I I I I I I I I I I I I I I I I 1 1 1980 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958f738aIJordarV 118 3-14-89 rspCO

Conclusions

Additional power generating capacity is needed to meet forecasted 19952005demand growth

A 400 MW oil shale-to-power project at Sultani can meet a portion of this need

U A second 400 MW oil shale project maybe required if water is available

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOW0O-8LURO5

i

Economic Feasibility

N Order-of-magnitude costs

N Economic analysis

- Jordan study options

- Project size effect

m Comparison with alternative fuels

- Fuel requirement

- Project financing effect

- Alternate fuel price effect

- Estimated cost of electricity

N Summary financial analysis

bull Material was developed by Bechtel Power Company

Prefeasibility Study

go Oil Shale Fueled Power Generation VOOSO-ampDtJROh

ORDER-OF-MAGNITUDE COSTS

U Oil shale fuel

Power plant

I Integrated project- busbar

Preteasibility Study

Oil Shale Fueled Power Generation

VOO9O-ampDLUROS

Oil Shale Fuel Costs

Installed Capital Cost

Mine Development

Mine Equipment

Processing Plant

Spare Parts

Working Capital

Capitalized Interest

Total

Annual Operating Cost

Fuel Cost $UStonne

bull Based on 8020 debtequity ratio

20 MW

4900

11090

6945

1200

1200

4054

29389

5582

1431

US $1000 Factored

50 MW 4x100 MW

7833 30915

12202 66012

8388 50889

1300 5000

2200 10000

5108 39075

37031 201891

11556 53236

1188 684

Prefeasibility Study

Oil Shale Fueled Power Generation

VCO-ampDLUJ1O

Power Plant Costs

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Cost

Power faciities 57500 91800 567800

Owners cost 10200 20400 192700

Total 67700 112200 760500

Annual Operating Cost 2205 3248 17157(excluding fuel cost)

bullBased on 8020 debtequity ratio oil shale fueled

Prefeasibility Study

Oil Shale Fueled Power Generation

V00O8c4LLMO9

i

INTEGRATED PROJECT -BUSBAR COST

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Costs Mine amp shale processingPower block Waste disposal Infrastructure

29359 67700

1664 10000

37031 112200

2381 15000

201891 760500

8714 45000

TOTAL 108753 166612 1016105

Annual Operating Cost Mine amp shale processingPower block Waste disposal Infrastructure (a)

5582 2205

316

11556 3248

710

56430(b) 18186(b) 6004

Subtotal 8103 15514 80620

Capital Charges 139 9410 15596 106000

Total 17513 31110 186620

25-year levelized cost - - 218000

Busbar Cost millskWh First year 128 92 71 25-year levelized 83

(a) Housing and community facilities assumed self-liquidating(b) Includes first-year inflation adjustment

Based on 8020 debtequity ratio

Prefeasibility StudyOil Shale Fueled Power Generaion

VOOOO-8MLtROi0

ECONOMIC ANALYSIS

n Jordan study options

Project size effect

Fuel requirement

Project financing effect

Alternative fuel price effect

Estimated electricity cost

Summary financial analysis results

Prefeasibility Study

Oil Shale Fueled Powr Generation

VOOeO-BOCLLO1 I

i

Jordan Study Options

U Project size

- Demonstration = 20 MW

- Prototype = 50 MW

- Commercial = 400 MW (4x100)

Project financing

- Debtequity 8020

- Debtequity 5050

Imported alternative fuels cost assumptions

A B Crude oil $17bbl $24bbl

$120onne $170tonne

Low sulfur coal $ 50tonne $ 70tonne See Chevron forecast supporting assumptions

Prefeasibility StudyOil Shale Fueled Power Generation

VOOOO-8DLIJRO12

i

Crude Oil Price Trends

60

Source World Energy Outlook Chevron Corporation Oclober 1987

40

High trend

No Ir 20 ~~~~Arabian Light Spot I A u

IILowYUII trend

0 1970 1975 1980 1985 1990 1995

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958246aJodar 118 3-14-89 rsO

2000

Project Size Effect Shale Fuel Option

Project Size

Integrated facilities installed capital cost$ US million

Shale cost $UStonne(8020 debtequity)

Cost of power millskWh(8020 debtequity ratio)

20 MW

109

143

128

50 MW

167

118

92

400 MW (4x1 00)

1016

68

71

Prefeasibility Study Oil Sampae Fueled Power Generation

VOO O-8I0LJRO13

gt1

1

Power Block Investment Cost

3000

$2875 Excluding mining and offsite 2800

2600

2400

2200

2000

$1836 1800

$1613 1600

$1420 1400 1I 1 I

0 100 200 300 400 MWe

August 1988

Preleasibility Study OilShale Fueled Power Generation

179581147aJodar1 18 3-14-89 rspcl

Fuel Requirement - 4x100 MW Project

Coal = 12 million tpy

n Oil = 503000 tpy

Oil shale = 78 million tpy

Preleasibility Study

Oil Shale Fueled Power Generation

IO060-OLLIRO14

Financing Effect -Project

Oil Shale Fuel Option

Mine and shale processing

Power block

Waste disposal

Community facilities

Total

Coal-Fired Power Plant

Oil-Fired Power Plant

400 MW

Capital Cost ($US MM)

DebtEquity

8020 5050

202 187

760 760

9 8

45 45

1016 1000

647 647

463 463

Prefeasibility StudyOil Shale Fueled Power Generation

VOe-BD1JRO15

Financing Effect shy400 MW Project

Operating Costs ($US millionyr)

DebtEquity

8020 5050

Coal $70tonne 282 282

Oil $24bbl 254 254

Oil shale-fueled 218 236

Including fuel

Prefeasibility Study

SOil Shale Fueled Power Generaion

VOOIt JLMO I

Alternate Fuel Price Effect shy4x100 MW Project

Financing Basis DebtEquity Ratio

Alternate Fuel Price

Imported coal $50tonne $70tonne

Imported oil $17bbl ($120tonne) $24bbl ($170tonne)

Cumulative 25-yr Net Benefit

Favoring Oil Shale (US $MM) shy

8020 5050

778 315 2531 2068

(18) (506)1810 1322

Prefeasibility Study

Oil Shale Fueled Power Generation

Voo -I DLU-A 2

i

Comparison of Cumulative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

32 Pay Out Year shy

400 MW PlantOil Shale vs Imported Coal (8020 debtequty)

30

28 -Cumulative fuel cost savings forcoal $70ton

Cumulative fuel cost savings for coaJ $50ton

26---------- Cumulative Incremental capital plus OampM costs

24

22 -

18 -0

W- Cumulative net benefit for shae vs coal $50ton 2B Cumulative net benefit for shale vs coal $70ton

co16C -

14 -

12 -

10 -

09

06 -Payout inyear 1

Payout Inyear 9 for coal $50ton - -- - - -shy

02 0 I

0 1 2 3 4 5 Nowl Yewr in which sauings in fWe colsacm-ewi tat hsawinitl

ca=al wosaand OampM costs

6

_iiM

7 8

9 10

------ - -amp -

11 12 13 14Year of Operation

--

15

- - --shy

16 17

I

18

1

19

I

20

I

21

I

22

I

23

I

24 25

Prefeasibility StudyOil Shale Fueled Power Generation

17958d351aJordanr 3-14-89 rsO

118

Comparison of Cumuiative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

28 Pay Out Year shy

400 MW Plant Oil Shale vs Imported Coal (5050 debtequity)

26shy2

24-

Cumulaive fuel nst savings for coal 0 $70ton Cumulative fuel cost savings for coal $50ton Cumulative Incremental capital plus OampM corts

22 -

20 -

18 -- Cumuladve net benefit for shle vs coal $50ton B Cumuarve net benefit for sale vs coal $70ton

16 -

C 14

12

10

08 -06 - Payout In year 1for coal $50ton

04

Payout Inyear 1

for coal $70ton02~

0 0

-No

02-

1 2

Yew inrY MCM cajlaI rl

3 4 5 6

sngm inW coas 0 ort hghWcentWin

0tOM cori

7

--

8

- -

9 10 11 12 13 14

Year of Operation

15 16 17

I

18

IIII

19 20 21 22 23 24 25

Preieasibility Study Oil Shale Fueled Power Generation

17958451 bJordarV118 3-14-89 rsipcI

Estimated Cost of Power- 400 MW (4 x 100)

FUEL

ImportedCoal

$50T

$70fT

1st Year

68 88

Levelized

78 107

Sultani Oil Shale

71 83

ImportedOil

$1713

$2413

56

67

76

96

0 10 20 30 40 50

I 60

I 70

I 80

I 90 100 110 120

Mills per kWh

Prefeasibility Study Oil Shale Fueled Power Generation

179581251 cJordarVl 18 3-14-89 rspc1

Summary Financial Analysis Results

Project size

Debt equity ratio

- Investment cost

- Power cost

- 25-year net benefit

- Project implementation

Alternative fuel price

Economic Comparison

Very significant

Not significant

Not significant

Very significant

Critical

Very significant

Prefeasibility Study

Oil Shale Fueled Power Generation

VY0 tDLUAi3

i

Study Conclusions

Feasibility

Timeliness

Expansion conditions

Environmental impacts

Development advantages

Prefeasibility Study

Oil Shale Fueled Power Generation VW41-1AiUA

4

Feasibility

Oil shale fueled power generation is technically and economically justifiedunder certain conditions

N Need for additional generating capacity

exists

- 6 annual peak demand growth - Orderly retirement of olderhigh cost

generating capacity needed

U Higher costs are expected for imported fuels

- 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

-OP b i j~~4shy

-4protntiYPe 4 demo plnt orP42 t~Plant orPootypeProje(-7hould

that Rj

demo 4Therefore-44 JEA anxinus

the

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

27Pag 4- 1 2S c i n 4 4

4i2Sectjo4-18-4 Secio 4-4 014

lt th~ae hi4h -tasisso syste thrug27 ~ 04lag arstl~art-p tasforme ed 2p27132Kvdieanwhy notthroug

EAto- is protmm~~ thegnJgt~~ pracie an ect ~ platqrby

28Pg 4 s heonnenotedto~the 32K rc powr

It not8 Scection rie049teoervnrain prctc de1

rh u n trae f2V3K anerd not throughgeterAntor

27 P3e-1r p ant weung-a

-If I

2tEll10 DRWE-jOi ASOt Mint~~al d~c~e o hepwrgnrto

ELCTRInYJORD UTHORITY-

Ate~

21Pge41 ection 4 04- 5

sindicated~ t hthigh the unit outputredu f hecondenser Injengtd~ibbvePressureed incg desrin hi h riseb vmbi nt emperatureWe bel~ieve

PleaIse provide us with th rscrapcity for th-e three options n nt generating~

21-Iisidca ted that~ thediaatgeofCBi theSheavy fn oe consumnptionPlease~ providethe us withpecntgA

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

400 MW COAL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO 5050

NET GENERATION - MWe 40000 CAPACITY FACTOR - 75 ANNUAL GENERATION MKWhYR 2628 SUB TOTAL PLANT COSTS (TPC) $1000 $620000

FIXED 0 amp M COSTS MH $ MH FIRST YEAR COST$1O00

------- --------- --- ---- --- --- ------------

OPERATING LABOR 351936 $3 $1100 MAINTENANCE LABOR 4000 of 150 OF TPC 3720

MAINTENANCE MATERIAL 6000

ADMIN LABOR of 150

3000 OF TPC

OF 0 amp M LABOR 5580 1446

SUB TOTAL FIXED OampM COSTS $11846

VARIABLE 0 amp M COSTS QUANTITY UNIT COST

VARIABLE MAINTENANCE 2628 MKWh 10 MILLKWH $ 2628 PROCESS WATER 13500000 GALLON 02 SGAL $ 2700 GENERAL PLANT CHEMICALS ALLOW 50 FUEL OIL 1000000 GALLON 035 $GAL $ 350 WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290SPECIAL BOILER MAINT ALLOW 0

SUB TOTAL VARIABLE OampM COSTS $ 8018

TOTAL FIXED amp VARIABLE OampM COSTS $19864 TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $8227 $TN $99139

(INCL INFLATION ADJUSTMENT)

B DEBT EQUITY RATIO =========== 8020

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $17574

WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290

TOTAL FIXED amp VARIABLE OampM COSTS $19864TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $5877 $TN $70814

(INCL INFLATION ADJUSTMENT)

6-21

Table 612 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY

400 MW OIL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO

NET GENERATION -

CAPACITY FACTOR -

ANNUAL GENERATION SUB TOTAL PLANT COSTS (TPC)

FIXED 0 amp M COSTS

OPERATING LABOR MAINTENANCE LABOR 4000 of

MAINTENANCE MATERIAL 6000 of

ADMIN LABOR

SUB TOTAL FIXED OampM COSTS

VARIABLE 0 amp M COSTS

VARIABLE MAINTENANCE PROCESS WATER GENERAL PLANT CHEMICALS FUEL OIL WASTE DISPOSAL (Section 6027) SPECIAL BOILER MAINT

SUB TOTAL VARIABLE OampM COSTS

5050

MWe

MKWhYR $1000

MH

262080

150

150 3000

QUANTITY

2628 MKWh 13500000 GALLON

1000000 GALLON 0 TNYR

TOTAL FIXED amp VARIABLE OampM COSTS FUEL OIL 503000 TNYR

B DEBT EQUITY RATIO =8020

40000 75

268 $443000

FIRST YEAR $ MH COST$1O00

$3 $ 800

OF TPC 2658

OF TPC 3987 OF 0 amp M LABOR 1037

$ 8482

UNIT COST

05 MILLKWH $ 1314 02 $GAL $ 2700

ALLOW 50 035 $GAL $ 350

$1000 $TN $ 0 ALLOW 0

$ 4414

$12896 $19981 $TN $100502

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $12896

WASTE DISPOSAL (Section 6027) 0 TNYR $1000 $TN $ 0

TOTAL FIXED amp VARIABLE OampM COSTS $12896 FUEL OIL 503000 TNYR $14104 $TN $70943

6-23

Page 12: fo; - pdf.usaid.gov

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

Pilot Plant Test Program (Contd)

U Analyzed one blended sample of shale

- Calorific value = 532 - 597 MJkg (approx 2250 BtuIlb)

- Carbon content (dry solids) = 162 - 187 wto

- Sulfur content (dry solids) = 30 - 33 wt

- Ash content (dry solids) = 667 - 684 wt

- Shale size = minus 8 mm

Key items determined

- Combustion efficiency

- Product ash distribution

- Product gas S02NOxCO content

- Data for boiler design

- Sulfur emissions reduction by Ca in fuel

S Prefeasibility Study Oil Shale Fueled Power Generation

VOO74GEAJI 10

Pilot Plant Test Results

U Combustion efficiency exceeded 985 in all tests

Ash distribution (btm ashfly ash) was 3565 to 4753 at 100 load typically4060

Low emissions were demonstrated

Typically S02 10 to 200 ppm gt 95 removal

limestone addition not required

NOx 60 to 120 ppm lt 020 lb106 Btu

Co 10 to 90 ppm lt 50 ppm

Prefeasibility Study Oi Shale Fueled Power Generation

TITLE

Ternpe -al-CuA vs 6 Ik

00

I00

7SA-A-

Fly Ai h

0

85 e

80-

0

00

i I 800 860 oo

T-er pe -

DATE OWN APPD DCNO- ------ -

_______f - _ IPG_

Pilot Plant Test Conclusions

It is technically feasible to burn the Sultani oil shale furnished by NRA in a Pyropower boiler

A high combustion efficiency in excess of 985 was demonstrated

SO2NOxCO emissions are all acceptably low with no limestone addition required

Prefeasibility StudyO Shale Fueled Power Generation

Conceptual Design Studies Scope

m Three project sizes

- 20 MW

- 50 MW

- 400 MW (4x100) factored for power plant portion

m Open-pit mine

- Shale processing at the surface - Waste disposal system

Power block

- Boiler

- Steam turbine

- Auxiliaries

Prefeasibility Study Oil Shale Fueled Power Generation

VOn 4FAIR 1

i

Project Layout 9 fc =f4j

deg2

o r -w (031

5_7EC 45U

iPefeaibiity tud

OlSeFuedP erGr in

179581113i~o(atyvv11

n1- 14 4pc

C)

Sultani Oil Shale Reserves

North South Area Area Total

Mineable shale tonne x 106 320 658 978

Fischer assay oil content wt 744 761 765

Overburden m3 x 106 384 627 1011

Stripping ratio m3m3 2161 1711 1861

bull Based on NRA core drilling and core analysis

Prefeasibility Study Oil Shale Fueled Power Generation

VWO41OFEAMI14

i

Sultani Oil Shale Analyses

Moisture

Ash (less CO 2 in CaCO 3 )

CO 2 (in CaCO 3 )

Carbon (organic)

Hydrogen

Nitrogen

Sulfur

Oxygen (by diff)

Total

High heating value BtuIb

Fischer assay oil content

bull Percent by weight

Design Basis Fuel

320

6680

1387

1132

113

048

255

065

10000

2250

840

Low High Calorific Calorific

Value Fuel Value Fuel

320 320

6730 6625

1414 1337

1020 1250

102 125

058 038

238 271

118 034

10000 10000

2000 2500

750 925

Preteasibility Study Oil Shale Fueled Power Generation

vo0N d-GEAR 1S

50 MW Oil Shale ProcessingPrototype Plant

Mlne Plant

_ 14 0 Haul0___) to Plant 1 Sorage

Portable Crusher

(-)100 mm Storage

(-) 100 mm Hopper UIU 400 th

Feed Bin

J 50

250 tvb

8 -m Circulating Load Impact3or0 0 30 0 0shy+8mm25

30 0L Sampler 0 1 30 0

p3 Day Storage

To Power Plant

Preleasibility StudyOil Shale Fueled Power Generation

17958101 SaJordanli 18 3-14-89 rsipc1

20 MW Oil Shale Demonstration Plant

Mine Plant

Haul00- 01 o

= Pb n Storage Portable _

110 mm Stora e 0

()100 mm r Hopper

U 400V

Feed Bin

CirculatingLoad3 Day Stoge

Prefea~ltSudy Shale Fueled Power Generation

179S 111p 1 11Joda3 yl 3-202-89 8vk2

I

Mine and Shale ProcessingDesign - 2050 MW Project

I Overburden removal (north pit area) 10-meter benches

- Drill and blast

- 10 m3 front-end loader

- 77-ton truck haulage

I Oil shale mining 10-meter benches

- Rippe and auger scraper

- Front-end loader

- Portable in-pit crusher

- 77-ton truck haulage

Oil shale processing

- Feed = minus 100 mm

- Product = minus 8 mm

- Capacity = 250 tph

- Reversible impactor

- Two vibrating screens

1 Prefeasibility Study Oil Shale Fueled Power Generation

V -M 1AMI1ARt46

400 MW Full-Scale Oil Shale ProcessingPlant

Feed MTnus 200 mm Samplerr

1000 bull 10000 Tonnes Live Storage Grade

200 m long(-) 200 mm -- =-- Plow Feeders

00 h 100000 Tonnes Live Storage

Stream 3 - Sampler Bin Stream 2

Stream th 31Da2000

Circulating Load 2i

NFw Feed r -17000t1 170001l 170 t 17000 t 17000 t

1000 th Silo with 7 Impactor (-1)8 mm Reapro- 3 Day Storage at Aver age Loadn

0 20 Feeders 20 m Diameter by 40 m High

JJJTHT To Power Plant

Prefeasibility Study Oil Shale Fueled Power Generation

179589 6aJordarV 1I8 3-14-89 rsipc1

Mine and Shale ProcessingDesign - 4x100 MW Project

m Overburden removal (north area) 10-meter benches

- Drill and blast

- Three 20 m3 shovels

- 136-ton truck haulage

m Oil shale mining 10-meter benches

- Two mechanical surface miners

- 136-ton trucks to pit hopper

- Belt conveyor = 2000 tph

- Traveling stacker

m Oil shale processing

- Feed = minus 200 mm

- Product = minus 8 mm

- Capacity = three 1000 tph units

Prefeasibility Study Oil Shale Fueled Power Generation

VOO79-ampGEAIAt 17

i

Steady-State Production Schedule

Overburden removal bench m3

20 MW demo project 5n MW prototype 4x100 MW full-scale plant

Oil shale mining and shale processing tonnes

20 MW project 50 MW project 4x100 MW project

HourlyDesign Capacity

282 234

1850

HourlyDesign Capacity

250 250

2000

Avg Daily Annual PEQuctiQa Production

1690 507000 4217 13 million

33333 10 million

Max Daily(a) Annual(b) Production Production

1733 390000 4324 973000

34578 78 million

(a) Based on 100 operating factor for power block

(b) Based on 75 operating factor for power block ( 20 MW project = 300 shiftsyr 50 MW project = 900 shiftsyr 400 MW project = 900 shiftsyr)

Prefeasibility Study Oil Shale Fueled Power Generation

Conceptual Power Plant Plans

m Pyroflow boiler

Power generating facilities

m Auxiliaries

S Preleasibility Study Oil ShaJe Fueled Power Generation

vo0o7dEAO 19

Pyroflow Boiler SteamConciflons

Flow rate 226700 kghr (500000 Ibhr)

Pressure 1099 kgcm2 abs (15635 psia)

Temperature 51280C (9550F)

Same for 20 50 and 100 MW designs

Prefeasibility Study Oil ShaJe Fueled Power Generation

vooGALMI 20

HtomCOPUIOTP

- 50005 5op

-- LEVAThUM ORPORAION

0

-VI

DZ 4

Power Block

Fuel handling system

- Day binsscrew feeders

Boiler

- Pyroflow circulating fluid bed combustor

Power generation

- Non reheat condensing steam turbine

- Conventional Rankin steam cycle

Ash handling system (btm ash irom combustor and flyash from bag house)

- Wetted in pug mill to add 20plusmn wt wpter

Plant service water

- Air-cooled condensors and small cooling tower from circulating trim water coolers

Plant raw water

- To cooling tower makeup

- To drinking water system

- To pump seals etc

Plant treated makeup water

- Demineralizer train

Preteasibility Study Oil Shale Fueled Power Generation

i

Onsite Infrastructure

Project office

Control house

U Maintenance shops warehouse

Laboratory

Employee service facility

Site developmentoperations service facilities

- Fire controlsecurity

- Communications

- Lighting

- Roads drainage and sewage

Prefeasibility StudyQ1I Shale Fueled Power Generation

voo4JG m 0 JV

i

BechtellPyropower50 MW Cogeneration Plant - Mt Poso California

W4t Prefeasibility Study --- 7 Oil Shale Fueled Power Generation

179586122aJordarv 118 3-14-89 rsO

Characteristics of Three Size Operations

Oil shale fuel tpy

Mine development excavation bank m3

Spent ash disposal tpy (wetted)

Water consumption 1000 m3yr

Staffing required

Community population

400 MW

20 MW 50 MW (4x1 00)

390000 973000 78 million

500000 1 million 85 million

327000 815000 61 million

538 907 1263

185 324 1046

700 1200 4000

Prefeasibility Study Oil Shale Fueled Power Generation

V000ofllAM1 23

Conceptual Designs Summary

N All BOP facilities involve conventional equipment and technology

100 MW unit operation involves boiler scale-up considerations

N Water consumption estimates

- Requirement for 4x100 MW project is 13 million m3 yr

- Water allocation of 2 million m3yr of water supports 6x100 MW

N Water availability probably limits total power generation from oil shale in Jordan

Prefeasibility Study Oil Shale Fueled Power Generation

V007041GEAOLMI

i

TECHNOLOGY RISK ASSESSMENT

Basic concepts

Key boiler scale-up design issues

Impact of scale-up

U Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Prefeasibility Study O1 Shale Fueled Power Generation

VOOh-7AEAAO 2

Basic Concepts

U CFBC is relatively new in the powerindustry

- Existing plants are small typically 20 to 50 MW

- There is limited operating experience with high-ash fuels

- Existing designs for lignite biomass and coal wastes show good plant performance

I Application of CFBC boiler design to oil shale fuel has defined risk that relates to scale-up of existing design

Similar CFBC technology is used in petroleum refining industry

- FCC cracking plant regenerators burn carbon residue off spent catalyst

- 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

FUEL ANALYSES

High Ash Fuel Projects Total Solids Input Basis

Gilberton Cambria North Branch

Carbon 4653 2749 1822 Hydrogen 153 164 160 Sulfur 073 222 234 Nitrogen 085 051 043 Oxygen 282 218 468 Moisture 1451 514 557 Ash 3303 6 0 6Z16

10000 10000 10000

HHVBtulb 7485 4809 3453

includes limestone feed a3 ash

includes CO2 in Ca~o3

CA89029 CAkw

Oil Shale

1132

113

255

048

065

320

-8062

10000

2250

Key Boiler Scale-Up DesignIssues

m Solids handling

- Feeding shale to combustor

- 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

Voo4tGEAMI 30

i

Mine and Shale Processing

U Fugitive dust emissions are controllable

- Wetting mine roads

- Enclose crushing plant equipment

Noise levels are controllable

- Enclose crushing plant equipment - Muffle truck exhausts

- Engineered waste disposal

Water effluents can be controlled

- Need good mine drainage design - Continue leachability studies on

waste dump piles

Prefeasibilily StudyOil Shale Fueled Po r Generaton

V0079OOG-4O 31

1

Power Plant

II Fugitive dust emissions are controllable

- Baghouse designoperation will minimize particulates in flue gas

- Wetting spent ash before disposal

N Gaseous emissions are controllable

- Pilot test results show acceptable SO2NOxCO in flue gas

- Develop baseline data for Sultani area

Develop air dispersion model for Sultani

Prefeasibility StudyOil Shale Fueled Power Generatio

V00 V-4GEA l32

i

Power Plant (Contd)

Noise levels are controllable

- Enclose boiler plant fans as required - Enclose turbines and pumps as

required

Water effluents are controllable

- Continue leachability studies on spent ash disposal

- Develop aquifer dispersion model

- Develop sewage and garbage disposal plan

Prefeasibility SludyOil Shale Fueled Power Generation

V00-4FAAI 33

Conclusions

No environmental constraints are anticipated on oil shale powerdevelopment

Gas effluents will meet World Bank standards

- Ash disposal is manageable

- The potential for groundwatercontamination appears low

- Water effluents will be minimal

Continued studies to develop air and groundwater baseline data are recommended

S Prefeasibility Study Oil Shale Fueled Power Generation

v0 9ampGLAMR 34

Power Demand vs SupplyAssessment

m Demand growth forecasts

Electrical generating capacity

= Power supply forecasts

= Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Preleasibility Study Oil Shaie Fuelod Power Generation

VO9- uLIROI

1

Power Demand Forecasts

Percent Annual Growth

JEA

Meta systems HaglerBailey and Bechtel National Inc

JEA Peak Demand Growth

1980 (actual) 1985 (actual) 1987 (actual) 1995 (forecast) 2005 (forecast)

1986 1990 to to

1990 2000

97 60

49 39

200 MW 475 MW 593 MW 900 MW

1400 MW

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOO-DLURO2

i

JEA ElectricityGeneratingCapacity

1987 Installed

Capacity (MW) Aqaba 260

22

Zarqa 395

Marka 102

Karak 23

Miscellaneous 67

Subtotal JEA capacity 869

Other capacity - industrial 110

Total 979

Prefeasibility Study Oi1 Shale Fueled Power Generation

V000-6O0LFJRO3 (

Forecast New Power Generating Capacity Required

Fcst 1987 Required

New Peak Available Installed

Demand Capacity Shortfall (a) Capacity (b) (MM (MW) (MW) (MW)

Assumed capacityfactor (65) (75)

1995 requirement 900 636 264 352

2005 requirement 1400 636 764 1019

(a) Excludes proposed additions and retirements (b) Excludes possible power exports or imports

Load shedding or levelizing not considered

Preteasibility Study Oil Shale Fueled Power Generation

Vflcmf-R)LLAO4

i

Supply vs Demand Evaluation

1800

1600

1400 Forecast Peak Demands

1200 -

E Installed Capacity

0 800shy75--

U) Assumed Available Calcit

a 6 Ao600 shy0 o 65

400 shy

200

I I I I I I I I I I I I I I I I I I I I I I I 1 1 1980 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958f738aIJordarV 118 3-14-89 rspCO

Conclusions

Additional power generating capacity is needed to meet forecasted 19952005demand growth

A 400 MW oil shale-to-power project at Sultani can meet a portion of this need

U A second 400 MW oil shale project maybe required if water is available

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOW0O-8LURO5

i

Economic Feasibility

N Order-of-magnitude costs

N Economic analysis

- Jordan study options

- Project size effect

m Comparison with alternative fuels

- Fuel requirement

- Project financing effect

- Alternate fuel price effect

- Estimated cost of electricity

N Summary financial analysis

bull Material was developed by Bechtel Power Company

Prefeasibility Study

go Oil Shale Fueled Power Generation VOOSO-ampDtJROh

ORDER-OF-MAGNITUDE COSTS

U Oil shale fuel

Power plant

I Integrated project- busbar

Preteasibility Study

Oil Shale Fueled Power Generation

VOO9O-ampDLUROS

Oil Shale Fuel Costs

Installed Capital Cost

Mine Development

Mine Equipment

Processing Plant

Spare Parts

Working Capital

Capitalized Interest

Total

Annual Operating Cost

Fuel Cost $UStonne

bull Based on 8020 debtequity ratio

20 MW

4900

11090

6945

1200

1200

4054

29389

5582

1431

US $1000 Factored

50 MW 4x100 MW

7833 30915

12202 66012

8388 50889

1300 5000

2200 10000

5108 39075

37031 201891

11556 53236

1188 684

Prefeasibility Study

Oil Shale Fueled Power Generation

VCO-ampDLUJ1O

Power Plant Costs

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Cost

Power faciities 57500 91800 567800

Owners cost 10200 20400 192700

Total 67700 112200 760500

Annual Operating Cost 2205 3248 17157(excluding fuel cost)

bullBased on 8020 debtequity ratio oil shale fueled

Prefeasibility Study

Oil Shale Fueled Power Generation

V00O8c4LLMO9

i

INTEGRATED PROJECT -BUSBAR COST

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Costs Mine amp shale processingPower block Waste disposal Infrastructure

29359 67700

1664 10000

37031 112200

2381 15000

201891 760500

8714 45000

TOTAL 108753 166612 1016105

Annual Operating Cost Mine amp shale processingPower block Waste disposal Infrastructure (a)

5582 2205

316

11556 3248

710

56430(b) 18186(b) 6004

Subtotal 8103 15514 80620

Capital Charges 139 9410 15596 106000

Total 17513 31110 186620

25-year levelized cost - - 218000

Busbar Cost millskWh First year 128 92 71 25-year levelized 83

(a) Housing and community facilities assumed self-liquidating(b) Includes first-year inflation adjustment

Based on 8020 debtequity ratio

Prefeasibility StudyOil Shale Fueled Power Generaion

VOOOO-8MLtROi0

ECONOMIC ANALYSIS

n Jordan study options

Project size effect

Fuel requirement

Project financing effect

Alternative fuel price effect

Estimated electricity cost

Summary financial analysis results

Prefeasibility Study

Oil Shale Fueled Powr Generation

VOOeO-BOCLLO1 I

i

Jordan Study Options

U Project size

- Demonstration = 20 MW

- Prototype = 50 MW

- Commercial = 400 MW (4x100)

Project financing

- Debtequity 8020

- Debtequity 5050

Imported alternative fuels cost assumptions

A B Crude oil $17bbl $24bbl

$120onne $170tonne

Low sulfur coal $ 50tonne $ 70tonne See Chevron forecast supporting assumptions

Prefeasibility StudyOil Shale Fueled Power Generation

VOOOO-8DLIJRO12

i

Crude Oil Price Trends

60

Source World Energy Outlook Chevron Corporation Oclober 1987

40

High trend

No Ir 20 ~~~~Arabian Light Spot I A u

IILowYUII trend

0 1970 1975 1980 1985 1990 1995

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958246aJodar 118 3-14-89 rsO

2000

Project Size Effect Shale Fuel Option

Project Size

Integrated facilities installed capital cost$ US million

Shale cost $UStonne(8020 debtequity)

Cost of power millskWh(8020 debtequity ratio)

20 MW

109

143

128

50 MW

167

118

92

400 MW (4x1 00)

1016

68

71

Prefeasibility Study Oil Sampae Fueled Power Generation

VOO O-8I0LJRO13

gt1

1

Power Block Investment Cost

3000

$2875 Excluding mining and offsite 2800

2600

2400

2200

2000

$1836 1800

$1613 1600

$1420 1400 1I 1 I

0 100 200 300 400 MWe

August 1988

Preleasibility Study OilShale Fueled Power Generation

179581147aJodar1 18 3-14-89 rspcl

Fuel Requirement - 4x100 MW Project

Coal = 12 million tpy

n Oil = 503000 tpy

Oil shale = 78 million tpy

Preleasibility Study

Oil Shale Fueled Power Generation

IO060-OLLIRO14

Financing Effect -Project

Oil Shale Fuel Option

Mine and shale processing

Power block

Waste disposal

Community facilities

Total

Coal-Fired Power Plant

Oil-Fired Power Plant

400 MW

Capital Cost ($US MM)

DebtEquity

8020 5050

202 187

760 760

9 8

45 45

1016 1000

647 647

463 463

Prefeasibility StudyOil Shale Fueled Power Generation

VOe-BD1JRO15

Financing Effect shy400 MW Project

Operating Costs ($US millionyr)

DebtEquity

8020 5050

Coal $70tonne 282 282

Oil $24bbl 254 254

Oil shale-fueled 218 236

Including fuel

Prefeasibility Study

SOil Shale Fueled Power Generaion

VOOIt JLMO I

Alternate Fuel Price Effect shy4x100 MW Project

Financing Basis DebtEquity Ratio

Alternate Fuel Price

Imported coal $50tonne $70tonne

Imported oil $17bbl ($120tonne) $24bbl ($170tonne)

Cumulative 25-yr Net Benefit

Favoring Oil Shale (US $MM) shy

8020 5050

778 315 2531 2068

(18) (506)1810 1322

Prefeasibility Study

Oil Shale Fueled Power Generation

Voo -I DLU-A 2

i

Comparison of Cumulative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

32 Pay Out Year shy

400 MW PlantOil Shale vs Imported Coal (8020 debtequty)

30

28 -Cumulative fuel cost savings forcoal $70ton

Cumulative fuel cost savings for coaJ $50ton

26---------- Cumulative Incremental capital plus OampM costs

24

22 -

18 -0

W- Cumulative net benefit for shae vs coal $50ton 2B Cumulative net benefit for shale vs coal $70ton

co16C -

14 -

12 -

10 -

09

06 -Payout inyear 1

Payout Inyear 9 for coal $50ton - -- - - -shy

02 0 I

0 1 2 3 4 5 Nowl Yewr in which sauings in fWe colsacm-ewi tat hsawinitl

ca=al wosaand OampM costs

6

_iiM

7 8

9 10

------ - -amp -

11 12 13 14Year of Operation

--

15

- - --shy

16 17

I

18

1

19

I

20

I

21

I

22

I

23

I

24 25

Prefeasibility StudyOil Shale Fueled Power Generation

17958d351aJordanr 3-14-89 rsO

118

Comparison of Cumuiative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

28 Pay Out Year shy

400 MW Plant Oil Shale vs Imported Coal (5050 debtequity)

26shy2

24-

Cumulaive fuel nst savings for coal 0 $70ton Cumulative fuel cost savings for coal $50ton Cumulative Incremental capital plus OampM corts

22 -

20 -

18 -- Cumuladve net benefit for shle vs coal $50ton B Cumuarve net benefit for sale vs coal $70ton

16 -

C 14

12

10

08 -06 - Payout In year 1for coal $50ton

04

Payout Inyear 1

for coal $70ton02~

0 0

-No

02-

1 2

Yew inrY MCM cajlaI rl

3 4 5 6

sngm inW coas 0 ort hghWcentWin

0tOM cori

7

--

8

- -

9 10 11 12 13 14

Year of Operation

15 16 17

I

18

IIII

19 20 21 22 23 24 25

Preieasibility Study Oil Shale Fueled Power Generation

17958451 bJordarV118 3-14-89 rsipcI

Estimated Cost of Power- 400 MW (4 x 100)

FUEL

ImportedCoal

$50T

$70fT

1st Year

68 88

Levelized

78 107

Sultani Oil Shale

71 83

ImportedOil

$1713

$2413

56

67

76

96

0 10 20 30 40 50

I 60

I 70

I 80

I 90 100 110 120

Mills per kWh

Prefeasibility Study Oil Shale Fueled Power Generation

179581251 cJordarVl 18 3-14-89 rspc1

Summary Financial Analysis Results

Project size

Debt equity ratio

- Investment cost

- Power cost

- 25-year net benefit

- Project implementation

Alternative fuel price

Economic Comparison

Very significant

Not significant

Not significant

Very significant

Critical

Very significant

Prefeasibility Study

Oil Shale Fueled Power Generation

VY0 tDLUAi3

i

Study Conclusions

Feasibility

Timeliness

Expansion conditions

Environmental impacts

Development advantages

Prefeasibility Study

Oil Shale Fueled Power Generation VW41-1AiUA

4

Feasibility

Oil shale fueled power generation is technically and economically justifiedunder certain conditions

N Need for additional generating capacity

exists

- 6 annual peak demand growth - Orderly retirement of olderhigh cost

generating capacity needed

U Higher costs are expected for imported fuels

- 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

-OP b i j~~4shy

-4protntiYPe 4 demo plnt orP42 t~Plant orPootypeProje(-7hould

that Rj

demo 4Therefore-44 JEA anxinus

the

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

27Pag 4- 1 2S c i n 4 4

4i2Sectjo4-18-4 Secio 4-4 014

lt th~ae hi4h -tasisso syste thrug27 ~ 04lag arstl~art-p tasforme ed 2p27132Kvdieanwhy notthroug

EAto- is protmm~~ thegnJgt~~ pracie an ect ~ platqrby

28Pg 4 s heonnenotedto~the 32K rc powr

It not8 Scection rie049teoervnrain prctc de1

rh u n trae f2V3K anerd not throughgeterAntor

27 P3e-1r p ant weung-a

-If I

2tEll10 DRWE-jOi ASOt Mint~~al d~c~e o hepwrgnrto

ELCTRInYJORD UTHORITY-

Ate~

21Pge41 ection 4 04- 5

sindicated~ t hthigh the unit outputredu f hecondenser Injengtd~ibbvePressureed incg desrin hi h riseb vmbi nt emperatureWe bel~ieve

PleaIse provide us with th rscrapcity for th-e three options n nt generating~

21-Iisidca ted that~ thediaatgeofCBi theSheavy fn oe consumnptionPlease~ providethe us withpecntgA

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

400 MW COAL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO 5050

NET GENERATION - MWe 40000 CAPACITY FACTOR - 75 ANNUAL GENERATION MKWhYR 2628 SUB TOTAL PLANT COSTS (TPC) $1000 $620000

FIXED 0 amp M COSTS MH $ MH FIRST YEAR COST$1O00

------- --------- --- ---- --- --- ------------

OPERATING LABOR 351936 $3 $1100 MAINTENANCE LABOR 4000 of 150 OF TPC 3720

MAINTENANCE MATERIAL 6000

ADMIN LABOR of 150

3000 OF TPC

OF 0 amp M LABOR 5580 1446

SUB TOTAL FIXED OampM COSTS $11846

VARIABLE 0 amp M COSTS QUANTITY UNIT COST

VARIABLE MAINTENANCE 2628 MKWh 10 MILLKWH $ 2628 PROCESS WATER 13500000 GALLON 02 SGAL $ 2700 GENERAL PLANT CHEMICALS ALLOW 50 FUEL OIL 1000000 GALLON 035 $GAL $ 350 WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290SPECIAL BOILER MAINT ALLOW 0

SUB TOTAL VARIABLE OampM COSTS $ 8018

TOTAL FIXED amp VARIABLE OampM COSTS $19864 TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $8227 $TN $99139

(INCL INFLATION ADJUSTMENT)

B DEBT EQUITY RATIO =========== 8020

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $17574

WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290

TOTAL FIXED amp VARIABLE OampM COSTS $19864TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $5877 $TN $70814

(INCL INFLATION ADJUSTMENT)

6-21

Table 612 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY

400 MW OIL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO

NET GENERATION -

CAPACITY FACTOR -

ANNUAL GENERATION SUB TOTAL PLANT COSTS (TPC)

FIXED 0 amp M COSTS

OPERATING LABOR MAINTENANCE LABOR 4000 of

MAINTENANCE MATERIAL 6000 of

ADMIN LABOR

SUB TOTAL FIXED OampM COSTS

VARIABLE 0 amp M COSTS

VARIABLE MAINTENANCE PROCESS WATER GENERAL PLANT CHEMICALS FUEL OIL WASTE DISPOSAL (Section 6027) SPECIAL BOILER MAINT

SUB TOTAL VARIABLE OampM COSTS

5050

MWe

MKWhYR $1000

MH

262080

150

150 3000

QUANTITY

2628 MKWh 13500000 GALLON

1000000 GALLON 0 TNYR

TOTAL FIXED amp VARIABLE OampM COSTS FUEL OIL 503000 TNYR

B DEBT EQUITY RATIO =8020

40000 75

268 $443000

FIRST YEAR $ MH COST$1O00

$3 $ 800

OF TPC 2658

OF TPC 3987 OF 0 amp M LABOR 1037

$ 8482

UNIT COST

05 MILLKWH $ 1314 02 $GAL $ 2700

ALLOW 50 035 $GAL $ 350

$1000 $TN $ 0 ALLOW 0

$ 4414

$12896 $19981 $TN $100502

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $12896

WASTE DISPOSAL (Section 6027) 0 TNYR $1000 $TN $ 0

TOTAL FIXED amp VARIABLE OampM COSTS $12896 FUEL OIL 503000 TNYR $14104 $TN $70943

6-23

Page 13: fo; - pdf.usaid.gov

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

Pilot Plant Test Program (Contd)

U Analyzed one blended sample of shale

- Calorific value = 532 - 597 MJkg (approx 2250 BtuIlb)

- Carbon content (dry solids) = 162 - 187 wto

- Sulfur content (dry solids) = 30 - 33 wt

- Ash content (dry solids) = 667 - 684 wt

- Shale size = minus 8 mm

Key items determined

- Combustion efficiency

- Product ash distribution

- Product gas S02NOxCO content

- Data for boiler design

- Sulfur emissions reduction by Ca in fuel

S Prefeasibility Study Oil Shale Fueled Power Generation

VOO74GEAJI 10

Pilot Plant Test Results

U Combustion efficiency exceeded 985 in all tests

Ash distribution (btm ashfly ash) was 3565 to 4753 at 100 load typically4060

Low emissions were demonstrated

Typically S02 10 to 200 ppm gt 95 removal

limestone addition not required

NOx 60 to 120 ppm lt 020 lb106 Btu

Co 10 to 90 ppm lt 50 ppm

Prefeasibility Study Oi Shale Fueled Power Generation

TITLE

Ternpe -al-CuA vs 6 Ik

00

I00

7SA-A-

Fly Ai h

0

85 e

80-

0

00

i I 800 860 oo

T-er pe -

DATE OWN APPD DCNO- ------ -

_______f - _ IPG_

Pilot Plant Test Conclusions

It is technically feasible to burn the Sultani oil shale furnished by NRA in a Pyropower boiler

A high combustion efficiency in excess of 985 was demonstrated

SO2NOxCO emissions are all acceptably low with no limestone addition required

Prefeasibility StudyO Shale Fueled Power Generation

Conceptual Design Studies Scope

m Three project sizes

- 20 MW

- 50 MW

- 400 MW (4x100) factored for power plant portion

m Open-pit mine

- Shale processing at the surface - Waste disposal system

Power block

- Boiler

- Steam turbine

- Auxiliaries

Prefeasibility Study Oil Shale Fueled Power Generation

VOn 4FAIR 1

i

Project Layout 9 fc =f4j

deg2

o r -w (031

5_7EC 45U

iPefeaibiity tud

OlSeFuedP erGr in

179581113i~o(atyvv11

n1- 14 4pc

C)

Sultani Oil Shale Reserves

North South Area Area Total

Mineable shale tonne x 106 320 658 978

Fischer assay oil content wt 744 761 765

Overburden m3 x 106 384 627 1011

Stripping ratio m3m3 2161 1711 1861

bull Based on NRA core drilling and core analysis

Prefeasibility Study Oil Shale Fueled Power Generation

VWO41OFEAMI14

i

Sultani Oil Shale Analyses

Moisture

Ash (less CO 2 in CaCO 3 )

CO 2 (in CaCO 3 )

Carbon (organic)

Hydrogen

Nitrogen

Sulfur

Oxygen (by diff)

Total

High heating value BtuIb

Fischer assay oil content

bull Percent by weight

Design Basis Fuel

320

6680

1387

1132

113

048

255

065

10000

2250

840

Low High Calorific Calorific

Value Fuel Value Fuel

320 320

6730 6625

1414 1337

1020 1250

102 125

058 038

238 271

118 034

10000 10000

2000 2500

750 925

Preteasibility Study Oil Shale Fueled Power Generation

vo0N d-GEAR 1S

50 MW Oil Shale ProcessingPrototype Plant

Mlne Plant

_ 14 0 Haul0___) to Plant 1 Sorage

Portable Crusher

(-)100 mm Storage

(-) 100 mm Hopper UIU 400 th

Feed Bin

J 50

250 tvb

8 -m Circulating Load Impact3or0 0 30 0 0shy+8mm25

30 0L Sampler 0 1 30 0

p3 Day Storage

To Power Plant

Preleasibility StudyOil Shale Fueled Power Generation

17958101 SaJordanli 18 3-14-89 rsipc1

20 MW Oil Shale Demonstration Plant

Mine Plant

Haul00- 01 o

= Pb n Storage Portable _

110 mm Stora e 0

()100 mm r Hopper

U 400V

Feed Bin

CirculatingLoad3 Day Stoge

Prefea~ltSudy Shale Fueled Power Generation

179S 111p 1 11Joda3 yl 3-202-89 8vk2

I

Mine and Shale ProcessingDesign - 2050 MW Project

I Overburden removal (north pit area) 10-meter benches

- Drill and blast

- 10 m3 front-end loader

- 77-ton truck haulage

I Oil shale mining 10-meter benches

- Rippe and auger scraper

- Front-end loader

- Portable in-pit crusher

- 77-ton truck haulage

Oil shale processing

- Feed = minus 100 mm

- Product = minus 8 mm

- Capacity = 250 tph

- Reversible impactor

- Two vibrating screens

1 Prefeasibility Study Oil Shale Fueled Power Generation

V -M 1AMI1ARt46

400 MW Full-Scale Oil Shale ProcessingPlant

Feed MTnus 200 mm Samplerr

1000 bull 10000 Tonnes Live Storage Grade

200 m long(-) 200 mm -- =-- Plow Feeders

00 h 100000 Tonnes Live Storage

Stream 3 - Sampler Bin Stream 2

Stream th 31Da2000

Circulating Load 2i

NFw Feed r -17000t1 170001l 170 t 17000 t 17000 t

1000 th Silo with 7 Impactor (-1)8 mm Reapro- 3 Day Storage at Aver age Loadn

0 20 Feeders 20 m Diameter by 40 m High

JJJTHT To Power Plant

Prefeasibility Study Oil Shale Fueled Power Generation

179589 6aJordarV 1I8 3-14-89 rsipc1

Mine and Shale ProcessingDesign - 4x100 MW Project

m Overburden removal (north area) 10-meter benches

- Drill and blast

- Three 20 m3 shovels

- 136-ton truck haulage

m Oil shale mining 10-meter benches

- Two mechanical surface miners

- 136-ton trucks to pit hopper

- Belt conveyor = 2000 tph

- Traveling stacker

m Oil shale processing

- Feed = minus 200 mm

- Product = minus 8 mm

- Capacity = three 1000 tph units

Prefeasibility Study Oil Shale Fueled Power Generation

VOO79-ampGEAIAt 17

i

Steady-State Production Schedule

Overburden removal bench m3

20 MW demo project 5n MW prototype 4x100 MW full-scale plant

Oil shale mining and shale processing tonnes

20 MW project 50 MW project 4x100 MW project

HourlyDesign Capacity

282 234

1850

HourlyDesign Capacity

250 250

2000

Avg Daily Annual PEQuctiQa Production

1690 507000 4217 13 million

33333 10 million

Max Daily(a) Annual(b) Production Production

1733 390000 4324 973000

34578 78 million

(a) Based on 100 operating factor for power block

(b) Based on 75 operating factor for power block ( 20 MW project = 300 shiftsyr 50 MW project = 900 shiftsyr 400 MW project = 900 shiftsyr)

Prefeasibility Study Oil Shale Fueled Power Generation

Conceptual Power Plant Plans

m Pyroflow boiler

Power generating facilities

m Auxiliaries

S Preleasibility Study Oil ShaJe Fueled Power Generation

vo0o7dEAO 19

Pyroflow Boiler SteamConciflons

Flow rate 226700 kghr (500000 Ibhr)

Pressure 1099 kgcm2 abs (15635 psia)

Temperature 51280C (9550F)

Same for 20 50 and 100 MW designs

Prefeasibility Study Oil ShaJe Fueled Power Generation

vooGALMI 20

HtomCOPUIOTP

- 50005 5op

-- LEVAThUM ORPORAION

0

-VI

DZ 4

Power Block

Fuel handling system

- Day binsscrew feeders

Boiler

- Pyroflow circulating fluid bed combustor

Power generation

- Non reheat condensing steam turbine

- Conventional Rankin steam cycle

Ash handling system (btm ash irom combustor and flyash from bag house)

- Wetted in pug mill to add 20plusmn wt wpter

Plant service water

- Air-cooled condensors and small cooling tower from circulating trim water coolers

Plant raw water

- To cooling tower makeup

- To drinking water system

- To pump seals etc

Plant treated makeup water

- Demineralizer train

Preteasibility Study Oil Shale Fueled Power Generation

i

Onsite Infrastructure

Project office

Control house

U Maintenance shops warehouse

Laboratory

Employee service facility

Site developmentoperations service facilities

- Fire controlsecurity

- Communications

- Lighting

- Roads drainage and sewage

Prefeasibility StudyQ1I Shale Fueled Power Generation

voo4JG m 0 JV

i

BechtellPyropower50 MW Cogeneration Plant - Mt Poso California

W4t Prefeasibility Study --- 7 Oil Shale Fueled Power Generation

179586122aJordarv 118 3-14-89 rsO

Characteristics of Three Size Operations

Oil shale fuel tpy

Mine development excavation bank m3

Spent ash disposal tpy (wetted)

Water consumption 1000 m3yr

Staffing required

Community population

400 MW

20 MW 50 MW (4x1 00)

390000 973000 78 million

500000 1 million 85 million

327000 815000 61 million

538 907 1263

185 324 1046

700 1200 4000

Prefeasibility Study Oil Shale Fueled Power Generation

V000ofllAM1 23

Conceptual Designs Summary

N All BOP facilities involve conventional equipment and technology

100 MW unit operation involves boiler scale-up considerations

N Water consumption estimates

- Requirement for 4x100 MW project is 13 million m3 yr

- Water allocation of 2 million m3yr of water supports 6x100 MW

N Water availability probably limits total power generation from oil shale in Jordan

Prefeasibility Study Oil Shale Fueled Power Generation

V007041GEAOLMI

i

TECHNOLOGY RISK ASSESSMENT

Basic concepts

Key boiler scale-up design issues

Impact of scale-up

U Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Prefeasibility Study O1 Shale Fueled Power Generation

VOOh-7AEAAO 2

Basic Concepts

U CFBC is relatively new in the powerindustry

- Existing plants are small typically 20 to 50 MW

- There is limited operating experience with high-ash fuels

- Existing designs for lignite biomass and coal wastes show good plant performance

I Application of CFBC boiler design to oil shale fuel has defined risk that relates to scale-up of existing design

Similar CFBC technology is used in petroleum refining industry

- FCC cracking plant regenerators burn carbon residue off spent catalyst

- 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

FUEL ANALYSES

High Ash Fuel Projects Total Solids Input Basis

Gilberton Cambria North Branch

Carbon 4653 2749 1822 Hydrogen 153 164 160 Sulfur 073 222 234 Nitrogen 085 051 043 Oxygen 282 218 468 Moisture 1451 514 557 Ash 3303 6 0 6Z16

10000 10000 10000

HHVBtulb 7485 4809 3453

includes limestone feed a3 ash

includes CO2 in Ca~o3

CA89029 CAkw

Oil Shale

1132

113

255

048

065

320

-8062

10000

2250

Key Boiler Scale-Up DesignIssues

m Solids handling

- Feeding shale to combustor

- 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

Voo4tGEAMI 30

i

Mine and Shale Processing

U Fugitive dust emissions are controllable

- Wetting mine roads

- Enclose crushing plant equipment

Noise levels are controllable

- Enclose crushing plant equipment - Muffle truck exhausts

- Engineered waste disposal

Water effluents can be controlled

- Need good mine drainage design - Continue leachability studies on

waste dump piles

Prefeasibilily StudyOil Shale Fueled Po r Generaton

V0079OOG-4O 31

1

Power Plant

II Fugitive dust emissions are controllable

- Baghouse designoperation will minimize particulates in flue gas

- Wetting spent ash before disposal

N Gaseous emissions are controllable

- Pilot test results show acceptable SO2NOxCO in flue gas

- Develop baseline data for Sultani area

Develop air dispersion model for Sultani

Prefeasibility StudyOil Shale Fueled Power Generatio

V00 V-4GEA l32

i

Power Plant (Contd)

Noise levels are controllable

- Enclose boiler plant fans as required - Enclose turbines and pumps as

required

Water effluents are controllable

- Continue leachability studies on spent ash disposal

- Develop aquifer dispersion model

- Develop sewage and garbage disposal plan

Prefeasibility SludyOil Shale Fueled Power Generation

V00-4FAAI 33

Conclusions

No environmental constraints are anticipated on oil shale powerdevelopment

Gas effluents will meet World Bank standards

- Ash disposal is manageable

- The potential for groundwatercontamination appears low

- Water effluents will be minimal

Continued studies to develop air and groundwater baseline data are recommended

S Prefeasibility Study Oil Shale Fueled Power Generation

v0 9ampGLAMR 34

Power Demand vs SupplyAssessment

m Demand growth forecasts

Electrical generating capacity

= Power supply forecasts

= Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Preleasibility Study Oil Shaie Fuelod Power Generation

VO9- uLIROI

1

Power Demand Forecasts

Percent Annual Growth

JEA

Meta systems HaglerBailey and Bechtel National Inc

JEA Peak Demand Growth

1980 (actual) 1985 (actual) 1987 (actual) 1995 (forecast) 2005 (forecast)

1986 1990 to to

1990 2000

97 60

49 39

200 MW 475 MW 593 MW 900 MW

1400 MW

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOO-DLURO2

i

JEA ElectricityGeneratingCapacity

1987 Installed

Capacity (MW) Aqaba 260

22

Zarqa 395

Marka 102

Karak 23

Miscellaneous 67

Subtotal JEA capacity 869

Other capacity - industrial 110

Total 979

Prefeasibility Study Oi1 Shale Fueled Power Generation

V000-6O0LFJRO3 (

Forecast New Power Generating Capacity Required

Fcst 1987 Required

New Peak Available Installed

Demand Capacity Shortfall (a) Capacity (b) (MM (MW) (MW) (MW)

Assumed capacityfactor (65) (75)

1995 requirement 900 636 264 352

2005 requirement 1400 636 764 1019

(a) Excludes proposed additions and retirements (b) Excludes possible power exports or imports

Load shedding or levelizing not considered

Preteasibility Study Oil Shale Fueled Power Generation

Vflcmf-R)LLAO4

i

Supply vs Demand Evaluation

1800

1600

1400 Forecast Peak Demands

1200 -

E Installed Capacity

0 800shy75--

U) Assumed Available Calcit

a 6 Ao600 shy0 o 65

400 shy

200

I I I I I I I I I I I I I I I I I I I I I I I 1 1 1980 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958f738aIJordarV 118 3-14-89 rspCO

Conclusions

Additional power generating capacity is needed to meet forecasted 19952005demand growth

A 400 MW oil shale-to-power project at Sultani can meet a portion of this need

U A second 400 MW oil shale project maybe required if water is available

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOW0O-8LURO5

i

Economic Feasibility

N Order-of-magnitude costs

N Economic analysis

- Jordan study options

- Project size effect

m Comparison with alternative fuels

- Fuel requirement

- Project financing effect

- Alternate fuel price effect

- Estimated cost of electricity

N Summary financial analysis

bull Material was developed by Bechtel Power Company

Prefeasibility Study

go Oil Shale Fueled Power Generation VOOSO-ampDtJROh

ORDER-OF-MAGNITUDE COSTS

U Oil shale fuel

Power plant

I Integrated project- busbar

Preteasibility Study

Oil Shale Fueled Power Generation

VOO9O-ampDLUROS

Oil Shale Fuel Costs

Installed Capital Cost

Mine Development

Mine Equipment

Processing Plant

Spare Parts

Working Capital

Capitalized Interest

Total

Annual Operating Cost

Fuel Cost $UStonne

bull Based on 8020 debtequity ratio

20 MW

4900

11090

6945

1200

1200

4054

29389

5582

1431

US $1000 Factored

50 MW 4x100 MW

7833 30915

12202 66012

8388 50889

1300 5000

2200 10000

5108 39075

37031 201891

11556 53236

1188 684

Prefeasibility Study

Oil Shale Fueled Power Generation

VCO-ampDLUJ1O

Power Plant Costs

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Cost

Power faciities 57500 91800 567800

Owners cost 10200 20400 192700

Total 67700 112200 760500

Annual Operating Cost 2205 3248 17157(excluding fuel cost)

bullBased on 8020 debtequity ratio oil shale fueled

Prefeasibility Study

Oil Shale Fueled Power Generation

V00O8c4LLMO9

i

INTEGRATED PROJECT -BUSBAR COST

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Costs Mine amp shale processingPower block Waste disposal Infrastructure

29359 67700

1664 10000

37031 112200

2381 15000

201891 760500

8714 45000

TOTAL 108753 166612 1016105

Annual Operating Cost Mine amp shale processingPower block Waste disposal Infrastructure (a)

5582 2205

316

11556 3248

710

56430(b) 18186(b) 6004

Subtotal 8103 15514 80620

Capital Charges 139 9410 15596 106000

Total 17513 31110 186620

25-year levelized cost - - 218000

Busbar Cost millskWh First year 128 92 71 25-year levelized 83

(a) Housing and community facilities assumed self-liquidating(b) Includes first-year inflation adjustment

Based on 8020 debtequity ratio

Prefeasibility StudyOil Shale Fueled Power Generaion

VOOOO-8MLtROi0

ECONOMIC ANALYSIS

n Jordan study options

Project size effect

Fuel requirement

Project financing effect

Alternative fuel price effect

Estimated electricity cost

Summary financial analysis results

Prefeasibility Study

Oil Shale Fueled Powr Generation

VOOeO-BOCLLO1 I

i

Jordan Study Options

U Project size

- Demonstration = 20 MW

- Prototype = 50 MW

- Commercial = 400 MW (4x100)

Project financing

- Debtequity 8020

- Debtequity 5050

Imported alternative fuels cost assumptions

A B Crude oil $17bbl $24bbl

$120onne $170tonne

Low sulfur coal $ 50tonne $ 70tonne See Chevron forecast supporting assumptions

Prefeasibility StudyOil Shale Fueled Power Generation

VOOOO-8DLIJRO12

i

Crude Oil Price Trends

60

Source World Energy Outlook Chevron Corporation Oclober 1987

40

High trend

No Ir 20 ~~~~Arabian Light Spot I A u

IILowYUII trend

0 1970 1975 1980 1985 1990 1995

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958246aJodar 118 3-14-89 rsO

2000

Project Size Effect Shale Fuel Option

Project Size

Integrated facilities installed capital cost$ US million

Shale cost $UStonne(8020 debtequity)

Cost of power millskWh(8020 debtequity ratio)

20 MW

109

143

128

50 MW

167

118

92

400 MW (4x1 00)

1016

68

71

Prefeasibility Study Oil Sampae Fueled Power Generation

VOO O-8I0LJRO13

gt1

1

Power Block Investment Cost

3000

$2875 Excluding mining and offsite 2800

2600

2400

2200

2000

$1836 1800

$1613 1600

$1420 1400 1I 1 I

0 100 200 300 400 MWe

August 1988

Preleasibility Study OilShale Fueled Power Generation

179581147aJodar1 18 3-14-89 rspcl

Fuel Requirement - 4x100 MW Project

Coal = 12 million tpy

n Oil = 503000 tpy

Oil shale = 78 million tpy

Preleasibility Study

Oil Shale Fueled Power Generation

IO060-OLLIRO14

Financing Effect -Project

Oil Shale Fuel Option

Mine and shale processing

Power block

Waste disposal

Community facilities

Total

Coal-Fired Power Plant

Oil-Fired Power Plant

400 MW

Capital Cost ($US MM)

DebtEquity

8020 5050

202 187

760 760

9 8

45 45

1016 1000

647 647

463 463

Prefeasibility StudyOil Shale Fueled Power Generation

VOe-BD1JRO15

Financing Effect shy400 MW Project

Operating Costs ($US millionyr)

DebtEquity

8020 5050

Coal $70tonne 282 282

Oil $24bbl 254 254

Oil shale-fueled 218 236

Including fuel

Prefeasibility Study

SOil Shale Fueled Power Generaion

VOOIt JLMO I

Alternate Fuel Price Effect shy4x100 MW Project

Financing Basis DebtEquity Ratio

Alternate Fuel Price

Imported coal $50tonne $70tonne

Imported oil $17bbl ($120tonne) $24bbl ($170tonne)

Cumulative 25-yr Net Benefit

Favoring Oil Shale (US $MM) shy

8020 5050

778 315 2531 2068

(18) (506)1810 1322

Prefeasibility Study

Oil Shale Fueled Power Generation

Voo -I DLU-A 2

i

Comparison of Cumulative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

32 Pay Out Year shy

400 MW PlantOil Shale vs Imported Coal (8020 debtequty)

30

28 -Cumulative fuel cost savings forcoal $70ton

Cumulative fuel cost savings for coaJ $50ton

26---------- Cumulative Incremental capital plus OampM costs

24

22 -

18 -0

W- Cumulative net benefit for shae vs coal $50ton 2B Cumulative net benefit for shale vs coal $70ton

co16C -

14 -

12 -

10 -

09

06 -Payout inyear 1

Payout Inyear 9 for coal $50ton - -- - - -shy

02 0 I

0 1 2 3 4 5 Nowl Yewr in which sauings in fWe colsacm-ewi tat hsawinitl

ca=al wosaand OampM costs

6

_iiM

7 8

9 10

------ - -amp -

11 12 13 14Year of Operation

--

15

- - --shy

16 17

I

18

1

19

I

20

I

21

I

22

I

23

I

24 25

Prefeasibility StudyOil Shale Fueled Power Generation

17958d351aJordanr 3-14-89 rsO

118

Comparison of Cumuiative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

28 Pay Out Year shy

400 MW Plant Oil Shale vs Imported Coal (5050 debtequity)

26shy2

24-

Cumulaive fuel nst savings for coal 0 $70ton Cumulative fuel cost savings for coal $50ton Cumulative Incremental capital plus OampM corts

22 -

20 -

18 -- Cumuladve net benefit for shle vs coal $50ton B Cumuarve net benefit for sale vs coal $70ton

16 -

C 14

12

10

08 -06 - Payout In year 1for coal $50ton

04

Payout Inyear 1

for coal $70ton02~

0 0

-No

02-

1 2

Yew inrY MCM cajlaI rl

3 4 5 6

sngm inW coas 0 ort hghWcentWin

0tOM cori

7

--

8

- -

9 10 11 12 13 14

Year of Operation

15 16 17

I

18

IIII

19 20 21 22 23 24 25

Preieasibility Study Oil Shale Fueled Power Generation

17958451 bJordarV118 3-14-89 rsipcI

Estimated Cost of Power- 400 MW (4 x 100)

FUEL

ImportedCoal

$50T

$70fT

1st Year

68 88

Levelized

78 107

Sultani Oil Shale

71 83

ImportedOil

$1713

$2413

56

67

76

96

0 10 20 30 40 50

I 60

I 70

I 80

I 90 100 110 120

Mills per kWh

Prefeasibility Study Oil Shale Fueled Power Generation

179581251 cJordarVl 18 3-14-89 rspc1

Summary Financial Analysis Results

Project size

Debt equity ratio

- Investment cost

- Power cost

- 25-year net benefit

- Project implementation

Alternative fuel price

Economic Comparison

Very significant

Not significant

Not significant

Very significant

Critical

Very significant

Prefeasibility Study

Oil Shale Fueled Power Generation

VY0 tDLUAi3

i

Study Conclusions

Feasibility

Timeliness

Expansion conditions

Environmental impacts

Development advantages

Prefeasibility Study

Oil Shale Fueled Power Generation VW41-1AiUA

4

Feasibility

Oil shale fueled power generation is technically and economically justifiedunder certain conditions

N Need for additional generating capacity

exists

- 6 annual peak demand growth - Orderly retirement of olderhigh cost

generating capacity needed

U Higher costs are expected for imported fuels

- 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

-OP b i j~~4shy

-4protntiYPe 4 demo plnt orP42 t~Plant orPootypeProje(-7hould

that Rj

demo 4Therefore-44 JEA anxinus

the

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

27Pag 4- 1 2S c i n 4 4

4i2Sectjo4-18-4 Secio 4-4 014

lt th~ae hi4h -tasisso syste thrug27 ~ 04lag arstl~art-p tasforme ed 2p27132Kvdieanwhy notthroug

EAto- is protmm~~ thegnJgt~~ pracie an ect ~ platqrby

28Pg 4 s heonnenotedto~the 32K rc powr

It not8 Scection rie049teoervnrain prctc de1

rh u n trae f2V3K anerd not throughgeterAntor

27 P3e-1r p ant weung-a

-If I

2tEll10 DRWE-jOi ASOt Mint~~al d~c~e o hepwrgnrto

ELCTRInYJORD UTHORITY-

Ate~

21Pge41 ection 4 04- 5

sindicated~ t hthigh the unit outputredu f hecondenser Injengtd~ibbvePressureed incg desrin hi h riseb vmbi nt emperatureWe bel~ieve

PleaIse provide us with th rscrapcity for th-e three options n nt generating~

21-Iisidca ted that~ thediaatgeofCBi theSheavy fn oe consumnptionPlease~ providethe us withpecntgA

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

400 MW COAL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO 5050

NET GENERATION - MWe 40000 CAPACITY FACTOR - 75 ANNUAL GENERATION MKWhYR 2628 SUB TOTAL PLANT COSTS (TPC) $1000 $620000

FIXED 0 amp M COSTS MH $ MH FIRST YEAR COST$1O00

------- --------- --- ---- --- --- ------------

OPERATING LABOR 351936 $3 $1100 MAINTENANCE LABOR 4000 of 150 OF TPC 3720

MAINTENANCE MATERIAL 6000

ADMIN LABOR of 150

3000 OF TPC

OF 0 amp M LABOR 5580 1446

SUB TOTAL FIXED OampM COSTS $11846

VARIABLE 0 amp M COSTS QUANTITY UNIT COST

VARIABLE MAINTENANCE 2628 MKWh 10 MILLKWH $ 2628 PROCESS WATER 13500000 GALLON 02 SGAL $ 2700 GENERAL PLANT CHEMICALS ALLOW 50 FUEL OIL 1000000 GALLON 035 $GAL $ 350 WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290SPECIAL BOILER MAINT ALLOW 0

SUB TOTAL VARIABLE OampM COSTS $ 8018

TOTAL FIXED amp VARIABLE OampM COSTS $19864 TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $8227 $TN $99139

(INCL INFLATION ADJUSTMENT)

B DEBT EQUITY RATIO =========== 8020

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $17574

WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290

TOTAL FIXED amp VARIABLE OampM COSTS $19864TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $5877 $TN $70814

(INCL INFLATION ADJUSTMENT)

6-21

Table 612 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY

400 MW OIL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO

NET GENERATION -

CAPACITY FACTOR -

ANNUAL GENERATION SUB TOTAL PLANT COSTS (TPC)

FIXED 0 amp M COSTS

OPERATING LABOR MAINTENANCE LABOR 4000 of

MAINTENANCE MATERIAL 6000 of

ADMIN LABOR

SUB TOTAL FIXED OampM COSTS

VARIABLE 0 amp M COSTS

VARIABLE MAINTENANCE PROCESS WATER GENERAL PLANT CHEMICALS FUEL OIL WASTE DISPOSAL (Section 6027) SPECIAL BOILER MAINT

SUB TOTAL VARIABLE OampM COSTS

5050

MWe

MKWhYR $1000

MH

262080

150

150 3000

QUANTITY

2628 MKWh 13500000 GALLON

1000000 GALLON 0 TNYR

TOTAL FIXED amp VARIABLE OampM COSTS FUEL OIL 503000 TNYR

B DEBT EQUITY RATIO =8020

40000 75

268 $443000

FIRST YEAR $ MH COST$1O00

$3 $ 800

OF TPC 2658

OF TPC 3987 OF 0 amp M LABOR 1037

$ 8482

UNIT COST

05 MILLKWH $ 1314 02 $GAL $ 2700

ALLOW 50 035 $GAL $ 350

$1000 $TN $ 0 ALLOW 0

$ 4414

$12896 $19981 $TN $100502

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $12896

WASTE DISPOSAL (Section 6027) 0 TNYR $1000 $TN $ 0

TOTAL FIXED amp VARIABLE OampM COSTS $12896 FUEL OIL 503000 TNYR $14104 $TN $70943

6-23

Page 14: fo; - pdf.usaid.gov

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

Pilot Plant Test Program (Contd)

U Analyzed one blended sample of shale

- Calorific value = 532 - 597 MJkg (approx 2250 BtuIlb)

- Carbon content (dry solids) = 162 - 187 wto

- Sulfur content (dry solids) = 30 - 33 wt

- Ash content (dry solids) = 667 - 684 wt

- Shale size = minus 8 mm

Key items determined

- Combustion efficiency

- Product ash distribution

- Product gas S02NOxCO content

- Data for boiler design

- Sulfur emissions reduction by Ca in fuel

S Prefeasibility Study Oil Shale Fueled Power Generation

VOO74GEAJI 10

Pilot Plant Test Results

U Combustion efficiency exceeded 985 in all tests

Ash distribution (btm ashfly ash) was 3565 to 4753 at 100 load typically4060

Low emissions were demonstrated

Typically S02 10 to 200 ppm gt 95 removal

limestone addition not required

NOx 60 to 120 ppm lt 020 lb106 Btu

Co 10 to 90 ppm lt 50 ppm

Prefeasibility Study Oi Shale Fueled Power Generation

TITLE

Ternpe -al-CuA vs 6 Ik

00

I00

7SA-A-

Fly Ai h

0

85 e

80-

0

00

i I 800 860 oo

T-er pe -

DATE OWN APPD DCNO- ------ -

_______f - _ IPG_

Pilot Plant Test Conclusions

It is technically feasible to burn the Sultani oil shale furnished by NRA in a Pyropower boiler

A high combustion efficiency in excess of 985 was demonstrated

SO2NOxCO emissions are all acceptably low with no limestone addition required

Prefeasibility StudyO Shale Fueled Power Generation

Conceptual Design Studies Scope

m Three project sizes

- 20 MW

- 50 MW

- 400 MW (4x100) factored for power plant portion

m Open-pit mine

- Shale processing at the surface - Waste disposal system

Power block

- Boiler

- Steam turbine

- Auxiliaries

Prefeasibility Study Oil Shale Fueled Power Generation

VOn 4FAIR 1

i

Project Layout 9 fc =f4j

deg2

o r -w (031

5_7EC 45U

iPefeaibiity tud

OlSeFuedP erGr in

179581113i~o(atyvv11

n1- 14 4pc

C)

Sultani Oil Shale Reserves

North South Area Area Total

Mineable shale tonne x 106 320 658 978

Fischer assay oil content wt 744 761 765

Overburden m3 x 106 384 627 1011

Stripping ratio m3m3 2161 1711 1861

bull Based on NRA core drilling and core analysis

Prefeasibility Study Oil Shale Fueled Power Generation

VWO41OFEAMI14

i

Sultani Oil Shale Analyses

Moisture

Ash (less CO 2 in CaCO 3 )

CO 2 (in CaCO 3 )

Carbon (organic)

Hydrogen

Nitrogen

Sulfur

Oxygen (by diff)

Total

High heating value BtuIb

Fischer assay oil content

bull Percent by weight

Design Basis Fuel

320

6680

1387

1132

113

048

255

065

10000

2250

840

Low High Calorific Calorific

Value Fuel Value Fuel

320 320

6730 6625

1414 1337

1020 1250

102 125

058 038

238 271

118 034

10000 10000

2000 2500

750 925

Preteasibility Study Oil Shale Fueled Power Generation

vo0N d-GEAR 1S

50 MW Oil Shale ProcessingPrototype Plant

Mlne Plant

_ 14 0 Haul0___) to Plant 1 Sorage

Portable Crusher

(-)100 mm Storage

(-) 100 mm Hopper UIU 400 th

Feed Bin

J 50

250 tvb

8 -m Circulating Load Impact3or0 0 30 0 0shy+8mm25

30 0L Sampler 0 1 30 0

p3 Day Storage

To Power Plant

Preleasibility StudyOil Shale Fueled Power Generation

17958101 SaJordanli 18 3-14-89 rsipc1

20 MW Oil Shale Demonstration Plant

Mine Plant

Haul00- 01 o

= Pb n Storage Portable _

110 mm Stora e 0

()100 mm r Hopper

U 400V

Feed Bin

CirculatingLoad3 Day Stoge

Prefea~ltSudy Shale Fueled Power Generation

179S 111p 1 11Joda3 yl 3-202-89 8vk2

I

Mine and Shale ProcessingDesign - 2050 MW Project

I Overburden removal (north pit area) 10-meter benches

- Drill and blast

- 10 m3 front-end loader

- 77-ton truck haulage

I Oil shale mining 10-meter benches

- Rippe and auger scraper

- Front-end loader

- Portable in-pit crusher

- 77-ton truck haulage

Oil shale processing

- Feed = minus 100 mm

- Product = minus 8 mm

- Capacity = 250 tph

- Reversible impactor

- Two vibrating screens

1 Prefeasibility Study Oil Shale Fueled Power Generation

V -M 1AMI1ARt46

400 MW Full-Scale Oil Shale ProcessingPlant

Feed MTnus 200 mm Samplerr

1000 bull 10000 Tonnes Live Storage Grade

200 m long(-) 200 mm -- =-- Plow Feeders

00 h 100000 Tonnes Live Storage

Stream 3 - Sampler Bin Stream 2

Stream th 31Da2000

Circulating Load 2i

NFw Feed r -17000t1 170001l 170 t 17000 t 17000 t

1000 th Silo with 7 Impactor (-1)8 mm Reapro- 3 Day Storage at Aver age Loadn

0 20 Feeders 20 m Diameter by 40 m High

JJJTHT To Power Plant

Prefeasibility Study Oil Shale Fueled Power Generation

179589 6aJordarV 1I8 3-14-89 rsipc1

Mine and Shale ProcessingDesign - 4x100 MW Project

m Overburden removal (north area) 10-meter benches

- Drill and blast

- Three 20 m3 shovels

- 136-ton truck haulage

m Oil shale mining 10-meter benches

- Two mechanical surface miners

- 136-ton trucks to pit hopper

- Belt conveyor = 2000 tph

- Traveling stacker

m Oil shale processing

- Feed = minus 200 mm

- Product = minus 8 mm

- Capacity = three 1000 tph units

Prefeasibility Study Oil Shale Fueled Power Generation

VOO79-ampGEAIAt 17

i

Steady-State Production Schedule

Overburden removal bench m3

20 MW demo project 5n MW prototype 4x100 MW full-scale plant

Oil shale mining and shale processing tonnes

20 MW project 50 MW project 4x100 MW project

HourlyDesign Capacity

282 234

1850

HourlyDesign Capacity

250 250

2000

Avg Daily Annual PEQuctiQa Production

1690 507000 4217 13 million

33333 10 million

Max Daily(a) Annual(b) Production Production

1733 390000 4324 973000

34578 78 million

(a) Based on 100 operating factor for power block

(b) Based on 75 operating factor for power block ( 20 MW project = 300 shiftsyr 50 MW project = 900 shiftsyr 400 MW project = 900 shiftsyr)

Prefeasibility Study Oil Shale Fueled Power Generation

Conceptual Power Plant Plans

m Pyroflow boiler

Power generating facilities

m Auxiliaries

S Preleasibility Study Oil ShaJe Fueled Power Generation

vo0o7dEAO 19

Pyroflow Boiler SteamConciflons

Flow rate 226700 kghr (500000 Ibhr)

Pressure 1099 kgcm2 abs (15635 psia)

Temperature 51280C (9550F)

Same for 20 50 and 100 MW designs

Prefeasibility Study Oil ShaJe Fueled Power Generation

vooGALMI 20

HtomCOPUIOTP

- 50005 5op

-- LEVAThUM ORPORAION

0

-VI

DZ 4

Power Block

Fuel handling system

- Day binsscrew feeders

Boiler

- Pyroflow circulating fluid bed combustor

Power generation

- Non reheat condensing steam turbine

- Conventional Rankin steam cycle

Ash handling system (btm ash irom combustor and flyash from bag house)

- Wetted in pug mill to add 20plusmn wt wpter

Plant service water

- Air-cooled condensors and small cooling tower from circulating trim water coolers

Plant raw water

- To cooling tower makeup

- To drinking water system

- To pump seals etc

Plant treated makeup water

- Demineralizer train

Preteasibility Study Oil Shale Fueled Power Generation

i

Onsite Infrastructure

Project office

Control house

U Maintenance shops warehouse

Laboratory

Employee service facility

Site developmentoperations service facilities

- Fire controlsecurity

- Communications

- Lighting

- Roads drainage and sewage

Prefeasibility StudyQ1I Shale Fueled Power Generation

voo4JG m 0 JV

i

BechtellPyropower50 MW Cogeneration Plant - Mt Poso California

W4t Prefeasibility Study --- 7 Oil Shale Fueled Power Generation

179586122aJordarv 118 3-14-89 rsO

Characteristics of Three Size Operations

Oil shale fuel tpy

Mine development excavation bank m3

Spent ash disposal tpy (wetted)

Water consumption 1000 m3yr

Staffing required

Community population

400 MW

20 MW 50 MW (4x1 00)

390000 973000 78 million

500000 1 million 85 million

327000 815000 61 million

538 907 1263

185 324 1046

700 1200 4000

Prefeasibility Study Oil Shale Fueled Power Generation

V000ofllAM1 23

Conceptual Designs Summary

N All BOP facilities involve conventional equipment and technology

100 MW unit operation involves boiler scale-up considerations

N Water consumption estimates

- Requirement for 4x100 MW project is 13 million m3 yr

- Water allocation of 2 million m3yr of water supports 6x100 MW

N Water availability probably limits total power generation from oil shale in Jordan

Prefeasibility Study Oil Shale Fueled Power Generation

V007041GEAOLMI

i

TECHNOLOGY RISK ASSESSMENT

Basic concepts

Key boiler scale-up design issues

Impact of scale-up

U Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Prefeasibility Study O1 Shale Fueled Power Generation

VOOh-7AEAAO 2

Basic Concepts

U CFBC is relatively new in the powerindustry

- Existing plants are small typically 20 to 50 MW

- There is limited operating experience with high-ash fuels

- Existing designs for lignite biomass and coal wastes show good plant performance

I Application of CFBC boiler design to oil shale fuel has defined risk that relates to scale-up of existing design

Similar CFBC technology is used in petroleum refining industry

- FCC cracking plant regenerators burn carbon residue off spent catalyst

- 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

FUEL ANALYSES

High Ash Fuel Projects Total Solids Input Basis

Gilberton Cambria North Branch

Carbon 4653 2749 1822 Hydrogen 153 164 160 Sulfur 073 222 234 Nitrogen 085 051 043 Oxygen 282 218 468 Moisture 1451 514 557 Ash 3303 6 0 6Z16

10000 10000 10000

HHVBtulb 7485 4809 3453

includes limestone feed a3 ash

includes CO2 in Ca~o3

CA89029 CAkw

Oil Shale

1132

113

255

048

065

320

-8062

10000

2250

Key Boiler Scale-Up DesignIssues

m Solids handling

- Feeding shale to combustor

- 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

Voo4tGEAMI 30

i

Mine and Shale Processing

U Fugitive dust emissions are controllable

- Wetting mine roads

- Enclose crushing plant equipment

Noise levels are controllable

- Enclose crushing plant equipment - Muffle truck exhausts

- Engineered waste disposal

Water effluents can be controlled

- Need good mine drainage design - Continue leachability studies on

waste dump piles

Prefeasibilily StudyOil Shale Fueled Po r Generaton

V0079OOG-4O 31

1

Power Plant

II Fugitive dust emissions are controllable

- Baghouse designoperation will minimize particulates in flue gas

- Wetting spent ash before disposal

N Gaseous emissions are controllable

- Pilot test results show acceptable SO2NOxCO in flue gas

- Develop baseline data for Sultani area

Develop air dispersion model for Sultani

Prefeasibility StudyOil Shale Fueled Power Generatio

V00 V-4GEA l32

i

Power Plant (Contd)

Noise levels are controllable

- Enclose boiler plant fans as required - Enclose turbines and pumps as

required

Water effluents are controllable

- Continue leachability studies on spent ash disposal

- Develop aquifer dispersion model

- Develop sewage and garbage disposal plan

Prefeasibility SludyOil Shale Fueled Power Generation

V00-4FAAI 33

Conclusions

No environmental constraints are anticipated on oil shale powerdevelopment

Gas effluents will meet World Bank standards

- Ash disposal is manageable

- The potential for groundwatercontamination appears low

- Water effluents will be minimal

Continued studies to develop air and groundwater baseline data are recommended

S Prefeasibility Study Oil Shale Fueled Power Generation

v0 9ampGLAMR 34

Power Demand vs SupplyAssessment

m Demand growth forecasts

Electrical generating capacity

= Power supply forecasts

= Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Preleasibility Study Oil Shaie Fuelod Power Generation

VO9- uLIROI

1

Power Demand Forecasts

Percent Annual Growth

JEA

Meta systems HaglerBailey and Bechtel National Inc

JEA Peak Demand Growth

1980 (actual) 1985 (actual) 1987 (actual) 1995 (forecast) 2005 (forecast)

1986 1990 to to

1990 2000

97 60

49 39

200 MW 475 MW 593 MW 900 MW

1400 MW

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOO-DLURO2

i

JEA ElectricityGeneratingCapacity

1987 Installed

Capacity (MW) Aqaba 260

22

Zarqa 395

Marka 102

Karak 23

Miscellaneous 67

Subtotal JEA capacity 869

Other capacity - industrial 110

Total 979

Prefeasibility Study Oi1 Shale Fueled Power Generation

V000-6O0LFJRO3 (

Forecast New Power Generating Capacity Required

Fcst 1987 Required

New Peak Available Installed

Demand Capacity Shortfall (a) Capacity (b) (MM (MW) (MW) (MW)

Assumed capacityfactor (65) (75)

1995 requirement 900 636 264 352

2005 requirement 1400 636 764 1019

(a) Excludes proposed additions and retirements (b) Excludes possible power exports or imports

Load shedding or levelizing not considered

Preteasibility Study Oil Shale Fueled Power Generation

Vflcmf-R)LLAO4

i

Supply vs Demand Evaluation

1800

1600

1400 Forecast Peak Demands

1200 -

E Installed Capacity

0 800shy75--

U) Assumed Available Calcit

a 6 Ao600 shy0 o 65

400 shy

200

I I I I I I I I I I I I I I I I I I I I I I I 1 1 1980 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958f738aIJordarV 118 3-14-89 rspCO

Conclusions

Additional power generating capacity is needed to meet forecasted 19952005demand growth

A 400 MW oil shale-to-power project at Sultani can meet a portion of this need

U A second 400 MW oil shale project maybe required if water is available

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOW0O-8LURO5

i

Economic Feasibility

N Order-of-magnitude costs

N Economic analysis

- Jordan study options

- Project size effect

m Comparison with alternative fuels

- Fuel requirement

- Project financing effect

- Alternate fuel price effect

- Estimated cost of electricity

N Summary financial analysis

bull Material was developed by Bechtel Power Company

Prefeasibility Study

go Oil Shale Fueled Power Generation VOOSO-ampDtJROh

ORDER-OF-MAGNITUDE COSTS

U Oil shale fuel

Power plant

I Integrated project- busbar

Preteasibility Study

Oil Shale Fueled Power Generation

VOO9O-ampDLUROS

Oil Shale Fuel Costs

Installed Capital Cost

Mine Development

Mine Equipment

Processing Plant

Spare Parts

Working Capital

Capitalized Interest

Total

Annual Operating Cost

Fuel Cost $UStonne

bull Based on 8020 debtequity ratio

20 MW

4900

11090

6945

1200

1200

4054

29389

5582

1431

US $1000 Factored

50 MW 4x100 MW

7833 30915

12202 66012

8388 50889

1300 5000

2200 10000

5108 39075

37031 201891

11556 53236

1188 684

Prefeasibility Study

Oil Shale Fueled Power Generation

VCO-ampDLUJ1O

Power Plant Costs

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Cost

Power faciities 57500 91800 567800

Owners cost 10200 20400 192700

Total 67700 112200 760500

Annual Operating Cost 2205 3248 17157(excluding fuel cost)

bullBased on 8020 debtequity ratio oil shale fueled

Prefeasibility Study

Oil Shale Fueled Power Generation

V00O8c4LLMO9

i

INTEGRATED PROJECT -BUSBAR COST

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Costs Mine amp shale processingPower block Waste disposal Infrastructure

29359 67700

1664 10000

37031 112200

2381 15000

201891 760500

8714 45000

TOTAL 108753 166612 1016105

Annual Operating Cost Mine amp shale processingPower block Waste disposal Infrastructure (a)

5582 2205

316

11556 3248

710

56430(b) 18186(b) 6004

Subtotal 8103 15514 80620

Capital Charges 139 9410 15596 106000

Total 17513 31110 186620

25-year levelized cost - - 218000

Busbar Cost millskWh First year 128 92 71 25-year levelized 83

(a) Housing and community facilities assumed self-liquidating(b) Includes first-year inflation adjustment

Based on 8020 debtequity ratio

Prefeasibility StudyOil Shale Fueled Power Generaion

VOOOO-8MLtROi0

ECONOMIC ANALYSIS

n Jordan study options

Project size effect

Fuel requirement

Project financing effect

Alternative fuel price effect

Estimated electricity cost

Summary financial analysis results

Prefeasibility Study

Oil Shale Fueled Powr Generation

VOOeO-BOCLLO1 I

i

Jordan Study Options

U Project size

- Demonstration = 20 MW

- Prototype = 50 MW

- Commercial = 400 MW (4x100)

Project financing

- Debtequity 8020

- Debtequity 5050

Imported alternative fuels cost assumptions

A B Crude oil $17bbl $24bbl

$120onne $170tonne

Low sulfur coal $ 50tonne $ 70tonne See Chevron forecast supporting assumptions

Prefeasibility StudyOil Shale Fueled Power Generation

VOOOO-8DLIJRO12

i

Crude Oil Price Trends

60

Source World Energy Outlook Chevron Corporation Oclober 1987

40

High trend

No Ir 20 ~~~~Arabian Light Spot I A u

IILowYUII trend

0 1970 1975 1980 1985 1990 1995

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958246aJodar 118 3-14-89 rsO

2000

Project Size Effect Shale Fuel Option

Project Size

Integrated facilities installed capital cost$ US million

Shale cost $UStonne(8020 debtequity)

Cost of power millskWh(8020 debtequity ratio)

20 MW

109

143

128

50 MW

167

118

92

400 MW (4x1 00)

1016

68

71

Prefeasibility Study Oil Sampae Fueled Power Generation

VOO O-8I0LJRO13

gt1

1

Power Block Investment Cost

3000

$2875 Excluding mining and offsite 2800

2600

2400

2200

2000

$1836 1800

$1613 1600

$1420 1400 1I 1 I

0 100 200 300 400 MWe

August 1988

Preleasibility Study OilShale Fueled Power Generation

179581147aJodar1 18 3-14-89 rspcl

Fuel Requirement - 4x100 MW Project

Coal = 12 million tpy

n Oil = 503000 tpy

Oil shale = 78 million tpy

Preleasibility Study

Oil Shale Fueled Power Generation

IO060-OLLIRO14

Financing Effect -Project

Oil Shale Fuel Option

Mine and shale processing

Power block

Waste disposal

Community facilities

Total

Coal-Fired Power Plant

Oil-Fired Power Plant

400 MW

Capital Cost ($US MM)

DebtEquity

8020 5050

202 187

760 760

9 8

45 45

1016 1000

647 647

463 463

Prefeasibility StudyOil Shale Fueled Power Generation

VOe-BD1JRO15

Financing Effect shy400 MW Project

Operating Costs ($US millionyr)

DebtEquity

8020 5050

Coal $70tonne 282 282

Oil $24bbl 254 254

Oil shale-fueled 218 236

Including fuel

Prefeasibility Study

SOil Shale Fueled Power Generaion

VOOIt JLMO I

Alternate Fuel Price Effect shy4x100 MW Project

Financing Basis DebtEquity Ratio

Alternate Fuel Price

Imported coal $50tonne $70tonne

Imported oil $17bbl ($120tonne) $24bbl ($170tonne)

Cumulative 25-yr Net Benefit

Favoring Oil Shale (US $MM) shy

8020 5050

778 315 2531 2068

(18) (506)1810 1322

Prefeasibility Study

Oil Shale Fueled Power Generation

Voo -I DLU-A 2

i

Comparison of Cumulative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

32 Pay Out Year shy

400 MW PlantOil Shale vs Imported Coal (8020 debtequty)

30

28 -Cumulative fuel cost savings forcoal $70ton

Cumulative fuel cost savings for coaJ $50ton

26---------- Cumulative Incremental capital plus OampM costs

24

22 -

18 -0

W- Cumulative net benefit for shae vs coal $50ton 2B Cumulative net benefit for shale vs coal $70ton

co16C -

14 -

12 -

10 -

09

06 -Payout inyear 1

Payout Inyear 9 for coal $50ton - -- - - -shy

02 0 I

0 1 2 3 4 5 Nowl Yewr in which sauings in fWe colsacm-ewi tat hsawinitl

ca=al wosaand OampM costs

6

_iiM

7 8

9 10

------ - -amp -

11 12 13 14Year of Operation

--

15

- - --shy

16 17

I

18

1

19

I

20

I

21

I

22

I

23

I

24 25

Prefeasibility StudyOil Shale Fueled Power Generation

17958d351aJordanr 3-14-89 rsO

118

Comparison of Cumuiative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

28 Pay Out Year shy

400 MW Plant Oil Shale vs Imported Coal (5050 debtequity)

26shy2

24-

Cumulaive fuel nst savings for coal 0 $70ton Cumulative fuel cost savings for coal $50ton Cumulative Incremental capital plus OampM corts

22 -

20 -

18 -- Cumuladve net benefit for shle vs coal $50ton B Cumuarve net benefit for sale vs coal $70ton

16 -

C 14

12

10

08 -06 - Payout In year 1for coal $50ton

04

Payout Inyear 1

for coal $70ton02~

0 0

-No

02-

1 2

Yew inrY MCM cajlaI rl

3 4 5 6

sngm inW coas 0 ort hghWcentWin

0tOM cori

7

--

8

- -

9 10 11 12 13 14

Year of Operation

15 16 17

I

18

IIII

19 20 21 22 23 24 25

Preieasibility Study Oil Shale Fueled Power Generation

17958451 bJordarV118 3-14-89 rsipcI

Estimated Cost of Power- 400 MW (4 x 100)

FUEL

ImportedCoal

$50T

$70fT

1st Year

68 88

Levelized

78 107

Sultani Oil Shale

71 83

ImportedOil

$1713

$2413

56

67

76

96

0 10 20 30 40 50

I 60

I 70

I 80

I 90 100 110 120

Mills per kWh

Prefeasibility Study Oil Shale Fueled Power Generation

179581251 cJordarVl 18 3-14-89 rspc1

Summary Financial Analysis Results

Project size

Debt equity ratio

- Investment cost

- Power cost

- 25-year net benefit

- Project implementation

Alternative fuel price

Economic Comparison

Very significant

Not significant

Not significant

Very significant

Critical

Very significant

Prefeasibility Study

Oil Shale Fueled Power Generation

VY0 tDLUAi3

i

Study Conclusions

Feasibility

Timeliness

Expansion conditions

Environmental impacts

Development advantages

Prefeasibility Study

Oil Shale Fueled Power Generation VW41-1AiUA

4

Feasibility

Oil shale fueled power generation is technically and economically justifiedunder certain conditions

N Need for additional generating capacity

exists

- 6 annual peak demand growth - Orderly retirement of olderhigh cost

generating capacity needed

U Higher costs are expected for imported fuels

- 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

-OP b i j~~4shy

-4protntiYPe 4 demo plnt orP42 t~Plant orPootypeProje(-7hould

that Rj

demo 4Therefore-44 JEA anxinus

the

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

27Pag 4- 1 2S c i n 4 4

4i2Sectjo4-18-4 Secio 4-4 014

lt th~ae hi4h -tasisso syste thrug27 ~ 04lag arstl~art-p tasforme ed 2p27132Kvdieanwhy notthroug

EAto- is protmm~~ thegnJgt~~ pracie an ect ~ platqrby

28Pg 4 s heonnenotedto~the 32K rc powr

It not8 Scection rie049teoervnrain prctc de1

rh u n trae f2V3K anerd not throughgeterAntor

27 P3e-1r p ant weung-a

-If I

2tEll10 DRWE-jOi ASOt Mint~~al d~c~e o hepwrgnrto

ELCTRInYJORD UTHORITY-

Ate~

21Pge41 ection 4 04- 5

sindicated~ t hthigh the unit outputredu f hecondenser Injengtd~ibbvePressureed incg desrin hi h riseb vmbi nt emperatureWe bel~ieve

PleaIse provide us with th rscrapcity for th-e three options n nt generating~

21-Iisidca ted that~ thediaatgeofCBi theSheavy fn oe consumnptionPlease~ providethe us withpecntgA

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

400 MW COAL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO 5050

NET GENERATION - MWe 40000 CAPACITY FACTOR - 75 ANNUAL GENERATION MKWhYR 2628 SUB TOTAL PLANT COSTS (TPC) $1000 $620000

FIXED 0 amp M COSTS MH $ MH FIRST YEAR COST$1O00

------- --------- --- ---- --- --- ------------

OPERATING LABOR 351936 $3 $1100 MAINTENANCE LABOR 4000 of 150 OF TPC 3720

MAINTENANCE MATERIAL 6000

ADMIN LABOR of 150

3000 OF TPC

OF 0 amp M LABOR 5580 1446

SUB TOTAL FIXED OampM COSTS $11846

VARIABLE 0 amp M COSTS QUANTITY UNIT COST

VARIABLE MAINTENANCE 2628 MKWh 10 MILLKWH $ 2628 PROCESS WATER 13500000 GALLON 02 SGAL $ 2700 GENERAL PLANT CHEMICALS ALLOW 50 FUEL OIL 1000000 GALLON 035 $GAL $ 350 WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290SPECIAL BOILER MAINT ALLOW 0

SUB TOTAL VARIABLE OampM COSTS $ 8018

TOTAL FIXED amp VARIABLE OampM COSTS $19864 TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $8227 $TN $99139

(INCL INFLATION ADJUSTMENT)

B DEBT EQUITY RATIO =========== 8020

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $17574

WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290

TOTAL FIXED amp VARIABLE OampM COSTS $19864TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $5877 $TN $70814

(INCL INFLATION ADJUSTMENT)

6-21

Table 612 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY

400 MW OIL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO

NET GENERATION -

CAPACITY FACTOR -

ANNUAL GENERATION SUB TOTAL PLANT COSTS (TPC)

FIXED 0 amp M COSTS

OPERATING LABOR MAINTENANCE LABOR 4000 of

MAINTENANCE MATERIAL 6000 of

ADMIN LABOR

SUB TOTAL FIXED OampM COSTS

VARIABLE 0 amp M COSTS

VARIABLE MAINTENANCE PROCESS WATER GENERAL PLANT CHEMICALS FUEL OIL WASTE DISPOSAL (Section 6027) SPECIAL BOILER MAINT

SUB TOTAL VARIABLE OampM COSTS

5050

MWe

MKWhYR $1000

MH

262080

150

150 3000

QUANTITY

2628 MKWh 13500000 GALLON

1000000 GALLON 0 TNYR

TOTAL FIXED amp VARIABLE OampM COSTS FUEL OIL 503000 TNYR

B DEBT EQUITY RATIO =8020

40000 75

268 $443000

FIRST YEAR $ MH COST$1O00

$3 $ 800

OF TPC 2658

OF TPC 3987 OF 0 amp M LABOR 1037

$ 8482

UNIT COST

05 MILLKWH $ 1314 02 $GAL $ 2700

ALLOW 50 035 $GAL $ 350

$1000 $TN $ 0 ALLOW 0

$ 4414

$12896 $19981 $TN $100502

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $12896

WASTE DISPOSAL (Section 6027) 0 TNYR $1000 $TN $ 0

TOTAL FIXED amp VARIABLE OampM COSTS $12896 FUEL OIL 503000 TNYR $14104 $TN $70943

6-23

Page 15: fo; - pdf.usaid.gov

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

Pilot Plant Test Program (Contd)

U Analyzed one blended sample of shale

- Calorific value = 532 - 597 MJkg (approx 2250 BtuIlb)

- Carbon content (dry solids) = 162 - 187 wto

- Sulfur content (dry solids) = 30 - 33 wt

- Ash content (dry solids) = 667 - 684 wt

- Shale size = minus 8 mm

Key items determined

- Combustion efficiency

- Product ash distribution

- Product gas S02NOxCO content

- Data for boiler design

- Sulfur emissions reduction by Ca in fuel

S Prefeasibility Study Oil Shale Fueled Power Generation

VOO74GEAJI 10

Pilot Plant Test Results

U Combustion efficiency exceeded 985 in all tests

Ash distribution (btm ashfly ash) was 3565 to 4753 at 100 load typically4060

Low emissions were demonstrated

Typically S02 10 to 200 ppm gt 95 removal

limestone addition not required

NOx 60 to 120 ppm lt 020 lb106 Btu

Co 10 to 90 ppm lt 50 ppm

Prefeasibility Study Oi Shale Fueled Power Generation

TITLE

Ternpe -al-CuA vs 6 Ik

00

I00

7SA-A-

Fly Ai h

0

85 e

80-

0

00

i I 800 860 oo

T-er pe -

DATE OWN APPD DCNO- ------ -

_______f - _ IPG_

Pilot Plant Test Conclusions

It is technically feasible to burn the Sultani oil shale furnished by NRA in a Pyropower boiler

A high combustion efficiency in excess of 985 was demonstrated

SO2NOxCO emissions are all acceptably low with no limestone addition required

Prefeasibility StudyO Shale Fueled Power Generation

Conceptual Design Studies Scope

m Three project sizes

- 20 MW

- 50 MW

- 400 MW (4x100) factored for power plant portion

m Open-pit mine

- Shale processing at the surface - Waste disposal system

Power block

- Boiler

- Steam turbine

- Auxiliaries

Prefeasibility Study Oil Shale Fueled Power Generation

VOn 4FAIR 1

i

Project Layout 9 fc =f4j

deg2

o r -w (031

5_7EC 45U

iPefeaibiity tud

OlSeFuedP erGr in

179581113i~o(atyvv11

n1- 14 4pc

C)

Sultani Oil Shale Reserves

North South Area Area Total

Mineable shale tonne x 106 320 658 978

Fischer assay oil content wt 744 761 765

Overburden m3 x 106 384 627 1011

Stripping ratio m3m3 2161 1711 1861

bull Based on NRA core drilling and core analysis

Prefeasibility Study Oil Shale Fueled Power Generation

VWO41OFEAMI14

i

Sultani Oil Shale Analyses

Moisture

Ash (less CO 2 in CaCO 3 )

CO 2 (in CaCO 3 )

Carbon (organic)

Hydrogen

Nitrogen

Sulfur

Oxygen (by diff)

Total

High heating value BtuIb

Fischer assay oil content

bull Percent by weight

Design Basis Fuel

320

6680

1387

1132

113

048

255

065

10000

2250

840

Low High Calorific Calorific

Value Fuel Value Fuel

320 320

6730 6625

1414 1337

1020 1250

102 125

058 038

238 271

118 034

10000 10000

2000 2500

750 925

Preteasibility Study Oil Shale Fueled Power Generation

vo0N d-GEAR 1S

50 MW Oil Shale ProcessingPrototype Plant

Mlne Plant

_ 14 0 Haul0___) to Plant 1 Sorage

Portable Crusher

(-)100 mm Storage

(-) 100 mm Hopper UIU 400 th

Feed Bin

J 50

250 tvb

8 -m Circulating Load Impact3or0 0 30 0 0shy+8mm25

30 0L Sampler 0 1 30 0

p3 Day Storage

To Power Plant

Preleasibility StudyOil Shale Fueled Power Generation

17958101 SaJordanli 18 3-14-89 rsipc1

20 MW Oil Shale Demonstration Plant

Mine Plant

Haul00- 01 o

= Pb n Storage Portable _

110 mm Stora e 0

()100 mm r Hopper

U 400V

Feed Bin

CirculatingLoad3 Day Stoge

Prefea~ltSudy Shale Fueled Power Generation

179S 111p 1 11Joda3 yl 3-202-89 8vk2

I

Mine and Shale ProcessingDesign - 2050 MW Project

I Overburden removal (north pit area) 10-meter benches

- Drill and blast

- 10 m3 front-end loader

- 77-ton truck haulage

I Oil shale mining 10-meter benches

- Rippe and auger scraper

- Front-end loader

- Portable in-pit crusher

- 77-ton truck haulage

Oil shale processing

- Feed = minus 100 mm

- Product = minus 8 mm

- Capacity = 250 tph

- Reversible impactor

- Two vibrating screens

1 Prefeasibility Study Oil Shale Fueled Power Generation

V -M 1AMI1ARt46

400 MW Full-Scale Oil Shale ProcessingPlant

Feed MTnus 200 mm Samplerr

1000 bull 10000 Tonnes Live Storage Grade

200 m long(-) 200 mm -- =-- Plow Feeders

00 h 100000 Tonnes Live Storage

Stream 3 - Sampler Bin Stream 2

Stream th 31Da2000

Circulating Load 2i

NFw Feed r -17000t1 170001l 170 t 17000 t 17000 t

1000 th Silo with 7 Impactor (-1)8 mm Reapro- 3 Day Storage at Aver age Loadn

0 20 Feeders 20 m Diameter by 40 m High

JJJTHT To Power Plant

Prefeasibility Study Oil Shale Fueled Power Generation

179589 6aJordarV 1I8 3-14-89 rsipc1

Mine and Shale ProcessingDesign - 4x100 MW Project

m Overburden removal (north area) 10-meter benches

- Drill and blast

- Three 20 m3 shovels

- 136-ton truck haulage

m Oil shale mining 10-meter benches

- Two mechanical surface miners

- 136-ton trucks to pit hopper

- Belt conveyor = 2000 tph

- Traveling stacker

m Oil shale processing

- Feed = minus 200 mm

- Product = minus 8 mm

- Capacity = three 1000 tph units

Prefeasibility Study Oil Shale Fueled Power Generation

VOO79-ampGEAIAt 17

i

Steady-State Production Schedule

Overburden removal bench m3

20 MW demo project 5n MW prototype 4x100 MW full-scale plant

Oil shale mining and shale processing tonnes

20 MW project 50 MW project 4x100 MW project

HourlyDesign Capacity

282 234

1850

HourlyDesign Capacity

250 250

2000

Avg Daily Annual PEQuctiQa Production

1690 507000 4217 13 million

33333 10 million

Max Daily(a) Annual(b) Production Production

1733 390000 4324 973000

34578 78 million

(a) Based on 100 operating factor for power block

(b) Based on 75 operating factor for power block ( 20 MW project = 300 shiftsyr 50 MW project = 900 shiftsyr 400 MW project = 900 shiftsyr)

Prefeasibility Study Oil Shale Fueled Power Generation

Conceptual Power Plant Plans

m Pyroflow boiler

Power generating facilities

m Auxiliaries

S Preleasibility Study Oil ShaJe Fueled Power Generation

vo0o7dEAO 19

Pyroflow Boiler SteamConciflons

Flow rate 226700 kghr (500000 Ibhr)

Pressure 1099 kgcm2 abs (15635 psia)

Temperature 51280C (9550F)

Same for 20 50 and 100 MW designs

Prefeasibility Study Oil ShaJe Fueled Power Generation

vooGALMI 20

HtomCOPUIOTP

- 50005 5op

-- LEVAThUM ORPORAION

0

-VI

DZ 4

Power Block

Fuel handling system

- Day binsscrew feeders

Boiler

- Pyroflow circulating fluid bed combustor

Power generation

- Non reheat condensing steam turbine

- Conventional Rankin steam cycle

Ash handling system (btm ash irom combustor and flyash from bag house)

- Wetted in pug mill to add 20plusmn wt wpter

Plant service water

- Air-cooled condensors and small cooling tower from circulating trim water coolers

Plant raw water

- To cooling tower makeup

- To drinking water system

- To pump seals etc

Plant treated makeup water

- Demineralizer train

Preteasibility Study Oil Shale Fueled Power Generation

i

Onsite Infrastructure

Project office

Control house

U Maintenance shops warehouse

Laboratory

Employee service facility

Site developmentoperations service facilities

- Fire controlsecurity

- Communications

- Lighting

- Roads drainage and sewage

Prefeasibility StudyQ1I Shale Fueled Power Generation

voo4JG m 0 JV

i

BechtellPyropower50 MW Cogeneration Plant - Mt Poso California

W4t Prefeasibility Study --- 7 Oil Shale Fueled Power Generation

179586122aJordarv 118 3-14-89 rsO

Characteristics of Three Size Operations

Oil shale fuel tpy

Mine development excavation bank m3

Spent ash disposal tpy (wetted)

Water consumption 1000 m3yr

Staffing required

Community population

400 MW

20 MW 50 MW (4x1 00)

390000 973000 78 million

500000 1 million 85 million

327000 815000 61 million

538 907 1263

185 324 1046

700 1200 4000

Prefeasibility Study Oil Shale Fueled Power Generation

V000ofllAM1 23

Conceptual Designs Summary

N All BOP facilities involve conventional equipment and technology

100 MW unit operation involves boiler scale-up considerations

N Water consumption estimates

- Requirement for 4x100 MW project is 13 million m3 yr

- Water allocation of 2 million m3yr of water supports 6x100 MW

N Water availability probably limits total power generation from oil shale in Jordan

Prefeasibility Study Oil Shale Fueled Power Generation

V007041GEAOLMI

i

TECHNOLOGY RISK ASSESSMENT

Basic concepts

Key boiler scale-up design issues

Impact of scale-up

U Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Prefeasibility Study O1 Shale Fueled Power Generation

VOOh-7AEAAO 2

Basic Concepts

U CFBC is relatively new in the powerindustry

- Existing plants are small typically 20 to 50 MW

- There is limited operating experience with high-ash fuels

- Existing designs for lignite biomass and coal wastes show good plant performance

I Application of CFBC boiler design to oil shale fuel has defined risk that relates to scale-up of existing design

Similar CFBC technology is used in petroleum refining industry

- FCC cracking plant regenerators burn carbon residue off spent catalyst

- 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

FUEL ANALYSES

High Ash Fuel Projects Total Solids Input Basis

Gilberton Cambria North Branch

Carbon 4653 2749 1822 Hydrogen 153 164 160 Sulfur 073 222 234 Nitrogen 085 051 043 Oxygen 282 218 468 Moisture 1451 514 557 Ash 3303 6 0 6Z16

10000 10000 10000

HHVBtulb 7485 4809 3453

includes limestone feed a3 ash

includes CO2 in Ca~o3

CA89029 CAkw

Oil Shale

1132

113

255

048

065

320

-8062

10000

2250

Key Boiler Scale-Up DesignIssues

m Solids handling

- Feeding shale to combustor

- 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

Voo4tGEAMI 30

i

Mine and Shale Processing

U Fugitive dust emissions are controllable

- Wetting mine roads

- Enclose crushing plant equipment

Noise levels are controllable

- Enclose crushing plant equipment - Muffle truck exhausts

- Engineered waste disposal

Water effluents can be controlled

- Need good mine drainage design - Continue leachability studies on

waste dump piles

Prefeasibilily StudyOil Shale Fueled Po r Generaton

V0079OOG-4O 31

1

Power Plant

II Fugitive dust emissions are controllable

- Baghouse designoperation will minimize particulates in flue gas

- Wetting spent ash before disposal

N Gaseous emissions are controllable

- Pilot test results show acceptable SO2NOxCO in flue gas

- Develop baseline data for Sultani area

Develop air dispersion model for Sultani

Prefeasibility StudyOil Shale Fueled Power Generatio

V00 V-4GEA l32

i

Power Plant (Contd)

Noise levels are controllable

- Enclose boiler plant fans as required - Enclose turbines and pumps as

required

Water effluents are controllable

- Continue leachability studies on spent ash disposal

- Develop aquifer dispersion model

- Develop sewage and garbage disposal plan

Prefeasibility SludyOil Shale Fueled Power Generation

V00-4FAAI 33

Conclusions

No environmental constraints are anticipated on oil shale powerdevelopment

Gas effluents will meet World Bank standards

- Ash disposal is manageable

- The potential for groundwatercontamination appears low

- Water effluents will be minimal

Continued studies to develop air and groundwater baseline data are recommended

S Prefeasibility Study Oil Shale Fueled Power Generation

v0 9ampGLAMR 34

Power Demand vs SupplyAssessment

m Demand growth forecasts

Electrical generating capacity

= Power supply forecasts

= Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Preleasibility Study Oil Shaie Fuelod Power Generation

VO9- uLIROI

1

Power Demand Forecasts

Percent Annual Growth

JEA

Meta systems HaglerBailey and Bechtel National Inc

JEA Peak Demand Growth

1980 (actual) 1985 (actual) 1987 (actual) 1995 (forecast) 2005 (forecast)

1986 1990 to to

1990 2000

97 60

49 39

200 MW 475 MW 593 MW 900 MW

1400 MW

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOO-DLURO2

i

JEA ElectricityGeneratingCapacity

1987 Installed

Capacity (MW) Aqaba 260

22

Zarqa 395

Marka 102

Karak 23

Miscellaneous 67

Subtotal JEA capacity 869

Other capacity - industrial 110

Total 979

Prefeasibility Study Oi1 Shale Fueled Power Generation

V000-6O0LFJRO3 (

Forecast New Power Generating Capacity Required

Fcst 1987 Required

New Peak Available Installed

Demand Capacity Shortfall (a) Capacity (b) (MM (MW) (MW) (MW)

Assumed capacityfactor (65) (75)

1995 requirement 900 636 264 352

2005 requirement 1400 636 764 1019

(a) Excludes proposed additions and retirements (b) Excludes possible power exports or imports

Load shedding or levelizing not considered

Preteasibility Study Oil Shale Fueled Power Generation

Vflcmf-R)LLAO4

i

Supply vs Demand Evaluation

1800

1600

1400 Forecast Peak Demands

1200 -

E Installed Capacity

0 800shy75--

U) Assumed Available Calcit

a 6 Ao600 shy0 o 65

400 shy

200

I I I I I I I I I I I I I I I I I I I I I I I 1 1 1980 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958f738aIJordarV 118 3-14-89 rspCO

Conclusions

Additional power generating capacity is needed to meet forecasted 19952005demand growth

A 400 MW oil shale-to-power project at Sultani can meet a portion of this need

U A second 400 MW oil shale project maybe required if water is available

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOW0O-8LURO5

i

Economic Feasibility

N Order-of-magnitude costs

N Economic analysis

- Jordan study options

- Project size effect

m Comparison with alternative fuels

- Fuel requirement

- Project financing effect

- Alternate fuel price effect

- Estimated cost of electricity

N Summary financial analysis

bull Material was developed by Bechtel Power Company

Prefeasibility Study

go Oil Shale Fueled Power Generation VOOSO-ampDtJROh

ORDER-OF-MAGNITUDE COSTS

U Oil shale fuel

Power plant

I Integrated project- busbar

Preteasibility Study

Oil Shale Fueled Power Generation

VOO9O-ampDLUROS

Oil Shale Fuel Costs

Installed Capital Cost

Mine Development

Mine Equipment

Processing Plant

Spare Parts

Working Capital

Capitalized Interest

Total

Annual Operating Cost

Fuel Cost $UStonne

bull Based on 8020 debtequity ratio

20 MW

4900

11090

6945

1200

1200

4054

29389

5582

1431

US $1000 Factored

50 MW 4x100 MW

7833 30915

12202 66012

8388 50889

1300 5000

2200 10000

5108 39075

37031 201891

11556 53236

1188 684

Prefeasibility Study

Oil Shale Fueled Power Generation

VCO-ampDLUJ1O

Power Plant Costs

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Cost

Power faciities 57500 91800 567800

Owners cost 10200 20400 192700

Total 67700 112200 760500

Annual Operating Cost 2205 3248 17157(excluding fuel cost)

bullBased on 8020 debtequity ratio oil shale fueled

Prefeasibility Study

Oil Shale Fueled Power Generation

V00O8c4LLMO9

i

INTEGRATED PROJECT -BUSBAR COST

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Costs Mine amp shale processingPower block Waste disposal Infrastructure

29359 67700

1664 10000

37031 112200

2381 15000

201891 760500

8714 45000

TOTAL 108753 166612 1016105

Annual Operating Cost Mine amp shale processingPower block Waste disposal Infrastructure (a)

5582 2205

316

11556 3248

710

56430(b) 18186(b) 6004

Subtotal 8103 15514 80620

Capital Charges 139 9410 15596 106000

Total 17513 31110 186620

25-year levelized cost - - 218000

Busbar Cost millskWh First year 128 92 71 25-year levelized 83

(a) Housing and community facilities assumed self-liquidating(b) Includes first-year inflation adjustment

Based on 8020 debtequity ratio

Prefeasibility StudyOil Shale Fueled Power Generaion

VOOOO-8MLtROi0

ECONOMIC ANALYSIS

n Jordan study options

Project size effect

Fuel requirement

Project financing effect

Alternative fuel price effect

Estimated electricity cost

Summary financial analysis results

Prefeasibility Study

Oil Shale Fueled Powr Generation

VOOeO-BOCLLO1 I

i

Jordan Study Options

U Project size

- Demonstration = 20 MW

- Prototype = 50 MW

- Commercial = 400 MW (4x100)

Project financing

- Debtequity 8020

- Debtequity 5050

Imported alternative fuels cost assumptions

A B Crude oil $17bbl $24bbl

$120onne $170tonne

Low sulfur coal $ 50tonne $ 70tonne See Chevron forecast supporting assumptions

Prefeasibility StudyOil Shale Fueled Power Generation

VOOOO-8DLIJRO12

i

Crude Oil Price Trends

60

Source World Energy Outlook Chevron Corporation Oclober 1987

40

High trend

No Ir 20 ~~~~Arabian Light Spot I A u

IILowYUII trend

0 1970 1975 1980 1985 1990 1995

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958246aJodar 118 3-14-89 rsO

2000

Project Size Effect Shale Fuel Option

Project Size

Integrated facilities installed capital cost$ US million

Shale cost $UStonne(8020 debtequity)

Cost of power millskWh(8020 debtequity ratio)

20 MW

109

143

128

50 MW

167

118

92

400 MW (4x1 00)

1016

68

71

Prefeasibility Study Oil Sampae Fueled Power Generation

VOO O-8I0LJRO13

gt1

1

Power Block Investment Cost

3000

$2875 Excluding mining and offsite 2800

2600

2400

2200

2000

$1836 1800

$1613 1600

$1420 1400 1I 1 I

0 100 200 300 400 MWe

August 1988

Preleasibility Study OilShale Fueled Power Generation

179581147aJodar1 18 3-14-89 rspcl

Fuel Requirement - 4x100 MW Project

Coal = 12 million tpy

n Oil = 503000 tpy

Oil shale = 78 million tpy

Preleasibility Study

Oil Shale Fueled Power Generation

IO060-OLLIRO14

Financing Effect -Project

Oil Shale Fuel Option

Mine and shale processing

Power block

Waste disposal

Community facilities

Total

Coal-Fired Power Plant

Oil-Fired Power Plant

400 MW

Capital Cost ($US MM)

DebtEquity

8020 5050

202 187

760 760

9 8

45 45

1016 1000

647 647

463 463

Prefeasibility StudyOil Shale Fueled Power Generation

VOe-BD1JRO15

Financing Effect shy400 MW Project

Operating Costs ($US millionyr)

DebtEquity

8020 5050

Coal $70tonne 282 282

Oil $24bbl 254 254

Oil shale-fueled 218 236

Including fuel

Prefeasibility Study

SOil Shale Fueled Power Generaion

VOOIt JLMO I

Alternate Fuel Price Effect shy4x100 MW Project

Financing Basis DebtEquity Ratio

Alternate Fuel Price

Imported coal $50tonne $70tonne

Imported oil $17bbl ($120tonne) $24bbl ($170tonne)

Cumulative 25-yr Net Benefit

Favoring Oil Shale (US $MM) shy

8020 5050

778 315 2531 2068

(18) (506)1810 1322

Prefeasibility Study

Oil Shale Fueled Power Generation

Voo -I DLU-A 2

i

Comparison of Cumulative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

32 Pay Out Year shy

400 MW PlantOil Shale vs Imported Coal (8020 debtequty)

30

28 -Cumulative fuel cost savings forcoal $70ton

Cumulative fuel cost savings for coaJ $50ton

26---------- Cumulative Incremental capital plus OampM costs

24

22 -

18 -0

W- Cumulative net benefit for shae vs coal $50ton 2B Cumulative net benefit for shale vs coal $70ton

co16C -

14 -

12 -

10 -

09

06 -Payout inyear 1

Payout Inyear 9 for coal $50ton - -- - - -shy

02 0 I

0 1 2 3 4 5 Nowl Yewr in which sauings in fWe colsacm-ewi tat hsawinitl

ca=al wosaand OampM costs

6

_iiM

7 8

9 10

------ - -amp -

11 12 13 14Year of Operation

--

15

- - --shy

16 17

I

18

1

19

I

20

I

21

I

22

I

23

I

24 25

Prefeasibility StudyOil Shale Fueled Power Generation

17958d351aJordanr 3-14-89 rsO

118

Comparison of Cumuiative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

28 Pay Out Year shy

400 MW Plant Oil Shale vs Imported Coal (5050 debtequity)

26shy2

24-

Cumulaive fuel nst savings for coal 0 $70ton Cumulative fuel cost savings for coal $50ton Cumulative Incremental capital plus OampM corts

22 -

20 -

18 -- Cumuladve net benefit for shle vs coal $50ton B Cumuarve net benefit for sale vs coal $70ton

16 -

C 14

12

10

08 -06 - Payout In year 1for coal $50ton

04

Payout Inyear 1

for coal $70ton02~

0 0

-No

02-

1 2

Yew inrY MCM cajlaI rl

3 4 5 6

sngm inW coas 0 ort hghWcentWin

0tOM cori

7

--

8

- -

9 10 11 12 13 14

Year of Operation

15 16 17

I

18

IIII

19 20 21 22 23 24 25

Preieasibility Study Oil Shale Fueled Power Generation

17958451 bJordarV118 3-14-89 rsipcI

Estimated Cost of Power- 400 MW (4 x 100)

FUEL

ImportedCoal

$50T

$70fT

1st Year

68 88

Levelized

78 107

Sultani Oil Shale

71 83

ImportedOil

$1713

$2413

56

67

76

96

0 10 20 30 40 50

I 60

I 70

I 80

I 90 100 110 120

Mills per kWh

Prefeasibility Study Oil Shale Fueled Power Generation

179581251 cJordarVl 18 3-14-89 rspc1

Summary Financial Analysis Results

Project size

Debt equity ratio

- Investment cost

- Power cost

- 25-year net benefit

- Project implementation

Alternative fuel price

Economic Comparison

Very significant

Not significant

Not significant

Very significant

Critical

Very significant

Prefeasibility Study

Oil Shale Fueled Power Generation

VY0 tDLUAi3

i

Study Conclusions

Feasibility

Timeliness

Expansion conditions

Environmental impacts

Development advantages

Prefeasibility Study

Oil Shale Fueled Power Generation VW41-1AiUA

4

Feasibility

Oil shale fueled power generation is technically and economically justifiedunder certain conditions

N Need for additional generating capacity

exists

- 6 annual peak demand growth - Orderly retirement of olderhigh cost

generating capacity needed

U Higher costs are expected for imported fuels

- 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

-OP b i j~~4shy

-4protntiYPe 4 demo plnt orP42 t~Plant orPootypeProje(-7hould

that Rj

demo 4Therefore-44 JEA anxinus

the

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

27Pag 4- 1 2S c i n 4 4

4i2Sectjo4-18-4 Secio 4-4 014

lt th~ae hi4h -tasisso syste thrug27 ~ 04lag arstl~art-p tasforme ed 2p27132Kvdieanwhy notthroug

EAto- is protmm~~ thegnJgt~~ pracie an ect ~ platqrby

28Pg 4 s heonnenotedto~the 32K rc powr

It not8 Scection rie049teoervnrain prctc de1

rh u n trae f2V3K anerd not throughgeterAntor

27 P3e-1r p ant weung-a

-If I

2tEll10 DRWE-jOi ASOt Mint~~al d~c~e o hepwrgnrto

ELCTRInYJORD UTHORITY-

Ate~

21Pge41 ection 4 04- 5

sindicated~ t hthigh the unit outputredu f hecondenser Injengtd~ibbvePressureed incg desrin hi h riseb vmbi nt emperatureWe bel~ieve

PleaIse provide us with th rscrapcity for th-e three options n nt generating~

21-Iisidca ted that~ thediaatgeofCBi theSheavy fn oe consumnptionPlease~ providethe us withpecntgA

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

400 MW COAL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO 5050

NET GENERATION - MWe 40000 CAPACITY FACTOR - 75 ANNUAL GENERATION MKWhYR 2628 SUB TOTAL PLANT COSTS (TPC) $1000 $620000

FIXED 0 amp M COSTS MH $ MH FIRST YEAR COST$1O00

------- --------- --- ---- --- --- ------------

OPERATING LABOR 351936 $3 $1100 MAINTENANCE LABOR 4000 of 150 OF TPC 3720

MAINTENANCE MATERIAL 6000

ADMIN LABOR of 150

3000 OF TPC

OF 0 amp M LABOR 5580 1446

SUB TOTAL FIXED OampM COSTS $11846

VARIABLE 0 amp M COSTS QUANTITY UNIT COST

VARIABLE MAINTENANCE 2628 MKWh 10 MILLKWH $ 2628 PROCESS WATER 13500000 GALLON 02 SGAL $ 2700 GENERAL PLANT CHEMICALS ALLOW 50 FUEL OIL 1000000 GALLON 035 $GAL $ 350 WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290SPECIAL BOILER MAINT ALLOW 0

SUB TOTAL VARIABLE OampM COSTS $ 8018

TOTAL FIXED amp VARIABLE OampM COSTS $19864 TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $8227 $TN $99139

(INCL INFLATION ADJUSTMENT)

B DEBT EQUITY RATIO =========== 8020

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $17574

WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290

TOTAL FIXED amp VARIABLE OampM COSTS $19864TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $5877 $TN $70814

(INCL INFLATION ADJUSTMENT)

6-21

Table 612 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY

400 MW OIL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO

NET GENERATION -

CAPACITY FACTOR -

ANNUAL GENERATION SUB TOTAL PLANT COSTS (TPC)

FIXED 0 amp M COSTS

OPERATING LABOR MAINTENANCE LABOR 4000 of

MAINTENANCE MATERIAL 6000 of

ADMIN LABOR

SUB TOTAL FIXED OampM COSTS

VARIABLE 0 amp M COSTS

VARIABLE MAINTENANCE PROCESS WATER GENERAL PLANT CHEMICALS FUEL OIL WASTE DISPOSAL (Section 6027) SPECIAL BOILER MAINT

SUB TOTAL VARIABLE OampM COSTS

5050

MWe

MKWhYR $1000

MH

262080

150

150 3000

QUANTITY

2628 MKWh 13500000 GALLON

1000000 GALLON 0 TNYR

TOTAL FIXED amp VARIABLE OampM COSTS FUEL OIL 503000 TNYR

B DEBT EQUITY RATIO =8020

40000 75

268 $443000

FIRST YEAR $ MH COST$1O00

$3 $ 800

OF TPC 2658

OF TPC 3987 OF 0 amp M LABOR 1037

$ 8482

UNIT COST

05 MILLKWH $ 1314 02 $GAL $ 2700

ALLOW 50 035 $GAL $ 350

$1000 $TN $ 0 ALLOW 0

$ 4414

$12896 $19981 $TN $100502

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $12896

WASTE DISPOSAL (Section 6027) 0 TNYR $1000 $TN $ 0

TOTAL FIXED amp VARIABLE OampM COSTS $12896 FUEL OIL 503000 TNYR $14104 $TN $70943

6-23

Page 16: fo; - pdf.usaid.gov

Pilot Plant Test Program (Contd)

U Analyzed one blended sample of shale

- Calorific value = 532 - 597 MJkg (approx 2250 BtuIlb)

- Carbon content (dry solids) = 162 - 187 wto

- Sulfur content (dry solids) = 30 - 33 wt

- Ash content (dry solids) = 667 - 684 wt

- Shale size = minus 8 mm

Key items determined

- Combustion efficiency

- Product ash distribution

- Product gas S02NOxCO content

- Data for boiler design

- Sulfur emissions reduction by Ca in fuel

S Prefeasibility Study Oil Shale Fueled Power Generation

VOO74GEAJI 10

Pilot Plant Test Results

U Combustion efficiency exceeded 985 in all tests

Ash distribution (btm ashfly ash) was 3565 to 4753 at 100 load typically4060

Low emissions were demonstrated

Typically S02 10 to 200 ppm gt 95 removal

limestone addition not required

NOx 60 to 120 ppm lt 020 lb106 Btu

Co 10 to 90 ppm lt 50 ppm

Prefeasibility Study Oi Shale Fueled Power Generation

TITLE

Ternpe -al-CuA vs 6 Ik

00

I00

7SA-A-

Fly Ai h

0

85 e

80-

0

00

i I 800 860 oo

T-er pe -

DATE OWN APPD DCNO- ------ -

_______f - _ IPG_

Pilot Plant Test Conclusions

It is technically feasible to burn the Sultani oil shale furnished by NRA in a Pyropower boiler

A high combustion efficiency in excess of 985 was demonstrated

SO2NOxCO emissions are all acceptably low with no limestone addition required

Prefeasibility StudyO Shale Fueled Power Generation

Conceptual Design Studies Scope

m Three project sizes

- 20 MW

- 50 MW

- 400 MW (4x100) factored for power plant portion

m Open-pit mine

- Shale processing at the surface - Waste disposal system

Power block

- Boiler

- Steam turbine

- Auxiliaries

Prefeasibility Study Oil Shale Fueled Power Generation

VOn 4FAIR 1

i

Project Layout 9 fc =f4j

deg2

o r -w (031

5_7EC 45U

iPefeaibiity tud

OlSeFuedP erGr in

179581113i~o(atyvv11

n1- 14 4pc

C)

Sultani Oil Shale Reserves

North South Area Area Total

Mineable shale tonne x 106 320 658 978

Fischer assay oil content wt 744 761 765

Overburden m3 x 106 384 627 1011

Stripping ratio m3m3 2161 1711 1861

bull Based on NRA core drilling and core analysis

Prefeasibility Study Oil Shale Fueled Power Generation

VWO41OFEAMI14

i

Sultani Oil Shale Analyses

Moisture

Ash (less CO 2 in CaCO 3 )

CO 2 (in CaCO 3 )

Carbon (organic)

Hydrogen

Nitrogen

Sulfur

Oxygen (by diff)

Total

High heating value BtuIb

Fischer assay oil content

bull Percent by weight

Design Basis Fuel

320

6680

1387

1132

113

048

255

065

10000

2250

840

Low High Calorific Calorific

Value Fuel Value Fuel

320 320

6730 6625

1414 1337

1020 1250

102 125

058 038

238 271

118 034

10000 10000

2000 2500

750 925

Preteasibility Study Oil Shale Fueled Power Generation

vo0N d-GEAR 1S

50 MW Oil Shale ProcessingPrototype Plant

Mlne Plant

_ 14 0 Haul0___) to Plant 1 Sorage

Portable Crusher

(-)100 mm Storage

(-) 100 mm Hopper UIU 400 th

Feed Bin

J 50

250 tvb

8 -m Circulating Load Impact3or0 0 30 0 0shy+8mm25

30 0L Sampler 0 1 30 0

p3 Day Storage

To Power Plant

Preleasibility StudyOil Shale Fueled Power Generation

17958101 SaJordanli 18 3-14-89 rsipc1

20 MW Oil Shale Demonstration Plant

Mine Plant

Haul00- 01 o

= Pb n Storage Portable _

110 mm Stora e 0

()100 mm r Hopper

U 400V

Feed Bin

CirculatingLoad3 Day Stoge

Prefea~ltSudy Shale Fueled Power Generation

179S 111p 1 11Joda3 yl 3-202-89 8vk2

I

Mine and Shale ProcessingDesign - 2050 MW Project

I Overburden removal (north pit area) 10-meter benches

- Drill and blast

- 10 m3 front-end loader

- 77-ton truck haulage

I Oil shale mining 10-meter benches

- Rippe and auger scraper

- Front-end loader

- Portable in-pit crusher

- 77-ton truck haulage

Oil shale processing

- Feed = minus 100 mm

- Product = minus 8 mm

- Capacity = 250 tph

- Reversible impactor

- Two vibrating screens

1 Prefeasibility Study Oil Shale Fueled Power Generation

V -M 1AMI1ARt46

400 MW Full-Scale Oil Shale ProcessingPlant

Feed MTnus 200 mm Samplerr

1000 bull 10000 Tonnes Live Storage Grade

200 m long(-) 200 mm -- =-- Plow Feeders

00 h 100000 Tonnes Live Storage

Stream 3 - Sampler Bin Stream 2

Stream th 31Da2000

Circulating Load 2i

NFw Feed r -17000t1 170001l 170 t 17000 t 17000 t

1000 th Silo with 7 Impactor (-1)8 mm Reapro- 3 Day Storage at Aver age Loadn

0 20 Feeders 20 m Diameter by 40 m High

JJJTHT To Power Plant

Prefeasibility Study Oil Shale Fueled Power Generation

179589 6aJordarV 1I8 3-14-89 rsipc1

Mine and Shale ProcessingDesign - 4x100 MW Project

m Overburden removal (north area) 10-meter benches

- Drill and blast

- Three 20 m3 shovels

- 136-ton truck haulage

m Oil shale mining 10-meter benches

- Two mechanical surface miners

- 136-ton trucks to pit hopper

- Belt conveyor = 2000 tph

- Traveling stacker

m Oil shale processing

- Feed = minus 200 mm

- Product = minus 8 mm

- Capacity = three 1000 tph units

Prefeasibility Study Oil Shale Fueled Power Generation

VOO79-ampGEAIAt 17

i

Steady-State Production Schedule

Overburden removal bench m3

20 MW demo project 5n MW prototype 4x100 MW full-scale plant

Oil shale mining and shale processing tonnes

20 MW project 50 MW project 4x100 MW project

HourlyDesign Capacity

282 234

1850

HourlyDesign Capacity

250 250

2000

Avg Daily Annual PEQuctiQa Production

1690 507000 4217 13 million

33333 10 million

Max Daily(a) Annual(b) Production Production

1733 390000 4324 973000

34578 78 million

(a) Based on 100 operating factor for power block

(b) Based on 75 operating factor for power block ( 20 MW project = 300 shiftsyr 50 MW project = 900 shiftsyr 400 MW project = 900 shiftsyr)

Prefeasibility Study Oil Shale Fueled Power Generation

Conceptual Power Plant Plans

m Pyroflow boiler

Power generating facilities

m Auxiliaries

S Preleasibility Study Oil ShaJe Fueled Power Generation

vo0o7dEAO 19

Pyroflow Boiler SteamConciflons

Flow rate 226700 kghr (500000 Ibhr)

Pressure 1099 kgcm2 abs (15635 psia)

Temperature 51280C (9550F)

Same for 20 50 and 100 MW designs

Prefeasibility Study Oil ShaJe Fueled Power Generation

vooGALMI 20

HtomCOPUIOTP

- 50005 5op

-- LEVAThUM ORPORAION

0

-VI

DZ 4

Power Block

Fuel handling system

- Day binsscrew feeders

Boiler

- Pyroflow circulating fluid bed combustor

Power generation

- Non reheat condensing steam turbine

- Conventional Rankin steam cycle

Ash handling system (btm ash irom combustor and flyash from bag house)

- Wetted in pug mill to add 20plusmn wt wpter

Plant service water

- Air-cooled condensors and small cooling tower from circulating trim water coolers

Plant raw water

- To cooling tower makeup

- To drinking water system

- To pump seals etc

Plant treated makeup water

- Demineralizer train

Preteasibility Study Oil Shale Fueled Power Generation

i

Onsite Infrastructure

Project office

Control house

U Maintenance shops warehouse

Laboratory

Employee service facility

Site developmentoperations service facilities

- Fire controlsecurity

- Communications

- Lighting

- Roads drainage and sewage

Prefeasibility StudyQ1I Shale Fueled Power Generation

voo4JG m 0 JV

i

BechtellPyropower50 MW Cogeneration Plant - Mt Poso California

W4t Prefeasibility Study --- 7 Oil Shale Fueled Power Generation

179586122aJordarv 118 3-14-89 rsO

Characteristics of Three Size Operations

Oil shale fuel tpy

Mine development excavation bank m3

Spent ash disposal tpy (wetted)

Water consumption 1000 m3yr

Staffing required

Community population

400 MW

20 MW 50 MW (4x1 00)

390000 973000 78 million

500000 1 million 85 million

327000 815000 61 million

538 907 1263

185 324 1046

700 1200 4000

Prefeasibility Study Oil Shale Fueled Power Generation

V000ofllAM1 23

Conceptual Designs Summary

N All BOP facilities involve conventional equipment and technology

100 MW unit operation involves boiler scale-up considerations

N Water consumption estimates

- Requirement for 4x100 MW project is 13 million m3 yr

- Water allocation of 2 million m3yr of water supports 6x100 MW

N Water availability probably limits total power generation from oil shale in Jordan

Prefeasibility Study Oil Shale Fueled Power Generation

V007041GEAOLMI

i

TECHNOLOGY RISK ASSESSMENT

Basic concepts

Key boiler scale-up design issues

Impact of scale-up

U Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Prefeasibility Study O1 Shale Fueled Power Generation

VOOh-7AEAAO 2

Basic Concepts

U CFBC is relatively new in the powerindustry

- Existing plants are small typically 20 to 50 MW

- There is limited operating experience with high-ash fuels

- Existing designs for lignite biomass and coal wastes show good plant performance

I Application of CFBC boiler design to oil shale fuel has defined risk that relates to scale-up of existing design

Similar CFBC technology is used in petroleum refining industry

- FCC cracking plant regenerators burn carbon residue off spent catalyst

- 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

FUEL ANALYSES

High Ash Fuel Projects Total Solids Input Basis

Gilberton Cambria North Branch

Carbon 4653 2749 1822 Hydrogen 153 164 160 Sulfur 073 222 234 Nitrogen 085 051 043 Oxygen 282 218 468 Moisture 1451 514 557 Ash 3303 6 0 6Z16

10000 10000 10000

HHVBtulb 7485 4809 3453

includes limestone feed a3 ash

includes CO2 in Ca~o3

CA89029 CAkw

Oil Shale

1132

113

255

048

065

320

-8062

10000

2250

Key Boiler Scale-Up DesignIssues

m Solids handling

- Feeding shale to combustor

- 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

Voo4tGEAMI 30

i

Mine and Shale Processing

U Fugitive dust emissions are controllable

- Wetting mine roads

- Enclose crushing plant equipment

Noise levels are controllable

- Enclose crushing plant equipment - Muffle truck exhausts

- Engineered waste disposal

Water effluents can be controlled

- Need good mine drainage design - Continue leachability studies on

waste dump piles

Prefeasibilily StudyOil Shale Fueled Po r Generaton

V0079OOG-4O 31

1

Power Plant

II Fugitive dust emissions are controllable

- Baghouse designoperation will minimize particulates in flue gas

- Wetting spent ash before disposal

N Gaseous emissions are controllable

- Pilot test results show acceptable SO2NOxCO in flue gas

- Develop baseline data for Sultani area

Develop air dispersion model for Sultani

Prefeasibility StudyOil Shale Fueled Power Generatio

V00 V-4GEA l32

i

Power Plant (Contd)

Noise levels are controllable

- Enclose boiler plant fans as required - Enclose turbines and pumps as

required

Water effluents are controllable

- Continue leachability studies on spent ash disposal

- Develop aquifer dispersion model

- Develop sewage and garbage disposal plan

Prefeasibility SludyOil Shale Fueled Power Generation

V00-4FAAI 33

Conclusions

No environmental constraints are anticipated on oil shale powerdevelopment

Gas effluents will meet World Bank standards

- Ash disposal is manageable

- The potential for groundwatercontamination appears low

- Water effluents will be minimal

Continued studies to develop air and groundwater baseline data are recommended

S Prefeasibility Study Oil Shale Fueled Power Generation

v0 9ampGLAMR 34

Power Demand vs SupplyAssessment

m Demand growth forecasts

Electrical generating capacity

= Power supply forecasts

= Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Preleasibility Study Oil Shaie Fuelod Power Generation

VO9- uLIROI

1

Power Demand Forecasts

Percent Annual Growth

JEA

Meta systems HaglerBailey and Bechtel National Inc

JEA Peak Demand Growth

1980 (actual) 1985 (actual) 1987 (actual) 1995 (forecast) 2005 (forecast)

1986 1990 to to

1990 2000

97 60

49 39

200 MW 475 MW 593 MW 900 MW

1400 MW

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOO-DLURO2

i

JEA ElectricityGeneratingCapacity

1987 Installed

Capacity (MW) Aqaba 260

22

Zarqa 395

Marka 102

Karak 23

Miscellaneous 67

Subtotal JEA capacity 869

Other capacity - industrial 110

Total 979

Prefeasibility Study Oi1 Shale Fueled Power Generation

V000-6O0LFJRO3 (

Forecast New Power Generating Capacity Required

Fcst 1987 Required

New Peak Available Installed

Demand Capacity Shortfall (a) Capacity (b) (MM (MW) (MW) (MW)

Assumed capacityfactor (65) (75)

1995 requirement 900 636 264 352

2005 requirement 1400 636 764 1019

(a) Excludes proposed additions and retirements (b) Excludes possible power exports or imports

Load shedding or levelizing not considered

Preteasibility Study Oil Shale Fueled Power Generation

Vflcmf-R)LLAO4

i

Supply vs Demand Evaluation

1800

1600

1400 Forecast Peak Demands

1200 -

E Installed Capacity

0 800shy75--

U) Assumed Available Calcit

a 6 Ao600 shy0 o 65

400 shy

200

I I I I I I I I I I I I I I I I I I I I I I I 1 1 1980 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958f738aIJordarV 118 3-14-89 rspCO

Conclusions

Additional power generating capacity is needed to meet forecasted 19952005demand growth

A 400 MW oil shale-to-power project at Sultani can meet a portion of this need

U A second 400 MW oil shale project maybe required if water is available

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOW0O-8LURO5

i

Economic Feasibility

N Order-of-magnitude costs

N Economic analysis

- Jordan study options

- Project size effect

m Comparison with alternative fuels

- Fuel requirement

- Project financing effect

- Alternate fuel price effect

- Estimated cost of electricity

N Summary financial analysis

bull Material was developed by Bechtel Power Company

Prefeasibility Study

go Oil Shale Fueled Power Generation VOOSO-ampDtJROh

ORDER-OF-MAGNITUDE COSTS

U Oil shale fuel

Power plant

I Integrated project- busbar

Preteasibility Study

Oil Shale Fueled Power Generation

VOO9O-ampDLUROS

Oil Shale Fuel Costs

Installed Capital Cost

Mine Development

Mine Equipment

Processing Plant

Spare Parts

Working Capital

Capitalized Interest

Total

Annual Operating Cost

Fuel Cost $UStonne

bull Based on 8020 debtequity ratio

20 MW

4900

11090

6945

1200

1200

4054

29389

5582

1431

US $1000 Factored

50 MW 4x100 MW

7833 30915

12202 66012

8388 50889

1300 5000

2200 10000

5108 39075

37031 201891

11556 53236

1188 684

Prefeasibility Study

Oil Shale Fueled Power Generation

VCO-ampDLUJ1O

Power Plant Costs

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Cost

Power faciities 57500 91800 567800

Owners cost 10200 20400 192700

Total 67700 112200 760500

Annual Operating Cost 2205 3248 17157(excluding fuel cost)

bullBased on 8020 debtequity ratio oil shale fueled

Prefeasibility Study

Oil Shale Fueled Power Generation

V00O8c4LLMO9

i

INTEGRATED PROJECT -BUSBAR COST

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Costs Mine amp shale processingPower block Waste disposal Infrastructure

29359 67700

1664 10000

37031 112200

2381 15000

201891 760500

8714 45000

TOTAL 108753 166612 1016105

Annual Operating Cost Mine amp shale processingPower block Waste disposal Infrastructure (a)

5582 2205

316

11556 3248

710

56430(b) 18186(b) 6004

Subtotal 8103 15514 80620

Capital Charges 139 9410 15596 106000

Total 17513 31110 186620

25-year levelized cost - - 218000

Busbar Cost millskWh First year 128 92 71 25-year levelized 83

(a) Housing and community facilities assumed self-liquidating(b) Includes first-year inflation adjustment

Based on 8020 debtequity ratio

Prefeasibility StudyOil Shale Fueled Power Generaion

VOOOO-8MLtROi0

ECONOMIC ANALYSIS

n Jordan study options

Project size effect

Fuel requirement

Project financing effect

Alternative fuel price effect

Estimated electricity cost

Summary financial analysis results

Prefeasibility Study

Oil Shale Fueled Powr Generation

VOOeO-BOCLLO1 I

i

Jordan Study Options

U Project size

- Demonstration = 20 MW

- Prototype = 50 MW

- Commercial = 400 MW (4x100)

Project financing

- Debtequity 8020

- Debtequity 5050

Imported alternative fuels cost assumptions

A B Crude oil $17bbl $24bbl

$120onne $170tonne

Low sulfur coal $ 50tonne $ 70tonne See Chevron forecast supporting assumptions

Prefeasibility StudyOil Shale Fueled Power Generation

VOOOO-8DLIJRO12

i

Crude Oil Price Trends

60

Source World Energy Outlook Chevron Corporation Oclober 1987

40

High trend

No Ir 20 ~~~~Arabian Light Spot I A u

IILowYUII trend

0 1970 1975 1980 1985 1990 1995

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958246aJodar 118 3-14-89 rsO

2000

Project Size Effect Shale Fuel Option

Project Size

Integrated facilities installed capital cost$ US million

Shale cost $UStonne(8020 debtequity)

Cost of power millskWh(8020 debtequity ratio)

20 MW

109

143

128

50 MW

167

118

92

400 MW (4x1 00)

1016

68

71

Prefeasibility Study Oil Sampae Fueled Power Generation

VOO O-8I0LJRO13

gt1

1

Power Block Investment Cost

3000

$2875 Excluding mining and offsite 2800

2600

2400

2200

2000

$1836 1800

$1613 1600

$1420 1400 1I 1 I

0 100 200 300 400 MWe

August 1988

Preleasibility Study OilShale Fueled Power Generation

179581147aJodar1 18 3-14-89 rspcl

Fuel Requirement - 4x100 MW Project

Coal = 12 million tpy

n Oil = 503000 tpy

Oil shale = 78 million tpy

Preleasibility Study

Oil Shale Fueled Power Generation

IO060-OLLIRO14

Financing Effect -Project

Oil Shale Fuel Option

Mine and shale processing

Power block

Waste disposal

Community facilities

Total

Coal-Fired Power Plant

Oil-Fired Power Plant

400 MW

Capital Cost ($US MM)

DebtEquity

8020 5050

202 187

760 760

9 8

45 45

1016 1000

647 647

463 463

Prefeasibility StudyOil Shale Fueled Power Generation

VOe-BD1JRO15

Financing Effect shy400 MW Project

Operating Costs ($US millionyr)

DebtEquity

8020 5050

Coal $70tonne 282 282

Oil $24bbl 254 254

Oil shale-fueled 218 236

Including fuel

Prefeasibility Study

SOil Shale Fueled Power Generaion

VOOIt JLMO I

Alternate Fuel Price Effect shy4x100 MW Project

Financing Basis DebtEquity Ratio

Alternate Fuel Price

Imported coal $50tonne $70tonne

Imported oil $17bbl ($120tonne) $24bbl ($170tonne)

Cumulative 25-yr Net Benefit

Favoring Oil Shale (US $MM) shy

8020 5050

778 315 2531 2068

(18) (506)1810 1322

Prefeasibility Study

Oil Shale Fueled Power Generation

Voo -I DLU-A 2

i

Comparison of Cumulative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

32 Pay Out Year shy

400 MW PlantOil Shale vs Imported Coal (8020 debtequty)

30

28 -Cumulative fuel cost savings forcoal $70ton

Cumulative fuel cost savings for coaJ $50ton

26---------- Cumulative Incremental capital plus OampM costs

24

22 -

18 -0

W- Cumulative net benefit for shae vs coal $50ton 2B Cumulative net benefit for shale vs coal $70ton

co16C -

14 -

12 -

10 -

09

06 -Payout inyear 1

Payout Inyear 9 for coal $50ton - -- - - -shy

02 0 I

0 1 2 3 4 5 Nowl Yewr in which sauings in fWe colsacm-ewi tat hsawinitl

ca=al wosaand OampM costs

6

_iiM

7 8

9 10

------ - -amp -

11 12 13 14Year of Operation

--

15

- - --shy

16 17

I

18

1

19

I

20

I

21

I

22

I

23

I

24 25

Prefeasibility StudyOil Shale Fueled Power Generation

17958d351aJordanr 3-14-89 rsO

118

Comparison of Cumuiative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

28 Pay Out Year shy

400 MW Plant Oil Shale vs Imported Coal (5050 debtequity)

26shy2

24-

Cumulaive fuel nst savings for coal 0 $70ton Cumulative fuel cost savings for coal $50ton Cumulative Incremental capital plus OampM corts

22 -

20 -

18 -- Cumuladve net benefit for shle vs coal $50ton B Cumuarve net benefit for sale vs coal $70ton

16 -

C 14

12

10

08 -06 - Payout In year 1for coal $50ton

04

Payout Inyear 1

for coal $70ton02~

0 0

-No

02-

1 2

Yew inrY MCM cajlaI rl

3 4 5 6

sngm inW coas 0 ort hghWcentWin

0tOM cori

7

--

8

- -

9 10 11 12 13 14

Year of Operation

15 16 17

I

18

IIII

19 20 21 22 23 24 25

Preieasibility Study Oil Shale Fueled Power Generation

17958451 bJordarV118 3-14-89 rsipcI

Estimated Cost of Power- 400 MW (4 x 100)

FUEL

ImportedCoal

$50T

$70fT

1st Year

68 88

Levelized

78 107

Sultani Oil Shale

71 83

ImportedOil

$1713

$2413

56

67

76

96

0 10 20 30 40 50

I 60

I 70

I 80

I 90 100 110 120

Mills per kWh

Prefeasibility Study Oil Shale Fueled Power Generation

179581251 cJordarVl 18 3-14-89 rspc1

Summary Financial Analysis Results

Project size

Debt equity ratio

- Investment cost

- Power cost

- 25-year net benefit

- Project implementation

Alternative fuel price

Economic Comparison

Very significant

Not significant

Not significant

Very significant

Critical

Very significant

Prefeasibility Study

Oil Shale Fueled Power Generation

VY0 tDLUAi3

i

Study Conclusions

Feasibility

Timeliness

Expansion conditions

Environmental impacts

Development advantages

Prefeasibility Study

Oil Shale Fueled Power Generation VW41-1AiUA

4

Feasibility

Oil shale fueled power generation is technically and economically justifiedunder certain conditions

N Need for additional generating capacity

exists

- 6 annual peak demand growth - Orderly retirement of olderhigh cost

generating capacity needed

U Higher costs are expected for imported fuels

- 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

-OP b i j~~4shy

-4protntiYPe 4 demo plnt orP42 t~Plant orPootypeProje(-7hould

that Rj

demo 4Therefore-44 JEA anxinus

the

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

27Pag 4- 1 2S c i n 4 4

4i2Sectjo4-18-4 Secio 4-4 014

lt th~ae hi4h -tasisso syste thrug27 ~ 04lag arstl~art-p tasforme ed 2p27132Kvdieanwhy notthroug

EAto- is protmm~~ thegnJgt~~ pracie an ect ~ platqrby

28Pg 4 s heonnenotedto~the 32K rc powr

It not8 Scection rie049teoervnrain prctc de1

rh u n trae f2V3K anerd not throughgeterAntor

27 P3e-1r p ant weung-a

-If I

2tEll10 DRWE-jOi ASOt Mint~~al d~c~e o hepwrgnrto

ELCTRInYJORD UTHORITY-

Ate~

21Pge41 ection 4 04- 5

sindicated~ t hthigh the unit outputredu f hecondenser Injengtd~ibbvePressureed incg desrin hi h riseb vmbi nt emperatureWe bel~ieve

PleaIse provide us with th rscrapcity for th-e three options n nt generating~

21-Iisidca ted that~ thediaatgeofCBi theSheavy fn oe consumnptionPlease~ providethe us withpecntgA

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

400 MW COAL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO 5050

NET GENERATION - MWe 40000 CAPACITY FACTOR - 75 ANNUAL GENERATION MKWhYR 2628 SUB TOTAL PLANT COSTS (TPC) $1000 $620000

FIXED 0 amp M COSTS MH $ MH FIRST YEAR COST$1O00

------- --------- --- ---- --- --- ------------

OPERATING LABOR 351936 $3 $1100 MAINTENANCE LABOR 4000 of 150 OF TPC 3720

MAINTENANCE MATERIAL 6000

ADMIN LABOR of 150

3000 OF TPC

OF 0 amp M LABOR 5580 1446

SUB TOTAL FIXED OampM COSTS $11846

VARIABLE 0 amp M COSTS QUANTITY UNIT COST

VARIABLE MAINTENANCE 2628 MKWh 10 MILLKWH $ 2628 PROCESS WATER 13500000 GALLON 02 SGAL $ 2700 GENERAL PLANT CHEMICALS ALLOW 50 FUEL OIL 1000000 GALLON 035 $GAL $ 350 WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290SPECIAL BOILER MAINT ALLOW 0

SUB TOTAL VARIABLE OampM COSTS $ 8018

TOTAL FIXED amp VARIABLE OampM COSTS $19864 TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $8227 $TN $99139

(INCL INFLATION ADJUSTMENT)

B DEBT EQUITY RATIO =========== 8020

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $17574

WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290

TOTAL FIXED amp VARIABLE OampM COSTS $19864TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $5877 $TN $70814

(INCL INFLATION ADJUSTMENT)

6-21

Table 612 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY

400 MW OIL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO

NET GENERATION -

CAPACITY FACTOR -

ANNUAL GENERATION SUB TOTAL PLANT COSTS (TPC)

FIXED 0 amp M COSTS

OPERATING LABOR MAINTENANCE LABOR 4000 of

MAINTENANCE MATERIAL 6000 of

ADMIN LABOR

SUB TOTAL FIXED OampM COSTS

VARIABLE 0 amp M COSTS

VARIABLE MAINTENANCE PROCESS WATER GENERAL PLANT CHEMICALS FUEL OIL WASTE DISPOSAL (Section 6027) SPECIAL BOILER MAINT

SUB TOTAL VARIABLE OampM COSTS

5050

MWe

MKWhYR $1000

MH

262080

150

150 3000

QUANTITY

2628 MKWh 13500000 GALLON

1000000 GALLON 0 TNYR

TOTAL FIXED amp VARIABLE OampM COSTS FUEL OIL 503000 TNYR

B DEBT EQUITY RATIO =8020

40000 75

268 $443000

FIRST YEAR $ MH COST$1O00

$3 $ 800

OF TPC 2658

OF TPC 3987 OF 0 amp M LABOR 1037

$ 8482

UNIT COST

05 MILLKWH $ 1314 02 $GAL $ 2700

ALLOW 50 035 $GAL $ 350

$1000 $TN $ 0 ALLOW 0

$ 4414

$12896 $19981 $TN $100502

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $12896

WASTE DISPOSAL (Section 6027) 0 TNYR $1000 $TN $ 0

TOTAL FIXED amp VARIABLE OampM COSTS $12896 FUEL OIL 503000 TNYR $14104 $TN $70943

6-23

Page 17: fo; - pdf.usaid.gov

Pilot Plant Test Results

U Combustion efficiency exceeded 985 in all tests

Ash distribution (btm ashfly ash) was 3565 to 4753 at 100 load typically4060

Low emissions were demonstrated

Typically S02 10 to 200 ppm gt 95 removal

limestone addition not required

NOx 60 to 120 ppm lt 020 lb106 Btu

Co 10 to 90 ppm lt 50 ppm

Prefeasibility Study Oi Shale Fueled Power Generation

TITLE

Ternpe -al-CuA vs 6 Ik

00

I00

7SA-A-

Fly Ai h

0

85 e

80-

0

00

i I 800 860 oo

T-er pe -

DATE OWN APPD DCNO- ------ -

_______f - _ IPG_

Pilot Plant Test Conclusions

It is technically feasible to burn the Sultani oil shale furnished by NRA in a Pyropower boiler

A high combustion efficiency in excess of 985 was demonstrated

SO2NOxCO emissions are all acceptably low with no limestone addition required

Prefeasibility StudyO Shale Fueled Power Generation

Conceptual Design Studies Scope

m Three project sizes

- 20 MW

- 50 MW

- 400 MW (4x100) factored for power plant portion

m Open-pit mine

- Shale processing at the surface - Waste disposal system

Power block

- Boiler

- Steam turbine

- Auxiliaries

Prefeasibility Study Oil Shale Fueled Power Generation

VOn 4FAIR 1

i

Project Layout 9 fc =f4j

deg2

o r -w (031

5_7EC 45U

iPefeaibiity tud

OlSeFuedP erGr in

179581113i~o(atyvv11

n1- 14 4pc

C)

Sultani Oil Shale Reserves

North South Area Area Total

Mineable shale tonne x 106 320 658 978

Fischer assay oil content wt 744 761 765

Overburden m3 x 106 384 627 1011

Stripping ratio m3m3 2161 1711 1861

bull Based on NRA core drilling and core analysis

Prefeasibility Study Oil Shale Fueled Power Generation

VWO41OFEAMI14

i

Sultani Oil Shale Analyses

Moisture

Ash (less CO 2 in CaCO 3 )

CO 2 (in CaCO 3 )

Carbon (organic)

Hydrogen

Nitrogen

Sulfur

Oxygen (by diff)

Total

High heating value BtuIb

Fischer assay oil content

bull Percent by weight

Design Basis Fuel

320

6680

1387

1132

113

048

255

065

10000

2250

840

Low High Calorific Calorific

Value Fuel Value Fuel

320 320

6730 6625

1414 1337

1020 1250

102 125

058 038

238 271

118 034

10000 10000

2000 2500

750 925

Preteasibility Study Oil Shale Fueled Power Generation

vo0N d-GEAR 1S

50 MW Oil Shale ProcessingPrototype Plant

Mlne Plant

_ 14 0 Haul0___) to Plant 1 Sorage

Portable Crusher

(-)100 mm Storage

(-) 100 mm Hopper UIU 400 th

Feed Bin

J 50

250 tvb

8 -m Circulating Load Impact3or0 0 30 0 0shy+8mm25

30 0L Sampler 0 1 30 0

p3 Day Storage

To Power Plant

Preleasibility StudyOil Shale Fueled Power Generation

17958101 SaJordanli 18 3-14-89 rsipc1

20 MW Oil Shale Demonstration Plant

Mine Plant

Haul00- 01 o

= Pb n Storage Portable _

110 mm Stora e 0

()100 mm r Hopper

U 400V

Feed Bin

CirculatingLoad3 Day Stoge

Prefea~ltSudy Shale Fueled Power Generation

179S 111p 1 11Joda3 yl 3-202-89 8vk2

I

Mine and Shale ProcessingDesign - 2050 MW Project

I Overburden removal (north pit area) 10-meter benches

- Drill and blast

- 10 m3 front-end loader

- 77-ton truck haulage

I Oil shale mining 10-meter benches

- Rippe and auger scraper

- Front-end loader

- Portable in-pit crusher

- 77-ton truck haulage

Oil shale processing

- Feed = minus 100 mm

- Product = minus 8 mm

- Capacity = 250 tph

- Reversible impactor

- Two vibrating screens

1 Prefeasibility Study Oil Shale Fueled Power Generation

V -M 1AMI1ARt46

400 MW Full-Scale Oil Shale ProcessingPlant

Feed MTnus 200 mm Samplerr

1000 bull 10000 Tonnes Live Storage Grade

200 m long(-) 200 mm -- =-- Plow Feeders

00 h 100000 Tonnes Live Storage

Stream 3 - Sampler Bin Stream 2

Stream th 31Da2000

Circulating Load 2i

NFw Feed r -17000t1 170001l 170 t 17000 t 17000 t

1000 th Silo with 7 Impactor (-1)8 mm Reapro- 3 Day Storage at Aver age Loadn

0 20 Feeders 20 m Diameter by 40 m High

JJJTHT To Power Plant

Prefeasibility Study Oil Shale Fueled Power Generation

179589 6aJordarV 1I8 3-14-89 rsipc1

Mine and Shale ProcessingDesign - 4x100 MW Project

m Overburden removal (north area) 10-meter benches

- Drill and blast

- Three 20 m3 shovels

- 136-ton truck haulage

m Oil shale mining 10-meter benches

- Two mechanical surface miners

- 136-ton trucks to pit hopper

- Belt conveyor = 2000 tph

- Traveling stacker

m Oil shale processing

- Feed = minus 200 mm

- Product = minus 8 mm

- Capacity = three 1000 tph units

Prefeasibility Study Oil Shale Fueled Power Generation

VOO79-ampGEAIAt 17

i

Steady-State Production Schedule

Overburden removal bench m3

20 MW demo project 5n MW prototype 4x100 MW full-scale plant

Oil shale mining and shale processing tonnes

20 MW project 50 MW project 4x100 MW project

HourlyDesign Capacity

282 234

1850

HourlyDesign Capacity

250 250

2000

Avg Daily Annual PEQuctiQa Production

1690 507000 4217 13 million

33333 10 million

Max Daily(a) Annual(b) Production Production

1733 390000 4324 973000

34578 78 million

(a) Based on 100 operating factor for power block

(b) Based on 75 operating factor for power block ( 20 MW project = 300 shiftsyr 50 MW project = 900 shiftsyr 400 MW project = 900 shiftsyr)

Prefeasibility Study Oil Shale Fueled Power Generation

Conceptual Power Plant Plans

m Pyroflow boiler

Power generating facilities

m Auxiliaries

S Preleasibility Study Oil ShaJe Fueled Power Generation

vo0o7dEAO 19

Pyroflow Boiler SteamConciflons

Flow rate 226700 kghr (500000 Ibhr)

Pressure 1099 kgcm2 abs (15635 psia)

Temperature 51280C (9550F)

Same for 20 50 and 100 MW designs

Prefeasibility Study Oil ShaJe Fueled Power Generation

vooGALMI 20

HtomCOPUIOTP

- 50005 5op

-- LEVAThUM ORPORAION

0

-VI

DZ 4

Power Block

Fuel handling system

- Day binsscrew feeders

Boiler

- Pyroflow circulating fluid bed combustor

Power generation

- Non reheat condensing steam turbine

- Conventional Rankin steam cycle

Ash handling system (btm ash irom combustor and flyash from bag house)

- Wetted in pug mill to add 20plusmn wt wpter

Plant service water

- Air-cooled condensors and small cooling tower from circulating trim water coolers

Plant raw water

- To cooling tower makeup

- To drinking water system

- To pump seals etc

Plant treated makeup water

- Demineralizer train

Preteasibility Study Oil Shale Fueled Power Generation

i

Onsite Infrastructure

Project office

Control house

U Maintenance shops warehouse

Laboratory

Employee service facility

Site developmentoperations service facilities

- Fire controlsecurity

- Communications

- Lighting

- Roads drainage and sewage

Prefeasibility StudyQ1I Shale Fueled Power Generation

voo4JG m 0 JV

i

BechtellPyropower50 MW Cogeneration Plant - Mt Poso California

W4t Prefeasibility Study --- 7 Oil Shale Fueled Power Generation

179586122aJordarv 118 3-14-89 rsO

Characteristics of Three Size Operations

Oil shale fuel tpy

Mine development excavation bank m3

Spent ash disposal tpy (wetted)

Water consumption 1000 m3yr

Staffing required

Community population

400 MW

20 MW 50 MW (4x1 00)

390000 973000 78 million

500000 1 million 85 million

327000 815000 61 million

538 907 1263

185 324 1046

700 1200 4000

Prefeasibility Study Oil Shale Fueled Power Generation

V000ofllAM1 23

Conceptual Designs Summary

N All BOP facilities involve conventional equipment and technology

100 MW unit operation involves boiler scale-up considerations

N Water consumption estimates

- Requirement for 4x100 MW project is 13 million m3 yr

- Water allocation of 2 million m3yr of water supports 6x100 MW

N Water availability probably limits total power generation from oil shale in Jordan

Prefeasibility Study Oil Shale Fueled Power Generation

V007041GEAOLMI

i

TECHNOLOGY RISK ASSESSMENT

Basic concepts

Key boiler scale-up design issues

Impact of scale-up

U Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Prefeasibility Study O1 Shale Fueled Power Generation

VOOh-7AEAAO 2

Basic Concepts

U CFBC is relatively new in the powerindustry

- Existing plants are small typically 20 to 50 MW

- There is limited operating experience with high-ash fuels

- Existing designs for lignite biomass and coal wastes show good plant performance

I Application of CFBC boiler design to oil shale fuel has defined risk that relates to scale-up of existing design

Similar CFBC technology is used in petroleum refining industry

- FCC cracking plant regenerators burn carbon residue off spent catalyst

- 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

FUEL ANALYSES

High Ash Fuel Projects Total Solids Input Basis

Gilberton Cambria North Branch

Carbon 4653 2749 1822 Hydrogen 153 164 160 Sulfur 073 222 234 Nitrogen 085 051 043 Oxygen 282 218 468 Moisture 1451 514 557 Ash 3303 6 0 6Z16

10000 10000 10000

HHVBtulb 7485 4809 3453

includes limestone feed a3 ash

includes CO2 in Ca~o3

CA89029 CAkw

Oil Shale

1132

113

255

048

065

320

-8062

10000

2250

Key Boiler Scale-Up DesignIssues

m Solids handling

- Feeding shale to combustor

- 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

Voo4tGEAMI 30

i

Mine and Shale Processing

U Fugitive dust emissions are controllable

- Wetting mine roads

- Enclose crushing plant equipment

Noise levels are controllable

- Enclose crushing plant equipment - Muffle truck exhausts

- Engineered waste disposal

Water effluents can be controlled

- Need good mine drainage design - Continue leachability studies on

waste dump piles

Prefeasibilily StudyOil Shale Fueled Po r Generaton

V0079OOG-4O 31

1

Power Plant

II Fugitive dust emissions are controllable

- Baghouse designoperation will minimize particulates in flue gas

- Wetting spent ash before disposal

N Gaseous emissions are controllable

- Pilot test results show acceptable SO2NOxCO in flue gas

- Develop baseline data for Sultani area

Develop air dispersion model for Sultani

Prefeasibility StudyOil Shale Fueled Power Generatio

V00 V-4GEA l32

i

Power Plant (Contd)

Noise levels are controllable

- Enclose boiler plant fans as required - Enclose turbines and pumps as

required

Water effluents are controllable

- Continue leachability studies on spent ash disposal

- Develop aquifer dispersion model

- Develop sewage and garbage disposal plan

Prefeasibility SludyOil Shale Fueled Power Generation

V00-4FAAI 33

Conclusions

No environmental constraints are anticipated on oil shale powerdevelopment

Gas effluents will meet World Bank standards

- Ash disposal is manageable

- The potential for groundwatercontamination appears low

- Water effluents will be minimal

Continued studies to develop air and groundwater baseline data are recommended

S Prefeasibility Study Oil Shale Fueled Power Generation

v0 9ampGLAMR 34

Power Demand vs SupplyAssessment

m Demand growth forecasts

Electrical generating capacity

= Power supply forecasts

= Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Preleasibility Study Oil Shaie Fuelod Power Generation

VO9- uLIROI

1

Power Demand Forecasts

Percent Annual Growth

JEA

Meta systems HaglerBailey and Bechtel National Inc

JEA Peak Demand Growth

1980 (actual) 1985 (actual) 1987 (actual) 1995 (forecast) 2005 (forecast)

1986 1990 to to

1990 2000

97 60

49 39

200 MW 475 MW 593 MW 900 MW

1400 MW

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOO-DLURO2

i

JEA ElectricityGeneratingCapacity

1987 Installed

Capacity (MW) Aqaba 260

22

Zarqa 395

Marka 102

Karak 23

Miscellaneous 67

Subtotal JEA capacity 869

Other capacity - industrial 110

Total 979

Prefeasibility Study Oi1 Shale Fueled Power Generation

V000-6O0LFJRO3 (

Forecast New Power Generating Capacity Required

Fcst 1987 Required

New Peak Available Installed

Demand Capacity Shortfall (a) Capacity (b) (MM (MW) (MW) (MW)

Assumed capacityfactor (65) (75)

1995 requirement 900 636 264 352

2005 requirement 1400 636 764 1019

(a) Excludes proposed additions and retirements (b) Excludes possible power exports or imports

Load shedding or levelizing not considered

Preteasibility Study Oil Shale Fueled Power Generation

Vflcmf-R)LLAO4

i

Supply vs Demand Evaluation

1800

1600

1400 Forecast Peak Demands

1200 -

E Installed Capacity

0 800shy75--

U) Assumed Available Calcit

a 6 Ao600 shy0 o 65

400 shy

200

I I I I I I I I I I I I I I I I I I I I I I I 1 1 1980 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958f738aIJordarV 118 3-14-89 rspCO

Conclusions

Additional power generating capacity is needed to meet forecasted 19952005demand growth

A 400 MW oil shale-to-power project at Sultani can meet a portion of this need

U A second 400 MW oil shale project maybe required if water is available

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOW0O-8LURO5

i

Economic Feasibility

N Order-of-magnitude costs

N Economic analysis

- Jordan study options

- Project size effect

m Comparison with alternative fuels

- Fuel requirement

- Project financing effect

- Alternate fuel price effect

- Estimated cost of electricity

N Summary financial analysis

bull Material was developed by Bechtel Power Company

Prefeasibility Study

go Oil Shale Fueled Power Generation VOOSO-ampDtJROh

ORDER-OF-MAGNITUDE COSTS

U Oil shale fuel

Power plant

I Integrated project- busbar

Preteasibility Study

Oil Shale Fueled Power Generation

VOO9O-ampDLUROS

Oil Shale Fuel Costs

Installed Capital Cost

Mine Development

Mine Equipment

Processing Plant

Spare Parts

Working Capital

Capitalized Interest

Total

Annual Operating Cost

Fuel Cost $UStonne

bull Based on 8020 debtequity ratio

20 MW

4900

11090

6945

1200

1200

4054

29389

5582

1431

US $1000 Factored

50 MW 4x100 MW

7833 30915

12202 66012

8388 50889

1300 5000

2200 10000

5108 39075

37031 201891

11556 53236

1188 684

Prefeasibility Study

Oil Shale Fueled Power Generation

VCO-ampDLUJ1O

Power Plant Costs

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Cost

Power faciities 57500 91800 567800

Owners cost 10200 20400 192700

Total 67700 112200 760500

Annual Operating Cost 2205 3248 17157(excluding fuel cost)

bullBased on 8020 debtequity ratio oil shale fueled

Prefeasibility Study

Oil Shale Fueled Power Generation

V00O8c4LLMO9

i

INTEGRATED PROJECT -BUSBAR COST

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Costs Mine amp shale processingPower block Waste disposal Infrastructure

29359 67700

1664 10000

37031 112200

2381 15000

201891 760500

8714 45000

TOTAL 108753 166612 1016105

Annual Operating Cost Mine amp shale processingPower block Waste disposal Infrastructure (a)

5582 2205

316

11556 3248

710

56430(b) 18186(b) 6004

Subtotal 8103 15514 80620

Capital Charges 139 9410 15596 106000

Total 17513 31110 186620

25-year levelized cost - - 218000

Busbar Cost millskWh First year 128 92 71 25-year levelized 83

(a) Housing and community facilities assumed self-liquidating(b) Includes first-year inflation adjustment

Based on 8020 debtequity ratio

Prefeasibility StudyOil Shale Fueled Power Generaion

VOOOO-8MLtROi0

ECONOMIC ANALYSIS

n Jordan study options

Project size effect

Fuel requirement

Project financing effect

Alternative fuel price effect

Estimated electricity cost

Summary financial analysis results

Prefeasibility Study

Oil Shale Fueled Powr Generation

VOOeO-BOCLLO1 I

i

Jordan Study Options

U Project size

- Demonstration = 20 MW

- Prototype = 50 MW

- Commercial = 400 MW (4x100)

Project financing

- Debtequity 8020

- Debtequity 5050

Imported alternative fuels cost assumptions

A B Crude oil $17bbl $24bbl

$120onne $170tonne

Low sulfur coal $ 50tonne $ 70tonne See Chevron forecast supporting assumptions

Prefeasibility StudyOil Shale Fueled Power Generation

VOOOO-8DLIJRO12

i

Crude Oil Price Trends

60

Source World Energy Outlook Chevron Corporation Oclober 1987

40

High trend

No Ir 20 ~~~~Arabian Light Spot I A u

IILowYUII trend

0 1970 1975 1980 1985 1990 1995

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958246aJodar 118 3-14-89 rsO

2000

Project Size Effect Shale Fuel Option

Project Size

Integrated facilities installed capital cost$ US million

Shale cost $UStonne(8020 debtequity)

Cost of power millskWh(8020 debtequity ratio)

20 MW

109

143

128

50 MW

167

118

92

400 MW (4x1 00)

1016

68

71

Prefeasibility Study Oil Sampae Fueled Power Generation

VOO O-8I0LJRO13

gt1

1

Power Block Investment Cost

3000

$2875 Excluding mining and offsite 2800

2600

2400

2200

2000

$1836 1800

$1613 1600

$1420 1400 1I 1 I

0 100 200 300 400 MWe

August 1988

Preleasibility Study OilShale Fueled Power Generation

179581147aJodar1 18 3-14-89 rspcl

Fuel Requirement - 4x100 MW Project

Coal = 12 million tpy

n Oil = 503000 tpy

Oil shale = 78 million tpy

Preleasibility Study

Oil Shale Fueled Power Generation

IO060-OLLIRO14

Financing Effect -Project

Oil Shale Fuel Option

Mine and shale processing

Power block

Waste disposal

Community facilities

Total

Coal-Fired Power Plant

Oil-Fired Power Plant

400 MW

Capital Cost ($US MM)

DebtEquity

8020 5050

202 187

760 760

9 8

45 45

1016 1000

647 647

463 463

Prefeasibility StudyOil Shale Fueled Power Generation

VOe-BD1JRO15

Financing Effect shy400 MW Project

Operating Costs ($US millionyr)

DebtEquity

8020 5050

Coal $70tonne 282 282

Oil $24bbl 254 254

Oil shale-fueled 218 236

Including fuel

Prefeasibility Study

SOil Shale Fueled Power Generaion

VOOIt JLMO I

Alternate Fuel Price Effect shy4x100 MW Project

Financing Basis DebtEquity Ratio

Alternate Fuel Price

Imported coal $50tonne $70tonne

Imported oil $17bbl ($120tonne) $24bbl ($170tonne)

Cumulative 25-yr Net Benefit

Favoring Oil Shale (US $MM) shy

8020 5050

778 315 2531 2068

(18) (506)1810 1322

Prefeasibility Study

Oil Shale Fueled Power Generation

Voo -I DLU-A 2

i

Comparison of Cumulative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

32 Pay Out Year shy

400 MW PlantOil Shale vs Imported Coal (8020 debtequty)

30

28 -Cumulative fuel cost savings forcoal $70ton

Cumulative fuel cost savings for coaJ $50ton

26---------- Cumulative Incremental capital plus OampM costs

24

22 -

18 -0

W- Cumulative net benefit for shae vs coal $50ton 2B Cumulative net benefit for shale vs coal $70ton

co16C -

14 -

12 -

10 -

09

06 -Payout inyear 1

Payout Inyear 9 for coal $50ton - -- - - -shy

02 0 I

0 1 2 3 4 5 Nowl Yewr in which sauings in fWe colsacm-ewi tat hsawinitl

ca=al wosaand OampM costs

6

_iiM

7 8

9 10

------ - -amp -

11 12 13 14Year of Operation

--

15

- - --shy

16 17

I

18

1

19

I

20

I

21

I

22

I

23

I

24 25

Prefeasibility StudyOil Shale Fueled Power Generation

17958d351aJordanr 3-14-89 rsO

118

Comparison of Cumuiative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

28 Pay Out Year shy

400 MW Plant Oil Shale vs Imported Coal (5050 debtequity)

26shy2

24-

Cumulaive fuel nst savings for coal 0 $70ton Cumulative fuel cost savings for coal $50ton Cumulative Incremental capital plus OampM corts

22 -

20 -

18 -- Cumuladve net benefit for shle vs coal $50ton B Cumuarve net benefit for sale vs coal $70ton

16 -

C 14

12

10

08 -06 - Payout In year 1for coal $50ton

04

Payout Inyear 1

for coal $70ton02~

0 0

-No

02-

1 2

Yew inrY MCM cajlaI rl

3 4 5 6

sngm inW coas 0 ort hghWcentWin

0tOM cori

7

--

8

- -

9 10 11 12 13 14

Year of Operation

15 16 17

I

18

IIII

19 20 21 22 23 24 25

Preieasibility Study Oil Shale Fueled Power Generation

17958451 bJordarV118 3-14-89 rsipcI

Estimated Cost of Power- 400 MW (4 x 100)

FUEL

ImportedCoal

$50T

$70fT

1st Year

68 88

Levelized

78 107

Sultani Oil Shale

71 83

ImportedOil

$1713

$2413

56

67

76

96

0 10 20 30 40 50

I 60

I 70

I 80

I 90 100 110 120

Mills per kWh

Prefeasibility Study Oil Shale Fueled Power Generation

179581251 cJordarVl 18 3-14-89 rspc1

Summary Financial Analysis Results

Project size

Debt equity ratio

- Investment cost

- Power cost

- 25-year net benefit

- Project implementation

Alternative fuel price

Economic Comparison

Very significant

Not significant

Not significant

Very significant

Critical

Very significant

Prefeasibility Study

Oil Shale Fueled Power Generation

VY0 tDLUAi3

i

Study Conclusions

Feasibility

Timeliness

Expansion conditions

Environmental impacts

Development advantages

Prefeasibility Study

Oil Shale Fueled Power Generation VW41-1AiUA

4

Feasibility

Oil shale fueled power generation is technically and economically justifiedunder certain conditions

N Need for additional generating capacity

exists

- 6 annual peak demand growth - Orderly retirement of olderhigh cost

generating capacity needed

U Higher costs are expected for imported fuels

- 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

-OP b i j~~4shy

-4protntiYPe 4 demo plnt orP42 t~Plant orPootypeProje(-7hould

that Rj

demo 4Therefore-44 JEA anxinus

the

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

27Pag 4- 1 2S c i n 4 4

4i2Sectjo4-18-4 Secio 4-4 014

lt th~ae hi4h -tasisso syste thrug27 ~ 04lag arstl~art-p tasforme ed 2p27132Kvdieanwhy notthroug

EAto- is protmm~~ thegnJgt~~ pracie an ect ~ platqrby

28Pg 4 s heonnenotedto~the 32K rc powr

It not8 Scection rie049teoervnrain prctc de1

rh u n trae f2V3K anerd not throughgeterAntor

27 P3e-1r p ant weung-a

-If I

2tEll10 DRWE-jOi ASOt Mint~~al d~c~e o hepwrgnrto

ELCTRInYJORD UTHORITY-

Ate~

21Pge41 ection 4 04- 5

sindicated~ t hthigh the unit outputredu f hecondenser Injengtd~ibbvePressureed incg desrin hi h riseb vmbi nt emperatureWe bel~ieve

PleaIse provide us with th rscrapcity for th-e three options n nt generating~

21-Iisidca ted that~ thediaatgeofCBi theSheavy fn oe consumnptionPlease~ providethe us withpecntgA

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

400 MW COAL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO 5050

NET GENERATION - MWe 40000 CAPACITY FACTOR - 75 ANNUAL GENERATION MKWhYR 2628 SUB TOTAL PLANT COSTS (TPC) $1000 $620000

FIXED 0 amp M COSTS MH $ MH FIRST YEAR COST$1O00

------- --------- --- ---- --- --- ------------

OPERATING LABOR 351936 $3 $1100 MAINTENANCE LABOR 4000 of 150 OF TPC 3720

MAINTENANCE MATERIAL 6000

ADMIN LABOR of 150

3000 OF TPC

OF 0 amp M LABOR 5580 1446

SUB TOTAL FIXED OampM COSTS $11846

VARIABLE 0 amp M COSTS QUANTITY UNIT COST

VARIABLE MAINTENANCE 2628 MKWh 10 MILLKWH $ 2628 PROCESS WATER 13500000 GALLON 02 SGAL $ 2700 GENERAL PLANT CHEMICALS ALLOW 50 FUEL OIL 1000000 GALLON 035 $GAL $ 350 WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290SPECIAL BOILER MAINT ALLOW 0

SUB TOTAL VARIABLE OampM COSTS $ 8018

TOTAL FIXED amp VARIABLE OampM COSTS $19864 TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $8227 $TN $99139

(INCL INFLATION ADJUSTMENT)

B DEBT EQUITY RATIO =========== 8020

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $17574

WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290

TOTAL FIXED amp VARIABLE OampM COSTS $19864TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $5877 $TN $70814

(INCL INFLATION ADJUSTMENT)

6-21

Table 612 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY

400 MW OIL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO

NET GENERATION -

CAPACITY FACTOR -

ANNUAL GENERATION SUB TOTAL PLANT COSTS (TPC)

FIXED 0 amp M COSTS

OPERATING LABOR MAINTENANCE LABOR 4000 of

MAINTENANCE MATERIAL 6000 of

ADMIN LABOR

SUB TOTAL FIXED OampM COSTS

VARIABLE 0 amp M COSTS

VARIABLE MAINTENANCE PROCESS WATER GENERAL PLANT CHEMICALS FUEL OIL WASTE DISPOSAL (Section 6027) SPECIAL BOILER MAINT

SUB TOTAL VARIABLE OampM COSTS

5050

MWe

MKWhYR $1000

MH

262080

150

150 3000

QUANTITY

2628 MKWh 13500000 GALLON

1000000 GALLON 0 TNYR

TOTAL FIXED amp VARIABLE OampM COSTS FUEL OIL 503000 TNYR

B DEBT EQUITY RATIO =8020

40000 75

268 $443000

FIRST YEAR $ MH COST$1O00

$3 $ 800

OF TPC 2658

OF TPC 3987 OF 0 amp M LABOR 1037

$ 8482

UNIT COST

05 MILLKWH $ 1314 02 $GAL $ 2700

ALLOW 50 035 $GAL $ 350

$1000 $TN $ 0 ALLOW 0

$ 4414

$12896 $19981 $TN $100502

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $12896

WASTE DISPOSAL (Section 6027) 0 TNYR $1000 $TN $ 0

TOTAL FIXED amp VARIABLE OampM COSTS $12896 FUEL OIL 503000 TNYR $14104 $TN $70943

6-23

Page 18: fo; - pdf.usaid.gov

TITLE

Ternpe -al-CuA vs 6 Ik

00

I00

7SA-A-

Fly Ai h

0

85 e

80-

0

00

i I 800 860 oo

T-er pe -

DATE OWN APPD DCNO- ------ -

_______f - _ IPG_

Pilot Plant Test Conclusions

It is technically feasible to burn the Sultani oil shale furnished by NRA in a Pyropower boiler

A high combustion efficiency in excess of 985 was demonstrated

SO2NOxCO emissions are all acceptably low with no limestone addition required

Prefeasibility StudyO Shale Fueled Power Generation

Conceptual Design Studies Scope

m Three project sizes

- 20 MW

- 50 MW

- 400 MW (4x100) factored for power plant portion

m Open-pit mine

- Shale processing at the surface - Waste disposal system

Power block

- Boiler

- Steam turbine

- Auxiliaries

Prefeasibility Study Oil Shale Fueled Power Generation

VOn 4FAIR 1

i

Project Layout 9 fc =f4j

deg2

o r -w (031

5_7EC 45U

iPefeaibiity tud

OlSeFuedP erGr in

179581113i~o(atyvv11

n1- 14 4pc

C)

Sultani Oil Shale Reserves

North South Area Area Total

Mineable shale tonne x 106 320 658 978

Fischer assay oil content wt 744 761 765

Overburden m3 x 106 384 627 1011

Stripping ratio m3m3 2161 1711 1861

bull Based on NRA core drilling and core analysis

Prefeasibility Study Oil Shale Fueled Power Generation

VWO41OFEAMI14

i

Sultani Oil Shale Analyses

Moisture

Ash (less CO 2 in CaCO 3 )

CO 2 (in CaCO 3 )

Carbon (organic)

Hydrogen

Nitrogen

Sulfur

Oxygen (by diff)

Total

High heating value BtuIb

Fischer assay oil content

bull Percent by weight

Design Basis Fuel

320

6680

1387

1132

113

048

255

065

10000

2250

840

Low High Calorific Calorific

Value Fuel Value Fuel

320 320

6730 6625

1414 1337

1020 1250

102 125

058 038

238 271

118 034

10000 10000

2000 2500

750 925

Preteasibility Study Oil Shale Fueled Power Generation

vo0N d-GEAR 1S

50 MW Oil Shale ProcessingPrototype Plant

Mlne Plant

_ 14 0 Haul0___) to Plant 1 Sorage

Portable Crusher

(-)100 mm Storage

(-) 100 mm Hopper UIU 400 th

Feed Bin

J 50

250 tvb

8 -m Circulating Load Impact3or0 0 30 0 0shy+8mm25

30 0L Sampler 0 1 30 0

p3 Day Storage

To Power Plant

Preleasibility StudyOil Shale Fueled Power Generation

17958101 SaJordanli 18 3-14-89 rsipc1

20 MW Oil Shale Demonstration Plant

Mine Plant

Haul00- 01 o

= Pb n Storage Portable _

110 mm Stora e 0

()100 mm r Hopper

U 400V

Feed Bin

CirculatingLoad3 Day Stoge

Prefea~ltSudy Shale Fueled Power Generation

179S 111p 1 11Joda3 yl 3-202-89 8vk2

I

Mine and Shale ProcessingDesign - 2050 MW Project

I Overburden removal (north pit area) 10-meter benches

- Drill and blast

- 10 m3 front-end loader

- 77-ton truck haulage

I Oil shale mining 10-meter benches

- Rippe and auger scraper

- Front-end loader

- Portable in-pit crusher

- 77-ton truck haulage

Oil shale processing

- Feed = minus 100 mm

- Product = minus 8 mm

- Capacity = 250 tph

- Reversible impactor

- Two vibrating screens

1 Prefeasibility Study Oil Shale Fueled Power Generation

V -M 1AMI1ARt46

400 MW Full-Scale Oil Shale ProcessingPlant

Feed MTnus 200 mm Samplerr

1000 bull 10000 Tonnes Live Storage Grade

200 m long(-) 200 mm -- =-- Plow Feeders

00 h 100000 Tonnes Live Storage

Stream 3 - Sampler Bin Stream 2

Stream th 31Da2000

Circulating Load 2i

NFw Feed r -17000t1 170001l 170 t 17000 t 17000 t

1000 th Silo with 7 Impactor (-1)8 mm Reapro- 3 Day Storage at Aver age Loadn

0 20 Feeders 20 m Diameter by 40 m High

JJJTHT To Power Plant

Prefeasibility Study Oil Shale Fueled Power Generation

179589 6aJordarV 1I8 3-14-89 rsipc1

Mine and Shale ProcessingDesign - 4x100 MW Project

m Overburden removal (north area) 10-meter benches

- Drill and blast

- Three 20 m3 shovels

- 136-ton truck haulage

m Oil shale mining 10-meter benches

- Two mechanical surface miners

- 136-ton trucks to pit hopper

- Belt conveyor = 2000 tph

- Traveling stacker

m Oil shale processing

- Feed = minus 200 mm

- Product = minus 8 mm

- Capacity = three 1000 tph units

Prefeasibility Study Oil Shale Fueled Power Generation

VOO79-ampGEAIAt 17

i

Steady-State Production Schedule

Overburden removal bench m3

20 MW demo project 5n MW prototype 4x100 MW full-scale plant

Oil shale mining and shale processing tonnes

20 MW project 50 MW project 4x100 MW project

HourlyDesign Capacity

282 234

1850

HourlyDesign Capacity

250 250

2000

Avg Daily Annual PEQuctiQa Production

1690 507000 4217 13 million

33333 10 million

Max Daily(a) Annual(b) Production Production

1733 390000 4324 973000

34578 78 million

(a) Based on 100 operating factor for power block

(b) Based on 75 operating factor for power block ( 20 MW project = 300 shiftsyr 50 MW project = 900 shiftsyr 400 MW project = 900 shiftsyr)

Prefeasibility Study Oil Shale Fueled Power Generation

Conceptual Power Plant Plans

m Pyroflow boiler

Power generating facilities

m Auxiliaries

S Preleasibility Study Oil ShaJe Fueled Power Generation

vo0o7dEAO 19

Pyroflow Boiler SteamConciflons

Flow rate 226700 kghr (500000 Ibhr)

Pressure 1099 kgcm2 abs (15635 psia)

Temperature 51280C (9550F)

Same for 20 50 and 100 MW designs

Prefeasibility Study Oil ShaJe Fueled Power Generation

vooGALMI 20

HtomCOPUIOTP

- 50005 5op

-- LEVAThUM ORPORAION

0

-VI

DZ 4

Power Block

Fuel handling system

- Day binsscrew feeders

Boiler

- Pyroflow circulating fluid bed combustor

Power generation

- Non reheat condensing steam turbine

- Conventional Rankin steam cycle

Ash handling system (btm ash irom combustor and flyash from bag house)

- Wetted in pug mill to add 20plusmn wt wpter

Plant service water

- Air-cooled condensors and small cooling tower from circulating trim water coolers

Plant raw water

- To cooling tower makeup

- To drinking water system

- To pump seals etc

Plant treated makeup water

- Demineralizer train

Preteasibility Study Oil Shale Fueled Power Generation

i

Onsite Infrastructure

Project office

Control house

U Maintenance shops warehouse

Laboratory

Employee service facility

Site developmentoperations service facilities

- Fire controlsecurity

- Communications

- Lighting

- Roads drainage and sewage

Prefeasibility StudyQ1I Shale Fueled Power Generation

voo4JG m 0 JV

i

BechtellPyropower50 MW Cogeneration Plant - Mt Poso California

W4t Prefeasibility Study --- 7 Oil Shale Fueled Power Generation

179586122aJordarv 118 3-14-89 rsO

Characteristics of Three Size Operations

Oil shale fuel tpy

Mine development excavation bank m3

Spent ash disposal tpy (wetted)

Water consumption 1000 m3yr

Staffing required

Community population

400 MW

20 MW 50 MW (4x1 00)

390000 973000 78 million

500000 1 million 85 million

327000 815000 61 million

538 907 1263

185 324 1046

700 1200 4000

Prefeasibility Study Oil Shale Fueled Power Generation

V000ofllAM1 23

Conceptual Designs Summary

N All BOP facilities involve conventional equipment and technology

100 MW unit operation involves boiler scale-up considerations

N Water consumption estimates

- Requirement for 4x100 MW project is 13 million m3 yr

- Water allocation of 2 million m3yr of water supports 6x100 MW

N Water availability probably limits total power generation from oil shale in Jordan

Prefeasibility Study Oil Shale Fueled Power Generation

V007041GEAOLMI

i

TECHNOLOGY RISK ASSESSMENT

Basic concepts

Key boiler scale-up design issues

Impact of scale-up

U Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Prefeasibility Study O1 Shale Fueled Power Generation

VOOh-7AEAAO 2

Basic Concepts

U CFBC is relatively new in the powerindustry

- Existing plants are small typically 20 to 50 MW

- There is limited operating experience with high-ash fuels

- Existing designs for lignite biomass and coal wastes show good plant performance

I Application of CFBC boiler design to oil shale fuel has defined risk that relates to scale-up of existing design

Similar CFBC technology is used in petroleum refining industry

- FCC cracking plant regenerators burn carbon residue off spent catalyst

- 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

FUEL ANALYSES

High Ash Fuel Projects Total Solids Input Basis

Gilberton Cambria North Branch

Carbon 4653 2749 1822 Hydrogen 153 164 160 Sulfur 073 222 234 Nitrogen 085 051 043 Oxygen 282 218 468 Moisture 1451 514 557 Ash 3303 6 0 6Z16

10000 10000 10000

HHVBtulb 7485 4809 3453

includes limestone feed a3 ash

includes CO2 in Ca~o3

CA89029 CAkw

Oil Shale

1132

113

255

048

065

320

-8062

10000

2250

Key Boiler Scale-Up DesignIssues

m Solids handling

- Feeding shale to combustor

- 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

Voo4tGEAMI 30

i

Mine and Shale Processing

U Fugitive dust emissions are controllable

- Wetting mine roads

- Enclose crushing plant equipment

Noise levels are controllable

- Enclose crushing plant equipment - Muffle truck exhausts

- Engineered waste disposal

Water effluents can be controlled

- Need good mine drainage design - Continue leachability studies on

waste dump piles

Prefeasibilily StudyOil Shale Fueled Po r Generaton

V0079OOG-4O 31

1

Power Plant

II Fugitive dust emissions are controllable

- Baghouse designoperation will minimize particulates in flue gas

- Wetting spent ash before disposal

N Gaseous emissions are controllable

- Pilot test results show acceptable SO2NOxCO in flue gas

- Develop baseline data for Sultani area

Develop air dispersion model for Sultani

Prefeasibility StudyOil Shale Fueled Power Generatio

V00 V-4GEA l32

i

Power Plant (Contd)

Noise levels are controllable

- Enclose boiler plant fans as required - Enclose turbines and pumps as

required

Water effluents are controllable

- Continue leachability studies on spent ash disposal

- Develop aquifer dispersion model

- Develop sewage and garbage disposal plan

Prefeasibility SludyOil Shale Fueled Power Generation

V00-4FAAI 33

Conclusions

No environmental constraints are anticipated on oil shale powerdevelopment

Gas effluents will meet World Bank standards

- Ash disposal is manageable

- The potential for groundwatercontamination appears low

- Water effluents will be minimal

Continued studies to develop air and groundwater baseline data are recommended

S Prefeasibility Study Oil Shale Fueled Power Generation

v0 9ampGLAMR 34

Power Demand vs SupplyAssessment

m Demand growth forecasts

Electrical generating capacity

= Power supply forecasts

= Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Preleasibility Study Oil Shaie Fuelod Power Generation

VO9- uLIROI

1

Power Demand Forecasts

Percent Annual Growth

JEA

Meta systems HaglerBailey and Bechtel National Inc

JEA Peak Demand Growth

1980 (actual) 1985 (actual) 1987 (actual) 1995 (forecast) 2005 (forecast)

1986 1990 to to

1990 2000

97 60

49 39

200 MW 475 MW 593 MW 900 MW

1400 MW

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOO-DLURO2

i

JEA ElectricityGeneratingCapacity

1987 Installed

Capacity (MW) Aqaba 260

22

Zarqa 395

Marka 102

Karak 23

Miscellaneous 67

Subtotal JEA capacity 869

Other capacity - industrial 110

Total 979

Prefeasibility Study Oi1 Shale Fueled Power Generation

V000-6O0LFJRO3 (

Forecast New Power Generating Capacity Required

Fcst 1987 Required

New Peak Available Installed

Demand Capacity Shortfall (a) Capacity (b) (MM (MW) (MW) (MW)

Assumed capacityfactor (65) (75)

1995 requirement 900 636 264 352

2005 requirement 1400 636 764 1019

(a) Excludes proposed additions and retirements (b) Excludes possible power exports or imports

Load shedding or levelizing not considered

Preteasibility Study Oil Shale Fueled Power Generation

Vflcmf-R)LLAO4

i

Supply vs Demand Evaluation

1800

1600

1400 Forecast Peak Demands

1200 -

E Installed Capacity

0 800shy75--

U) Assumed Available Calcit

a 6 Ao600 shy0 o 65

400 shy

200

I I I I I I I I I I I I I I I I I I I I I I I 1 1 1980 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958f738aIJordarV 118 3-14-89 rspCO

Conclusions

Additional power generating capacity is needed to meet forecasted 19952005demand growth

A 400 MW oil shale-to-power project at Sultani can meet a portion of this need

U A second 400 MW oil shale project maybe required if water is available

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOW0O-8LURO5

i

Economic Feasibility

N Order-of-magnitude costs

N Economic analysis

- Jordan study options

- Project size effect

m Comparison with alternative fuels

- Fuel requirement

- Project financing effect

- Alternate fuel price effect

- Estimated cost of electricity

N Summary financial analysis

bull Material was developed by Bechtel Power Company

Prefeasibility Study

go Oil Shale Fueled Power Generation VOOSO-ampDtJROh

ORDER-OF-MAGNITUDE COSTS

U Oil shale fuel

Power plant

I Integrated project- busbar

Preteasibility Study

Oil Shale Fueled Power Generation

VOO9O-ampDLUROS

Oil Shale Fuel Costs

Installed Capital Cost

Mine Development

Mine Equipment

Processing Plant

Spare Parts

Working Capital

Capitalized Interest

Total

Annual Operating Cost

Fuel Cost $UStonne

bull Based on 8020 debtequity ratio

20 MW

4900

11090

6945

1200

1200

4054

29389

5582

1431

US $1000 Factored

50 MW 4x100 MW

7833 30915

12202 66012

8388 50889

1300 5000

2200 10000

5108 39075

37031 201891

11556 53236

1188 684

Prefeasibility Study

Oil Shale Fueled Power Generation

VCO-ampDLUJ1O

Power Plant Costs

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Cost

Power faciities 57500 91800 567800

Owners cost 10200 20400 192700

Total 67700 112200 760500

Annual Operating Cost 2205 3248 17157(excluding fuel cost)

bullBased on 8020 debtequity ratio oil shale fueled

Prefeasibility Study

Oil Shale Fueled Power Generation

V00O8c4LLMO9

i

INTEGRATED PROJECT -BUSBAR COST

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Costs Mine amp shale processingPower block Waste disposal Infrastructure

29359 67700

1664 10000

37031 112200

2381 15000

201891 760500

8714 45000

TOTAL 108753 166612 1016105

Annual Operating Cost Mine amp shale processingPower block Waste disposal Infrastructure (a)

5582 2205

316

11556 3248

710

56430(b) 18186(b) 6004

Subtotal 8103 15514 80620

Capital Charges 139 9410 15596 106000

Total 17513 31110 186620

25-year levelized cost - - 218000

Busbar Cost millskWh First year 128 92 71 25-year levelized 83

(a) Housing and community facilities assumed self-liquidating(b) Includes first-year inflation adjustment

Based on 8020 debtequity ratio

Prefeasibility StudyOil Shale Fueled Power Generaion

VOOOO-8MLtROi0

ECONOMIC ANALYSIS

n Jordan study options

Project size effect

Fuel requirement

Project financing effect

Alternative fuel price effect

Estimated electricity cost

Summary financial analysis results

Prefeasibility Study

Oil Shale Fueled Powr Generation

VOOeO-BOCLLO1 I

i

Jordan Study Options

U Project size

- Demonstration = 20 MW

- Prototype = 50 MW

- Commercial = 400 MW (4x100)

Project financing

- Debtequity 8020

- Debtequity 5050

Imported alternative fuels cost assumptions

A B Crude oil $17bbl $24bbl

$120onne $170tonne

Low sulfur coal $ 50tonne $ 70tonne See Chevron forecast supporting assumptions

Prefeasibility StudyOil Shale Fueled Power Generation

VOOOO-8DLIJRO12

i

Crude Oil Price Trends

60

Source World Energy Outlook Chevron Corporation Oclober 1987

40

High trend

No Ir 20 ~~~~Arabian Light Spot I A u

IILowYUII trend

0 1970 1975 1980 1985 1990 1995

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958246aJodar 118 3-14-89 rsO

2000

Project Size Effect Shale Fuel Option

Project Size

Integrated facilities installed capital cost$ US million

Shale cost $UStonne(8020 debtequity)

Cost of power millskWh(8020 debtequity ratio)

20 MW

109

143

128

50 MW

167

118

92

400 MW (4x1 00)

1016

68

71

Prefeasibility Study Oil Sampae Fueled Power Generation

VOO O-8I0LJRO13

gt1

1

Power Block Investment Cost

3000

$2875 Excluding mining and offsite 2800

2600

2400

2200

2000

$1836 1800

$1613 1600

$1420 1400 1I 1 I

0 100 200 300 400 MWe

August 1988

Preleasibility Study OilShale Fueled Power Generation

179581147aJodar1 18 3-14-89 rspcl

Fuel Requirement - 4x100 MW Project

Coal = 12 million tpy

n Oil = 503000 tpy

Oil shale = 78 million tpy

Preleasibility Study

Oil Shale Fueled Power Generation

IO060-OLLIRO14

Financing Effect -Project

Oil Shale Fuel Option

Mine and shale processing

Power block

Waste disposal

Community facilities

Total

Coal-Fired Power Plant

Oil-Fired Power Plant

400 MW

Capital Cost ($US MM)

DebtEquity

8020 5050

202 187

760 760

9 8

45 45

1016 1000

647 647

463 463

Prefeasibility StudyOil Shale Fueled Power Generation

VOe-BD1JRO15

Financing Effect shy400 MW Project

Operating Costs ($US millionyr)

DebtEquity

8020 5050

Coal $70tonne 282 282

Oil $24bbl 254 254

Oil shale-fueled 218 236

Including fuel

Prefeasibility Study

SOil Shale Fueled Power Generaion

VOOIt JLMO I

Alternate Fuel Price Effect shy4x100 MW Project

Financing Basis DebtEquity Ratio

Alternate Fuel Price

Imported coal $50tonne $70tonne

Imported oil $17bbl ($120tonne) $24bbl ($170tonne)

Cumulative 25-yr Net Benefit

Favoring Oil Shale (US $MM) shy

8020 5050

778 315 2531 2068

(18) (506)1810 1322

Prefeasibility Study

Oil Shale Fueled Power Generation

Voo -I DLU-A 2

i

Comparison of Cumulative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

32 Pay Out Year shy

400 MW PlantOil Shale vs Imported Coal (8020 debtequty)

30

28 -Cumulative fuel cost savings forcoal $70ton

Cumulative fuel cost savings for coaJ $50ton

26---------- Cumulative Incremental capital plus OampM costs

24

22 -

18 -0

W- Cumulative net benefit for shae vs coal $50ton 2B Cumulative net benefit for shale vs coal $70ton

co16C -

14 -

12 -

10 -

09

06 -Payout inyear 1

Payout Inyear 9 for coal $50ton - -- - - -shy

02 0 I

0 1 2 3 4 5 Nowl Yewr in which sauings in fWe colsacm-ewi tat hsawinitl

ca=al wosaand OampM costs

6

_iiM

7 8

9 10

------ - -amp -

11 12 13 14Year of Operation

--

15

- - --shy

16 17

I

18

1

19

I

20

I

21

I

22

I

23

I

24 25

Prefeasibility StudyOil Shale Fueled Power Generation

17958d351aJordanr 3-14-89 rsO

118

Comparison of Cumuiative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

28 Pay Out Year shy

400 MW Plant Oil Shale vs Imported Coal (5050 debtequity)

26shy2

24-

Cumulaive fuel nst savings for coal 0 $70ton Cumulative fuel cost savings for coal $50ton Cumulative Incremental capital plus OampM corts

22 -

20 -

18 -- Cumuladve net benefit for shle vs coal $50ton B Cumuarve net benefit for sale vs coal $70ton

16 -

C 14

12

10

08 -06 - Payout In year 1for coal $50ton

04

Payout Inyear 1

for coal $70ton02~

0 0

-No

02-

1 2

Yew inrY MCM cajlaI rl

3 4 5 6

sngm inW coas 0 ort hghWcentWin

0tOM cori

7

--

8

- -

9 10 11 12 13 14

Year of Operation

15 16 17

I

18

IIII

19 20 21 22 23 24 25

Preieasibility Study Oil Shale Fueled Power Generation

17958451 bJordarV118 3-14-89 rsipcI

Estimated Cost of Power- 400 MW (4 x 100)

FUEL

ImportedCoal

$50T

$70fT

1st Year

68 88

Levelized

78 107

Sultani Oil Shale

71 83

ImportedOil

$1713

$2413

56

67

76

96

0 10 20 30 40 50

I 60

I 70

I 80

I 90 100 110 120

Mills per kWh

Prefeasibility Study Oil Shale Fueled Power Generation

179581251 cJordarVl 18 3-14-89 rspc1

Summary Financial Analysis Results

Project size

Debt equity ratio

- Investment cost

- Power cost

- 25-year net benefit

- Project implementation

Alternative fuel price

Economic Comparison

Very significant

Not significant

Not significant

Very significant

Critical

Very significant

Prefeasibility Study

Oil Shale Fueled Power Generation

VY0 tDLUAi3

i

Study Conclusions

Feasibility

Timeliness

Expansion conditions

Environmental impacts

Development advantages

Prefeasibility Study

Oil Shale Fueled Power Generation VW41-1AiUA

4

Feasibility

Oil shale fueled power generation is technically and economically justifiedunder certain conditions

N Need for additional generating capacity

exists

- 6 annual peak demand growth - Orderly retirement of olderhigh cost

generating capacity needed

U Higher costs are expected for imported fuels

- 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

-OP b i j~~4shy

-4protntiYPe 4 demo plnt orP42 t~Plant orPootypeProje(-7hould

that Rj

demo 4Therefore-44 JEA anxinus

the

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

27Pag 4- 1 2S c i n 4 4

4i2Sectjo4-18-4 Secio 4-4 014

lt th~ae hi4h -tasisso syste thrug27 ~ 04lag arstl~art-p tasforme ed 2p27132Kvdieanwhy notthroug

EAto- is protmm~~ thegnJgt~~ pracie an ect ~ platqrby

28Pg 4 s heonnenotedto~the 32K rc powr

It not8 Scection rie049teoervnrain prctc de1

rh u n trae f2V3K anerd not throughgeterAntor

27 P3e-1r p ant weung-a

-If I

2tEll10 DRWE-jOi ASOt Mint~~al d~c~e o hepwrgnrto

ELCTRInYJORD UTHORITY-

Ate~

21Pge41 ection 4 04- 5

sindicated~ t hthigh the unit outputredu f hecondenser Injengtd~ibbvePressureed incg desrin hi h riseb vmbi nt emperatureWe bel~ieve

PleaIse provide us with th rscrapcity for th-e three options n nt generating~

21-Iisidca ted that~ thediaatgeofCBi theSheavy fn oe consumnptionPlease~ providethe us withpecntgA

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

400 MW COAL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO 5050

NET GENERATION - MWe 40000 CAPACITY FACTOR - 75 ANNUAL GENERATION MKWhYR 2628 SUB TOTAL PLANT COSTS (TPC) $1000 $620000

FIXED 0 amp M COSTS MH $ MH FIRST YEAR COST$1O00

------- --------- --- ---- --- --- ------------

OPERATING LABOR 351936 $3 $1100 MAINTENANCE LABOR 4000 of 150 OF TPC 3720

MAINTENANCE MATERIAL 6000

ADMIN LABOR of 150

3000 OF TPC

OF 0 amp M LABOR 5580 1446

SUB TOTAL FIXED OampM COSTS $11846

VARIABLE 0 amp M COSTS QUANTITY UNIT COST

VARIABLE MAINTENANCE 2628 MKWh 10 MILLKWH $ 2628 PROCESS WATER 13500000 GALLON 02 SGAL $ 2700 GENERAL PLANT CHEMICALS ALLOW 50 FUEL OIL 1000000 GALLON 035 $GAL $ 350 WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290SPECIAL BOILER MAINT ALLOW 0

SUB TOTAL VARIABLE OampM COSTS $ 8018

TOTAL FIXED amp VARIABLE OampM COSTS $19864 TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $8227 $TN $99139

(INCL INFLATION ADJUSTMENT)

B DEBT EQUITY RATIO =========== 8020

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $17574

WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290

TOTAL FIXED amp VARIABLE OampM COSTS $19864TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $5877 $TN $70814

(INCL INFLATION ADJUSTMENT)

6-21

Table 612 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY

400 MW OIL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO

NET GENERATION -

CAPACITY FACTOR -

ANNUAL GENERATION SUB TOTAL PLANT COSTS (TPC)

FIXED 0 amp M COSTS

OPERATING LABOR MAINTENANCE LABOR 4000 of

MAINTENANCE MATERIAL 6000 of

ADMIN LABOR

SUB TOTAL FIXED OampM COSTS

VARIABLE 0 amp M COSTS

VARIABLE MAINTENANCE PROCESS WATER GENERAL PLANT CHEMICALS FUEL OIL WASTE DISPOSAL (Section 6027) SPECIAL BOILER MAINT

SUB TOTAL VARIABLE OampM COSTS

5050

MWe

MKWhYR $1000

MH

262080

150

150 3000

QUANTITY

2628 MKWh 13500000 GALLON

1000000 GALLON 0 TNYR

TOTAL FIXED amp VARIABLE OampM COSTS FUEL OIL 503000 TNYR

B DEBT EQUITY RATIO =8020

40000 75

268 $443000

FIRST YEAR $ MH COST$1O00

$3 $ 800

OF TPC 2658

OF TPC 3987 OF 0 amp M LABOR 1037

$ 8482

UNIT COST

05 MILLKWH $ 1314 02 $GAL $ 2700

ALLOW 50 035 $GAL $ 350

$1000 $TN $ 0 ALLOW 0

$ 4414

$12896 $19981 $TN $100502

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $12896

WASTE DISPOSAL (Section 6027) 0 TNYR $1000 $TN $ 0

TOTAL FIXED amp VARIABLE OampM COSTS $12896 FUEL OIL 503000 TNYR $14104 $TN $70943

6-23

Page 19: fo; - pdf.usaid.gov

Pilot Plant Test Conclusions

It is technically feasible to burn the Sultani oil shale furnished by NRA in a Pyropower boiler

A high combustion efficiency in excess of 985 was demonstrated

SO2NOxCO emissions are all acceptably low with no limestone addition required

Prefeasibility StudyO Shale Fueled Power Generation

Conceptual Design Studies Scope

m Three project sizes

- 20 MW

- 50 MW

- 400 MW (4x100) factored for power plant portion

m Open-pit mine

- Shale processing at the surface - Waste disposal system

Power block

- Boiler

- Steam turbine

- Auxiliaries

Prefeasibility Study Oil Shale Fueled Power Generation

VOn 4FAIR 1

i

Project Layout 9 fc =f4j

deg2

o r -w (031

5_7EC 45U

iPefeaibiity tud

OlSeFuedP erGr in

179581113i~o(atyvv11

n1- 14 4pc

C)

Sultani Oil Shale Reserves

North South Area Area Total

Mineable shale tonne x 106 320 658 978

Fischer assay oil content wt 744 761 765

Overburden m3 x 106 384 627 1011

Stripping ratio m3m3 2161 1711 1861

bull Based on NRA core drilling and core analysis

Prefeasibility Study Oil Shale Fueled Power Generation

VWO41OFEAMI14

i

Sultani Oil Shale Analyses

Moisture

Ash (less CO 2 in CaCO 3 )

CO 2 (in CaCO 3 )

Carbon (organic)

Hydrogen

Nitrogen

Sulfur

Oxygen (by diff)

Total

High heating value BtuIb

Fischer assay oil content

bull Percent by weight

Design Basis Fuel

320

6680

1387

1132

113

048

255

065

10000

2250

840

Low High Calorific Calorific

Value Fuel Value Fuel

320 320

6730 6625

1414 1337

1020 1250

102 125

058 038

238 271

118 034

10000 10000

2000 2500

750 925

Preteasibility Study Oil Shale Fueled Power Generation

vo0N d-GEAR 1S

50 MW Oil Shale ProcessingPrototype Plant

Mlne Plant

_ 14 0 Haul0___) to Plant 1 Sorage

Portable Crusher

(-)100 mm Storage

(-) 100 mm Hopper UIU 400 th

Feed Bin

J 50

250 tvb

8 -m Circulating Load Impact3or0 0 30 0 0shy+8mm25

30 0L Sampler 0 1 30 0

p3 Day Storage

To Power Plant

Preleasibility StudyOil Shale Fueled Power Generation

17958101 SaJordanli 18 3-14-89 rsipc1

20 MW Oil Shale Demonstration Plant

Mine Plant

Haul00- 01 o

= Pb n Storage Portable _

110 mm Stora e 0

()100 mm r Hopper

U 400V

Feed Bin

CirculatingLoad3 Day Stoge

Prefea~ltSudy Shale Fueled Power Generation

179S 111p 1 11Joda3 yl 3-202-89 8vk2

I

Mine and Shale ProcessingDesign - 2050 MW Project

I Overburden removal (north pit area) 10-meter benches

- Drill and blast

- 10 m3 front-end loader

- 77-ton truck haulage

I Oil shale mining 10-meter benches

- Rippe and auger scraper

- Front-end loader

- Portable in-pit crusher

- 77-ton truck haulage

Oil shale processing

- Feed = minus 100 mm

- Product = minus 8 mm

- Capacity = 250 tph

- Reversible impactor

- Two vibrating screens

1 Prefeasibility Study Oil Shale Fueled Power Generation

V -M 1AMI1ARt46

400 MW Full-Scale Oil Shale ProcessingPlant

Feed MTnus 200 mm Samplerr

1000 bull 10000 Tonnes Live Storage Grade

200 m long(-) 200 mm -- =-- Plow Feeders

00 h 100000 Tonnes Live Storage

Stream 3 - Sampler Bin Stream 2

Stream th 31Da2000

Circulating Load 2i

NFw Feed r -17000t1 170001l 170 t 17000 t 17000 t

1000 th Silo with 7 Impactor (-1)8 mm Reapro- 3 Day Storage at Aver age Loadn

0 20 Feeders 20 m Diameter by 40 m High

JJJTHT To Power Plant

Prefeasibility Study Oil Shale Fueled Power Generation

179589 6aJordarV 1I8 3-14-89 rsipc1

Mine and Shale ProcessingDesign - 4x100 MW Project

m Overburden removal (north area) 10-meter benches

- Drill and blast

- Three 20 m3 shovels

- 136-ton truck haulage

m Oil shale mining 10-meter benches

- Two mechanical surface miners

- 136-ton trucks to pit hopper

- Belt conveyor = 2000 tph

- Traveling stacker

m Oil shale processing

- Feed = minus 200 mm

- Product = minus 8 mm

- Capacity = three 1000 tph units

Prefeasibility Study Oil Shale Fueled Power Generation

VOO79-ampGEAIAt 17

i

Steady-State Production Schedule

Overburden removal bench m3

20 MW demo project 5n MW prototype 4x100 MW full-scale plant

Oil shale mining and shale processing tonnes

20 MW project 50 MW project 4x100 MW project

HourlyDesign Capacity

282 234

1850

HourlyDesign Capacity

250 250

2000

Avg Daily Annual PEQuctiQa Production

1690 507000 4217 13 million

33333 10 million

Max Daily(a) Annual(b) Production Production

1733 390000 4324 973000

34578 78 million

(a) Based on 100 operating factor for power block

(b) Based on 75 operating factor for power block ( 20 MW project = 300 shiftsyr 50 MW project = 900 shiftsyr 400 MW project = 900 shiftsyr)

Prefeasibility Study Oil Shale Fueled Power Generation

Conceptual Power Plant Plans

m Pyroflow boiler

Power generating facilities

m Auxiliaries

S Preleasibility Study Oil ShaJe Fueled Power Generation

vo0o7dEAO 19

Pyroflow Boiler SteamConciflons

Flow rate 226700 kghr (500000 Ibhr)

Pressure 1099 kgcm2 abs (15635 psia)

Temperature 51280C (9550F)

Same for 20 50 and 100 MW designs

Prefeasibility Study Oil ShaJe Fueled Power Generation

vooGALMI 20

HtomCOPUIOTP

- 50005 5op

-- LEVAThUM ORPORAION

0

-VI

DZ 4

Power Block

Fuel handling system

- Day binsscrew feeders

Boiler

- Pyroflow circulating fluid bed combustor

Power generation

- Non reheat condensing steam turbine

- Conventional Rankin steam cycle

Ash handling system (btm ash irom combustor and flyash from bag house)

- Wetted in pug mill to add 20plusmn wt wpter

Plant service water

- Air-cooled condensors and small cooling tower from circulating trim water coolers

Plant raw water

- To cooling tower makeup

- To drinking water system

- To pump seals etc

Plant treated makeup water

- Demineralizer train

Preteasibility Study Oil Shale Fueled Power Generation

i

Onsite Infrastructure

Project office

Control house

U Maintenance shops warehouse

Laboratory

Employee service facility

Site developmentoperations service facilities

- Fire controlsecurity

- Communications

- Lighting

- Roads drainage and sewage

Prefeasibility StudyQ1I Shale Fueled Power Generation

voo4JG m 0 JV

i

BechtellPyropower50 MW Cogeneration Plant - Mt Poso California

W4t Prefeasibility Study --- 7 Oil Shale Fueled Power Generation

179586122aJordarv 118 3-14-89 rsO

Characteristics of Three Size Operations

Oil shale fuel tpy

Mine development excavation bank m3

Spent ash disposal tpy (wetted)

Water consumption 1000 m3yr

Staffing required

Community population

400 MW

20 MW 50 MW (4x1 00)

390000 973000 78 million

500000 1 million 85 million

327000 815000 61 million

538 907 1263

185 324 1046

700 1200 4000

Prefeasibility Study Oil Shale Fueled Power Generation

V000ofllAM1 23

Conceptual Designs Summary

N All BOP facilities involve conventional equipment and technology

100 MW unit operation involves boiler scale-up considerations

N Water consumption estimates

- Requirement for 4x100 MW project is 13 million m3 yr

- Water allocation of 2 million m3yr of water supports 6x100 MW

N Water availability probably limits total power generation from oil shale in Jordan

Prefeasibility Study Oil Shale Fueled Power Generation

V007041GEAOLMI

i

TECHNOLOGY RISK ASSESSMENT

Basic concepts

Key boiler scale-up design issues

Impact of scale-up

U Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Prefeasibility Study O1 Shale Fueled Power Generation

VOOh-7AEAAO 2

Basic Concepts

U CFBC is relatively new in the powerindustry

- Existing plants are small typically 20 to 50 MW

- There is limited operating experience with high-ash fuels

- Existing designs for lignite biomass and coal wastes show good plant performance

I Application of CFBC boiler design to oil shale fuel has defined risk that relates to scale-up of existing design

Similar CFBC technology is used in petroleum refining industry

- FCC cracking plant regenerators burn carbon residue off spent catalyst

- 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

FUEL ANALYSES

High Ash Fuel Projects Total Solids Input Basis

Gilberton Cambria North Branch

Carbon 4653 2749 1822 Hydrogen 153 164 160 Sulfur 073 222 234 Nitrogen 085 051 043 Oxygen 282 218 468 Moisture 1451 514 557 Ash 3303 6 0 6Z16

10000 10000 10000

HHVBtulb 7485 4809 3453

includes limestone feed a3 ash

includes CO2 in Ca~o3

CA89029 CAkw

Oil Shale

1132

113

255

048

065

320

-8062

10000

2250

Key Boiler Scale-Up DesignIssues

m Solids handling

- Feeding shale to combustor

- 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

Voo4tGEAMI 30

i

Mine and Shale Processing

U Fugitive dust emissions are controllable

- Wetting mine roads

- Enclose crushing plant equipment

Noise levels are controllable

- Enclose crushing plant equipment - Muffle truck exhausts

- Engineered waste disposal

Water effluents can be controlled

- Need good mine drainage design - Continue leachability studies on

waste dump piles

Prefeasibilily StudyOil Shale Fueled Po r Generaton

V0079OOG-4O 31

1

Power Plant

II Fugitive dust emissions are controllable

- Baghouse designoperation will minimize particulates in flue gas

- Wetting spent ash before disposal

N Gaseous emissions are controllable

- Pilot test results show acceptable SO2NOxCO in flue gas

- Develop baseline data for Sultani area

Develop air dispersion model for Sultani

Prefeasibility StudyOil Shale Fueled Power Generatio

V00 V-4GEA l32

i

Power Plant (Contd)

Noise levels are controllable

- Enclose boiler plant fans as required - Enclose turbines and pumps as

required

Water effluents are controllable

- Continue leachability studies on spent ash disposal

- Develop aquifer dispersion model

- Develop sewage and garbage disposal plan

Prefeasibility SludyOil Shale Fueled Power Generation

V00-4FAAI 33

Conclusions

No environmental constraints are anticipated on oil shale powerdevelopment

Gas effluents will meet World Bank standards

- Ash disposal is manageable

- The potential for groundwatercontamination appears low

- Water effluents will be minimal

Continued studies to develop air and groundwater baseline data are recommended

S Prefeasibility Study Oil Shale Fueled Power Generation

v0 9ampGLAMR 34

Power Demand vs SupplyAssessment

m Demand growth forecasts

Electrical generating capacity

= Power supply forecasts

= Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Preleasibility Study Oil Shaie Fuelod Power Generation

VO9- uLIROI

1

Power Demand Forecasts

Percent Annual Growth

JEA

Meta systems HaglerBailey and Bechtel National Inc

JEA Peak Demand Growth

1980 (actual) 1985 (actual) 1987 (actual) 1995 (forecast) 2005 (forecast)

1986 1990 to to

1990 2000

97 60

49 39

200 MW 475 MW 593 MW 900 MW

1400 MW

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOO-DLURO2

i

JEA ElectricityGeneratingCapacity

1987 Installed

Capacity (MW) Aqaba 260

22

Zarqa 395

Marka 102

Karak 23

Miscellaneous 67

Subtotal JEA capacity 869

Other capacity - industrial 110

Total 979

Prefeasibility Study Oi1 Shale Fueled Power Generation

V000-6O0LFJRO3 (

Forecast New Power Generating Capacity Required

Fcst 1987 Required

New Peak Available Installed

Demand Capacity Shortfall (a) Capacity (b) (MM (MW) (MW) (MW)

Assumed capacityfactor (65) (75)

1995 requirement 900 636 264 352

2005 requirement 1400 636 764 1019

(a) Excludes proposed additions and retirements (b) Excludes possible power exports or imports

Load shedding or levelizing not considered

Preteasibility Study Oil Shale Fueled Power Generation

Vflcmf-R)LLAO4

i

Supply vs Demand Evaluation

1800

1600

1400 Forecast Peak Demands

1200 -

E Installed Capacity

0 800shy75--

U) Assumed Available Calcit

a 6 Ao600 shy0 o 65

400 shy

200

I I I I I I I I I I I I I I I I I I I I I I I 1 1 1980 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958f738aIJordarV 118 3-14-89 rspCO

Conclusions

Additional power generating capacity is needed to meet forecasted 19952005demand growth

A 400 MW oil shale-to-power project at Sultani can meet a portion of this need

U A second 400 MW oil shale project maybe required if water is available

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOW0O-8LURO5

i

Economic Feasibility

N Order-of-magnitude costs

N Economic analysis

- Jordan study options

- Project size effect

m Comparison with alternative fuels

- Fuel requirement

- Project financing effect

- Alternate fuel price effect

- Estimated cost of electricity

N Summary financial analysis

bull Material was developed by Bechtel Power Company

Prefeasibility Study

go Oil Shale Fueled Power Generation VOOSO-ampDtJROh

ORDER-OF-MAGNITUDE COSTS

U Oil shale fuel

Power plant

I Integrated project- busbar

Preteasibility Study

Oil Shale Fueled Power Generation

VOO9O-ampDLUROS

Oil Shale Fuel Costs

Installed Capital Cost

Mine Development

Mine Equipment

Processing Plant

Spare Parts

Working Capital

Capitalized Interest

Total

Annual Operating Cost

Fuel Cost $UStonne

bull Based on 8020 debtequity ratio

20 MW

4900

11090

6945

1200

1200

4054

29389

5582

1431

US $1000 Factored

50 MW 4x100 MW

7833 30915

12202 66012

8388 50889

1300 5000

2200 10000

5108 39075

37031 201891

11556 53236

1188 684

Prefeasibility Study

Oil Shale Fueled Power Generation

VCO-ampDLUJ1O

Power Plant Costs

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Cost

Power faciities 57500 91800 567800

Owners cost 10200 20400 192700

Total 67700 112200 760500

Annual Operating Cost 2205 3248 17157(excluding fuel cost)

bullBased on 8020 debtequity ratio oil shale fueled

Prefeasibility Study

Oil Shale Fueled Power Generation

V00O8c4LLMO9

i

INTEGRATED PROJECT -BUSBAR COST

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Costs Mine amp shale processingPower block Waste disposal Infrastructure

29359 67700

1664 10000

37031 112200

2381 15000

201891 760500

8714 45000

TOTAL 108753 166612 1016105

Annual Operating Cost Mine amp shale processingPower block Waste disposal Infrastructure (a)

5582 2205

316

11556 3248

710

56430(b) 18186(b) 6004

Subtotal 8103 15514 80620

Capital Charges 139 9410 15596 106000

Total 17513 31110 186620

25-year levelized cost - - 218000

Busbar Cost millskWh First year 128 92 71 25-year levelized 83

(a) Housing and community facilities assumed self-liquidating(b) Includes first-year inflation adjustment

Based on 8020 debtequity ratio

Prefeasibility StudyOil Shale Fueled Power Generaion

VOOOO-8MLtROi0

ECONOMIC ANALYSIS

n Jordan study options

Project size effect

Fuel requirement

Project financing effect

Alternative fuel price effect

Estimated electricity cost

Summary financial analysis results

Prefeasibility Study

Oil Shale Fueled Powr Generation

VOOeO-BOCLLO1 I

i

Jordan Study Options

U Project size

- Demonstration = 20 MW

- Prototype = 50 MW

- Commercial = 400 MW (4x100)

Project financing

- Debtequity 8020

- Debtequity 5050

Imported alternative fuels cost assumptions

A B Crude oil $17bbl $24bbl

$120onne $170tonne

Low sulfur coal $ 50tonne $ 70tonne See Chevron forecast supporting assumptions

Prefeasibility StudyOil Shale Fueled Power Generation

VOOOO-8DLIJRO12

i

Crude Oil Price Trends

60

Source World Energy Outlook Chevron Corporation Oclober 1987

40

High trend

No Ir 20 ~~~~Arabian Light Spot I A u

IILowYUII trend

0 1970 1975 1980 1985 1990 1995

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958246aJodar 118 3-14-89 rsO

2000

Project Size Effect Shale Fuel Option

Project Size

Integrated facilities installed capital cost$ US million

Shale cost $UStonne(8020 debtequity)

Cost of power millskWh(8020 debtequity ratio)

20 MW

109

143

128

50 MW

167

118

92

400 MW (4x1 00)

1016

68

71

Prefeasibility Study Oil Sampae Fueled Power Generation

VOO O-8I0LJRO13

gt1

1

Power Block Investment Cost

3000

$2875 Excluding mining and offsite 2800

2600

2400

2200

2000

$1836 1800

$1613 1600

$1420 1400 1I 1 I

0 100 200 300 400 MWe

August 1988

Preleasibility Study OilShale Fueled Power Generation

179581147aJodar1 18 3-14-89 rspcl

Fuel Requirement - 4x100 MW Project

Coal = 12 million tpy

n Oil = 503000 tpy

Oil shale = 78 million tpy

Preleasibility Study

Oil Shale Fueled Power Generation

IO060-OLLIRO14

Financing Effect -Project

Oil Shale Fuel Option

Mine and shale processing

Power block

Waste disposal

Community facilities

Total

Coal-Fired Power Plant

Oil-Fired Power Plant

400 MW

Capital Cost ($US MM)

DebtEquity

8020 5050

202 187

760 760

9 8

45 45

1016 1000

647 647

463 463

Prefeasibility StudyOil Shale Fueled Power Generation

VOe-BD1JRO15

Financing Effect shy400 MW Project

Operating Costs ($US millionyr)

DebtEquity

8020 5050

Coal $70tonne 282 282

Oil $24bbl 254 254

Oil shale-fueled 218 236

Including fuel

Prefeasibility Study

SOil Shale Fueled Power Generaion

VOOIt JLMO I

Alternate Fuel Price Effect shy4x100 MW Project

Financing Basis DebtEquity Ratio

Alternate Fuel Price

Imported coal $50tonne $70tonne

Imported oil $17bbl ($120tonne) $24bbl ($170tonne)

Cumulative 25-yr Net Benefit

Favoring Oil Shale (US $MM) shy

8020 5050

778 315 2531 2068

(18) (506)1810 1322

Prefeasibility Study

Oil Shale Fueled Power Generation

Voo -I DLU-A 2

i

Comparison of Cumulative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

32 Pay Out Year shy

400 MW PlantOil Shale vs Imported Coal (8020 debtequty)

30

28 -Cumulative fuel cost savings forcoal $70ton

Cumulative fuel cost savings for coaJ $50ton

26---------- Cumulative Incremental capital plus OampM costs

24

22 -

18 -0

W- Cumulative net benefit for shae vs coal $50ton 2B Cumulative net benefit for shale vs coal $70ton

co16C -

14 -

12 -

10 -

09

06 -Payout inyear 1

Payout Inyear 9 for coal $50ton - -- - - -shy

02 0 I

0 1 2 3 4 5 Nowl Yewr in which sauings in fWe colsacm-ewi tat hsawinitl

ca=al wosaand OampM costs

6

_iiM

7 8

9 10

------ - -amp -

11 12 13 14Year of Operation

--

15

- - --shy

16 17

I

18

1

19

I

20

I

21

I

22

I

23

I

24 25

Prefeasibility StudyOil Shale Fueled Power Generation

17958d351aJordanr 3-14-89 rsO

118

Comparison of Cumuiative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

28 Pay Out Year shy

400 MW Plant Oil Shale vs Imported Coal (5050 debtequity)

26shy2

24-

Cumulaive fuel nst savings for coal 0 $70ton Cumulative fuel cost savings for coal $50ton Cumulative Incremental capital plus OampM corts

22 -

20 -

18 -- Cumuladve net benefit for shle vs coal $50ton B Cumuarve net benefit for sale vs coal $70ton

16 -

C 14

12

10

08 -06 - Payout In year 1for coal $50ton

04

Payout Inyear 1

for coal $70ton02~

0 0

-No

02-

1 2

Yew inrY MCM cajlaI rl

3 4 5 6

sngm inW coas 0 ort hghWcentWin

0tOM cori

7

--

8

- -

9 10 11 12 13 14

Year of Operation

15 16 17

I

18

IIII

19 20 21 22 23 24 25

Preieasibility Study Oil Shale Fueled Power Generation

17958451 bJordarV118 3-14-89 rsipcI

Estimated Cost of Power- 400 MW (4 x 100)

FUEL

ImportedCoal

$50T

$70fT

1st Year

68 88

Levelized

78 107

Sultani Oil Shale

71 83

ImportedOil

$1713

$2413

56

67

76

96

0 10 20 30 40 50

I 60

I 70

I 80

I 90 100 110 120

Mills per kWh

Prefeasibility Study Oil Shale Fueled Power Generation

179581251 cJordarVl 18 3-14-89 rspc1

Summary Financial Analysis Results

Project size

Debt equity ratio

- Investment cost

- Power cost

- 25-year net benefit

- Project implementation

Alternative fuel price

Economic Comparison

Very significant

Not significant

Not significant

Very significant

Critical

Very significant

Prefeasibility Study

Oil Shale Fueled Power Generation

VY0 tDLUAi3

i

Study Conclusions

Feasibility

Timeliness

Expansion conditions

Environmental impacts

Development advantages

Prefeasibility Study

Oil Shale Fueled Power Generation VW41-1AiUA

4

Feasibility

Oil shale fueled power generation is technically and economically justifiedunder certain conditions

N Need for additional generating capacity

exists

- 6 annual peak demand growth - Orderly retirement of olderhigh cost

generating capacity needed

U Higher costs are expected for imported fuels

- 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

-OP b i j~~4shy

-4protntiYPe 4 demo plnt orP42 t~Plant orPootypeProje(-7hould

that Rj

demo 4Therefore-44 JEA anxinus

the

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

27Pag 4- 1 2S c i n 4 4

4i2Sectjo4-18-4 Secio 4-4 014

lt th~ae hi4h -tasisso syste thrug27 ~ 04lag arstl~art-p tasforme ed 2p27132Kvdieanwhy notthroug

EAto- is protmm~~ thegnJgt~~ pracie an ect ~ platqrby

28Pg 4 s heonnenotedto~the 32K rc powr

It not8 Scection rie049teoervnrain prctc de1

rh u n trae f2V3K anerd not throughgeterAntor

27 P3e-1r p ant weung-a

-If I

2tEll10 DRWE-jOi ASOt Mint~~al d~c~e o hepwrgnrto

ELCTRInYJORD UTHORITY-

Ate~

21Pge41 ection 4 04- 5

sindicated~ t hthigh the unit outputredu f hecondenser Injengtd~ibbvePressureed incg desrin hi h riseb vmbi nt emperatureWe bel~ieve

PleaIse provide us with th rscrapcity for th-e three options n nt generating~

21-Iisidca ted that~ thediaatgeofCBi theSheavy fn oe consumnptionPlease~ providethe us withpecntgA

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

400 MW COAL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO 5050

NET GENERATION - MWe 40000 CAPACITY FACTOR - 75 ANNUAL GENERATION MKWhYR 2628 SUB TOTAL PLANT COSTS (TPC) $1000 $620000

FIXED 0 amp M COSTS MH $ MH FIRST YEAR COST$1O00

------- --------- --- ---- --- --- ------------

OPERATING LABOR 351936 $3 $1100 MAINTENANCE LABOR 4000 of 150 OF TPC 3720

MAINTENANCE MATERIAL 6000

ADMIN LABOR of 150

3000 OF TPC

OF 0 amp M LABOR 5580 1446

SUB TOTAL FIXED OampM COSTS $11846

VARIABLE 0 amp M COSTS QUANTITY UNIT COST

VARIABLE MAINTENANCE 2628 MKWh 10 MILLKWH $ 2628 PROCESS WATER 13500000 GALLON 02 SGAL $ 2700 GENERAL PLANT CHEMICALS ALLOW 50 FUEL OIL 1000000 GALLON 035 $GAL $ 350 WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290SPECIAL BOILER MAINT ALLOW 0

SUB TOTAL VARIABLE OampM COSTS $ 8018

TOTAL FIXED amp VARIABLE OampM COSTS $19864 TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $8227 $TN $99139

(INCL INFLATION ADJUSTMENT)

B DEBT EQUITY RATIO =========== 8020

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $17574

WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290

TOTAL FIXED amp VARIABLE OampM COSTS $19864TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $5877 $TN $70814

(INCL INFLATION ADJUSTMENT)

6-21

Table 612 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY

400 MW OIL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO

NET GENERATION -

CAPACITY FACTOR -

ANNUAL GENERATION SUB TOTAL PLANT COSTS (TPC)

FIXED 0 amp M COSTS

OPERATING LABOR MAINTENANCE LABOR 4000 of

MAINTENANCE MATERIAL 6000 of

ADMIN LABOR

SUB TOTAL FIXED OampM COSTS

VARIABLE 0 amp M COSTS

VARIABLE MAINTENANCE PROCESS WATER GENERAL PLANT CHEMICALS FUEL OIL WASTE DISPOSAL (Section 6027) SPECIAL BOILER MAINT

SUB TOTAL VARIABLE OampM COSTS

5050

MWe

MKWhYR $1000

MH

262080

150

150 3000

QUANTITY

2628 MKWh 13500000 GALLON

1000000 GALLON 0 TNYR

TOTAL FIXED amp VARIABLE OampM COSTS FUEL OIL 503000 TNYR

B DEBT EQUITY RATIO =8020

40000 75

268 $443000

FIRST YEAR $ MH COST$1O00

$3 $ 800

OF TPC 2658

OF TPC 3987 OF 0 amp M LABOR 1037

$ 8482

UNIT COST

05 MILLKWH $ 1314 02 $GAL $ 2700

ALLOW 50 035 $GAL $ 350

$1000 $TN $ 0 ALLOW 0

$ 4414

$12896 $19981 $TN $100502

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $12896

WASTE DISPOSAL (Section 6027) 0 TNYR $1000 $TN $ 0

TOTAL FIXED amp VARIABLE OampM COSTS $12896 FUEL OIL 503000 TNYR $14104 $TN $70943

6-23

Page 20: fo; - pdf.usaid.gov

Conceptual Design Studies Scope

m Three project sizes

- 20 MW

- 50 MW

- 400 MW (4x100) factored for power plant portion

m Open-pit mine

- Shale processing at the surface - Waste disposal system

Power block

- Boiler

- Steam turbine

- Auxiliaries

Prefeasibility Study Oil Shale Fueled Power Generation

VOn 4FAIR 1

i

Project Layout 9 fc =f4j

deg2

o r -w (031

5_7EC 45U

iPefeaibiity tud

OlSeFuedP erGr in

179581113i~o(atyvv11

n1- 14 4pc

C)

Sultani Oil Shale Reserves

North South Area Area Total

Mineable shale tonne x 106 320 658 978

Fischer assay oil content wt 744 761 765

Overburden m3 x 106 384 627 1011

Stripping ratio m3m3 2161 1711 1861

bull Based on NRA core drilling and core analysis

Prefeasibility Study Oil Shale Fueled Power Generation

VWO41OFEAMI14

i

Sultani Oil Shale Analyses

Moisture

Ash (less CO 2 in CaCO 3 )

CO 2 (in CaCO 3 )

Carbon (organic)

Hydrogen

Nitrogen

Sulfur

Oxygen (by diff)

Total

High heating value BtuIb

Fischer assay oil content

bull Percent by weight

Design Basis Fuel

320

6680

1387

1132

113

048

255

065

10000

2250

840

Low High Calorific Calorific

Value Fuel Value Fuel

320 320

6730 6625

1414 1337

1020 1250

102 125

058 038

238 271

118 034

10000 10000

2000 2500

750 925

Preteasibility Study Oil Shale Fueled Power Generation

vo0N d-GEAR 1S

50 MW Oil Shale ProcessingPrototype Plant

Mlne Plant

_ 14 0 Haul0___) to Plant 1 Sorage

Portable Crusher

(-)100 mm Storage

(-) 100 mm Hopper UIU 400 th

Feed Bin

J 50

250 tvb

8 -m Circulating Load Impact3or0 0 30 0 0shy+8mm25

30 0L Sampler 0 1 30 0

p3 Day Storage

To Power Plant

Preleasibility StudyOil Shale Fueled Power Generation

17958101 SaJordanli 18 3-14-89 rsipc1

20 MW Oil Shale Demonstration Plant

Mine Plant

Haul00- 01 o

= Pb n Storage Portable _

110 mm Stora e 0

()100 mm r Hopper

U 400V

Feed Bin

CirculatingLoad3 Day Stoge

Prefea~ltSudy Shale Fueled Power Generation

179S 111p 1 11Joda3 yl 3-202-89 8vk2

I

Mine and Shale ProcessingDesign - 2050 MW Project

I Overburden removal (north pit area) 10-meter benches

- Drill and blast

- 10 m3 front-end loader

- 77-ton truck haulage

I Oil shale mining 10-meter benches

- Rippe and auger scraper

- Front-end loader

- Portable in-pit crusher

- 77-ton truck haulage

Oil shale processing

- Feed = minus 100 mm

- Product = minus 8 mm

- Capacity = 250 tph

- Reversible impactor

- Two vibrating screens

1 Prefeasibility Study Oil Shale Fueled Power Generation

V -M 1AMI1ARt46

400 MW Full-Scale Oil Shale ProcessingPlant

Feed MTnus 200 mm Samplerr

1000 bull 10000 Tonnes Live Storage Grade

200 m long(-) 200 mm -- =-- Plow Feeders

00 h 100000 Tonnes Live Storage

Stream 3 - Sampler Bin Stream 2

Stream th 31Da2000

Circulating Load 2i

NFw Feed r -17000t1 170001l 170 t 17000 t 17000 t

1000 th Silo with 7 Impactor (-1)8 mm Reapro- 3 Day Storage at Aver age Loadn

0 20 Feeders 20 m Diameter by 40 m High

JJJTHT To Power Plant

Prefeasibility Study Oil Shale Fueled Power Generation

179589 6aJordarV 1I8 3-14-89 rsipc1

Mine and Shale ProcessingDesign - 4x100 MW Project

m Overburden removal (north area) 10-meter benches

- Drill and blast

- Three 20 m3 shovels

- 136-ton truck haulage

m Oil shale mining 10-meter benches

- Two mechanical surface miners

- 136-ton trucks to pit hopper

- Belt conveyor = 2000 tph

- Traveling stacker

m Oil shale processing

- Feed = minus 200 mm

- Product = minus 8 mm

- Capacity = three 1000 tph units

Prefeasibility Study Oil Shale Fueled Power Generation

VOO79-ampGEAIAt 17

i

Steady-State Production Schedule

Overburden removal bench m3

20 MW demo project 5n MW prototype 4x100 MW full-scale plant

Oil shale mining and shale processing tonnes

20 MW project 50 MW project 4x100 MW project

HourlyDesign Capacity

282 234

1850

HourlyDesign Capacity

250 250

2000

Avg Daily Annual PEQuctiQa Production

1690 507000 4217 13 million

33333 10 million

Max Daily(a) Annual(b) Production Production

1733 390000 4324 973000

34578 78 million

(a) Based on 100 operating factor for power block

(b) Based on 75 operating factor for power block ( 20 MW project = 300 shiftsyr 50 MW project = 900 shiftsyr 400 MW project = 900 shiftsyr)

Prefeasibility Study Oil Shale Fueled Power Generation

Conceptual Power Plant Plans

m Pyroflow boiler

Power generating facilities

m Auxiliaries

S Preleasibility Study Oil ShaJe Fueled Power Generation

vo0o7dEAO 19

Pyroflow Boiler SteamConciflons

Flow rate 226700 kghr (500000 Ibhr)

Pressure 1099 kgcm2 abs (15635 psia)

Temperature 51280C (9550F)

Same for 20 50 and 100 MW designs

Prefeasibility Study Oil ShaJe Fueled Power Generation

vooGALMI 20

HtomCOPUIOTP

- 50005 5op

-- LEVAThUM ORPORAION

0

-VI

DZ 4

Power Block

Fuel handling system

- Day binsscrew feeders

Boiler

- Pyroflow circulating fluid bed combustor

Power generation

- Non reheat condensing steam turbine

- Conventional Rankin steam cycle

Ash handling system (btm ash irom combustor and flyash from bag house)

- Wetted in pug mill to add 20plusmn wt wpter

Plant service water

- Air-cooled condensors and small cooling tower from circulating trim water coolers

Plant raw water

- To cooling tower makeup

- To drinking water system

- To pump seals etc

Plant treated makeup water

- Demineralizer train

Preteasibility Study Oil Shale Fueled Power Generation

i

Onsite Infrastructure

Project office

Control house

U Maintenance shops warehouse

Laboratory

Employee service facility

Site developmentoperations service facilities

- Fire controlsecurity

- Communications

- Lighting

- Roads drainage and sewage

Prefeasibility StudyQ1I Shale Fueled Power Generation

voo4JG m 0 JV

i

BechtellPyropower50 MW Cogeneration Plant - Mt Poso California

W4t Prefeasibility Study --- 7 Oil Shale Fueled Power Generation

179586122aJordarv 118 3-14-89 rsO

Characteristics of Three Size Operations

Oil shale fuel tpy

Mine development excavation bank m3

Spent ash disposal tpy (wetted)

Water consumption 1000 m3yr

Staffing required

Community population

400 MW

20 MW 50 MW (4x1 00)

390000 973000 78 million

500000 1 million 85 million

327000 815000 61 million

538 907 1263

185 324 1046

700 1200 4000

Prefeasibility Study Oil Shale Fueled Power Generation

V000ofllAM1 23

Conceptual Designs Summary

N All BOP facilities involve conventional equipment and technology

100 MW unit operation involves boiler scale-up considerations

N Water consumption estimates

- Requirement for 4x100 MW project is 13 million m3 yr

- Water allocation of 2 million m3yr of water supports 6x100 MW

N Water availability probably limits total power generation from oil shale in Jordan

Prefeasibility Study Oil Shale Fueled Power Generation

V007041GEAOLMI

i

TECHNOLOGY RISK ASSESSMENT

Basic concepts

Key boiler scale-up design issues

Impact of scale-up

U Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Prefeasibility Study O1 Shale Fueled Power Generation

VOOh-7AEAAO 2

Basic Concepts

U CFBC is relatively new in the powerindustry

- Existing plants are small typically 20 to 50 MW

- There is limited operating experience with high-ash fuels

- Existing designs for lignite biomass and coal wastes show good plant performance

I Application of CFBC boiler design to oil shale fuel has defined risk that relates to scale-up of existing design

Similar CFBC technology is used in petroleum refining industry

- FCC cracking plant regenerators burn carbon residue off spent catalyst

- 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

FUEL ANALYSES

High Ash Fuel Projects Total Solids Input Basis

Gilberton Cambria North Branch

Carbon 4653 2749 1822 Hydrogen 153 164 160 Sulfur 073 222 234 Nitrogen 085 051 043 Oxygen 282 218 468 Moisture 1451 514 557 Ash 3303 6 0 6Z16

10000 10000 10000

HHVBtulb 7485 4809 3453

includes limestone feed a3 ash

includes CO2 in Ca~o3

CA89029 CAkw

Oil Shale

1132

113

255

048

065

320

-8062

10000

2250

Key Boiler Scale-Up DesignIssues

m Solids handling

- Feeding shale to combustor

- 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

Voo4tGEAMI 30

i

Mine and Shale Processing

U Fugitive dust emissions are controllable

- Wetting mine roads

- Enclose crushing plant equipment

Noise levels are controllable

- Enclose crushing plant equipment - Muffle truck exhausts

- Engineered waste disposal

Water effluents can be controlled

- Need good mine drainage design - Continue leachability studies on

waste dump piles

Prefeasibilily StudyOil Shale Fueled Po r Generaton

V0079OOG-4O 31

1

Power Plant

II Fugitive dust emissions are controllable

- Baghouse designoperation will minimize particulates in flue gas

- Wetting spent ash before disposal

N Gaseous emissions are controllable

- Pilot test results show acceptable SO2NOxCO in flue gas

- Develop baseline data for Sultani area

Develop air dispersion model for Sultani

Prefeasibility StudyOil Shale Fueled Power Generatio

V00 V-4GEA l32

i

Power Plant (Contd)

Noise levels are controllable

- Enclose boiler plant fans as required - Enclose turbines and pumps as

required

Water effluents are controllable

- Continue leachability studies on spent ash disposal

- Develop aquifer dispersion model

- Develop sewage and garbage disposal plan

Prefeasibility SludyOil Shale Fueled Power Generation

V00-4FAAI 33

Conclusions

No environmental constraints are anticipated on oil shale powerdevelopment

Gas effluents will meet World Bank standards

- Ash disposal is manageable

- The potential for groundwatercontamination appears low

- Water effluents will be minimal

Continued studies to develop air and groundwater baseline data are recommended

S Prefeasibility Study Oil Shale Fueled Power Generation

v0 9ampGLAMR 34

Power Demand vs SupplyAssessment

m Demand growth forecasts

Electrical generating capacity

= Power supply forecasts

= Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Preleasibility Study Oil Shaie Fuelod Power Generation

VO9- uLIROI

1

Power Demand Forecasts

Percent Annual Growth

JEA

Meta systems HaglerBailey and Bechtel National Inc

JEA Peak Demand Growth

1980 (actual) 1985 (actual) 1987 (actual) 1995 (forecast) 2005 (forecast)

1986 1990 to to

1990 2000

97 60

49 39

200 MW 475 MW 593 MW 900 MW

1400 MW

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOO-DLURO2

i

JEA ElectricityGeneratingCapacity

1987 Installed

Capacity (MW) Aqaba 260

22

Zarqa 395

Marka 102

Karak 23

Miscellaneous 67

Subtotal JEA capacity 869

Other capacity - industrial 110

Total 979

Prefeasibility Study Oi1 Shale Fueled Power Generation

V000-6O0LFJRO3 (

Forecast New Power Generating Capacity Required

Fcst 1987 Required

New Peak Available Installed

Demand Capacity Shortfall (a) Capacity (b) (MM (MW) (MW) (MW)

Assumed capacityfactor (65) (75)

1995 requirement 900 636 264 352

2005 requirement 1400 636 764 1019

(a) Excludes proposed additions and retirements (b) Excludes possible power exports or imports

Load shedding or levelizing not considered

Preteasibility Study Oil Shale Fueled Power Generation

Vflcmf-R)LLAO4

i

Supply vs Demand Evaluation

1800

1600

1400 Forecast Peak Demands

1200 -

E Installed Capacity

0 800shy75--

U) Assumed Available Calcit

a 6 Ao600 shy0 o 65

400 shy

200

I I I I I I I I I I I I I I I I I I I I I I I 1 1 1980 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958f738aIJordarV 118 3-14-89 rspCO

Conclusions

Additional power generating capacity is needed to meet forecasted 19952005demand growth

A 400 MW oil shale-to-power project at Sultani can meet a portion of this need

U A second 400 MW oil shale project maybe required if water is available

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOW0O-8LURO5

i

Economic Feasibility

N Order-of-magnitude costs

N Economic analysis

- Jordan study options

- Project size effect

m Comparison with alternative fuels

- Fuel requirement

- Project financing effect

- Alternate fuel price effect

- Estimated cost of electricity

N Summary financial analysis

bull Material was developed by Bechtel Power Company

Prefeasibility Study

go Oil Shale Fueled Power Generation VOOSO-ampDtJROh

ORDER-OF-MAGNITUDE COSTS

U Oil shale fuel

Power plant

I Integrated project- busbar

Preteasibility Study

Oil Shale Fueled Power Generation

VOO9O-ampDLUROS

Oil Shale Fuel Costs

Installed Capital Cost

Mine Development

Mine Equipment

Processing Plant

Spare Parts

Working Capital

Capitalized Interest

Total

Annual Operating Cost

Fuel Cost $UStonne

bull Based on 8020 debtequity ratio

20 MW

4900

11090

6945

1200

1200

4054

29389

5582

1431

US $1000 Factored

50 MW 4x100 MW

7833 30915

12202 66012

8388 50889

1300 5000

2200 10000

5108 39075

37031 201891

11556 53236

1188 684

Prefeasibility Study

Oil Shale Fueled Power Generation

VCO-ampDLUJ1O

Power Plant Costs

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Cost

Power faciities 57500 91800 567800

Owners cost 10200 20400 192700

Total 67700 112200 760500

Annual Operating Cost 2205 3248 17157(excluding fuel cost)

bullBased on 8020 debtequity ratio oil shale fueled

Prefeasibility Study

Oil Shale Fueled Power Generation

V00O8c4LLMO9

i

INTEGRATED PROJECT -BUSBAR COST

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Costs Mine amp shale processingPower block Waste disposal Infrastructure

29359 67700

1664 10000

37031 112200

2381 15000

201891 760500

8714 45000

TOTAL 108753 166612 1016105

Annual Operating Cost Mine amp shale processingPower block Waste disposal Infrastructure (a)

5582 2205

316

11556 3248

710

56430(b) 18186(b) 6004

Subtotal 8103 15514 80620

Capital Charges 139 9410 15596 106000

Total 17513 31110 186620

25-year levelized cost - - 218000

Busbar Cost millskWh First year 128 92 71 25-year levelized 83

(a) Housing and community facilities assumed self-liquidating(b) Includes first-year inflation adjustment

Based on 8020 debtequity ratio

Prefeasibility StudyOil Shale Fueled Power Generaion

VOOOO-8MLtROi0

ECONOMIC ANALYSIS

n Jordan study options

Project size effect

Fuel requirement

Project financing effect

Alternative fuel price effect

Estimated electricity cost

Summary financial analysis results

Prefeasibility Study

Oil Shale Fueled Powr Generation

VOOeO-BOCLLO1 I

i

Jordan Study Options

U Project size

- Demonstration = 20 MW

- Prototype = 50 MW

- Commercial = 400 MW (4x100)

Project financing

- Debtequity 8020

- Debtequity 5050

Imported alternative fuels cost assumptions

A B Crude oil $17bbl $24bbl

$120onne $170tonne

Low sulfur coal $ 50tonne $ 70tonne See Chevron forecast supporting assumptions

Prefeasibility StudyOil Shale Fueled Power Generation

VOOOO-8DLIJRO12

i

Crude Oil Price Trends

60

Source World Energy Outlook Chevron Corporation Oclober 1987

40

High trend

No Ir 20 ~~~~Arabian Light Spot I A u

IILowYUII trend

0 1970 1975 1980 1985 1990 1995

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958246aJodar 118 3-14-89 rsO

2000

Project Size Effect Shale Fuel Option

Project Size

Integrated facilities installed capital cost$ US million

Shale cost $UStonne(8020 debtequity)

Cost of power millskWh(8020 debtequity ratio)

20 MW

109

143

128

50 MW

167

118

92

400 MW (4x1 00)

1016

68

71

Prefeasibility Study Oil Sampae Fueled Power Generation

VOO O-8I0LJRO13

gt1

1

Power Block Investment Cost

3000

$2875 Excluding mining and offsite 2800

2600

2400

2200

2000

$1836 1800

$1613 1600

$1420 1400 1I 1 I

0 100 200 300 400 MWe

August 1988

Preleasibility Study OilShale Fueled Power Generation

179581147aJodar1 18 3-14-89 rspcl

Fuel Requirement - 4x100 MW Project

Coal = 12 million tpy

n Oil = 503000 tpy

Oil shale = 78 million tpy

Preleasibility Study

Oil Shale Fueled Power Generation

IO060-OLLIRO14

Financing Effect -Project

Oil Shale Fuel Option

Mine and shale processing

Power block

Waste disposal

Community facilities

Total

Coal-Fired Power Plant

Oil-Fired Power Plant

400 MW

Capital Cost ($US MM)

DebtEquity

8020 5050

202 187

760 760

9 8

45 45

1016 1000

647 647

463 463

Prefeasibility StudyOil Shale Fueled Power Generation

VOe-BD1JRO15

Financing Effect shy400 MW Project

Operating Costs ($US millionyr)

DebtEquity

8020 5050

Coal $70tonne 282 282

Oil $24bbl 254 254

Oil shale-fueled 218 236

Including fuel

Prefeasibility Study

SOil Shale Fueled Power Generaion

VOOIt JLMO I

Alternate Fuel Price Effect shy4x100 MW Project

Financing Basis DebtEquity Ratio

Alternate Fuel Price

Imported coal $50tonne $70tonne

Imported oil $17bbl ($120tonne) $24bbl ($170tonne)

Cumulative 25-yr Net Benefit

Favoring Oil Shale (US $MM) shy

8020 5050

778 315 2531 2068

(18) (506)1810 1322

Prefeasibility Study

Oil Shale Fueled Power Generation

Voo -I DLU-A 2

i

Comparison of Cumulative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

32 Pay Out Year shy

400 MW PlantOil Shale vs Imported Coal (8020 debtequty)

30

28 -Cumulative fuel cost savings forcoal $70ton

Cumulative fuel cost savings for coaJ $50ton

26---------- Cumulative Incremental capital plus OampM costs

24

22 -

18 -0

W- Cumulative net benefit for shae vs coal $50ton 2B Cumulative net benefit for shale vs coal $70ton

co16C -

14 -

12 -

10 -

09

06 -Payout inyear 1

Payout Inyear 9 for coal $50ton - -- - - -shy

02 0 I

0 1 2 3 4 5 Nowl Yewr in which sauings in fWe colsacm-ewi tat hsawinitl

ca=al wosaand OampM costs

6

_iiM

7 8

9 10

------ - -amp -

11 12 13 14Year of Operation

--

15

- - --shy

16 17

I

18

1

19

I

20

I

21

I

22

I

23

I

24 25

Prefeasibility StudyOil Shale Fueled Power Generation

17958d351aJordanr 3-14-89 rsO

118

Comparison of Cumuiative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

28 Pay Out Year shy

400 MW Plant Oil Shale vs Imported Coal (5050 debtequity)

26shy2

24-

Cumulaive fuel nst savings for coal 0 $70ton Cumulative fuel cost savings for coal $50ton Cumulative Incremental capital plus OampM corts

22 -

20 -

18 -- Cumuladve net benefit for shle vs coal $50ton B Cumuarve net benefit for sale vs coal $70ton

16 -

C 14

12

10

08 -06 - Payout In year 1for coal $50ton

04

Payout Inyear 1

for coal $70ton02~

0 0

-No

02-

1 2

Yew inrY MCM cajlaI rl

3 4 5 6

sngm inW coas 0 ort hghWcentWin

0tOM cori

7

--

8

- -

9 10 11 12 13 14

Year of Operation

15 16 17

I

18

IIII

19 20 21 22 23 24 25

Preieasibility Study Oil Shale Fueled Power Generation

17958451 bJordarV118 3-14-89 rsipcI

Estimated Cost of Power- 400 MW (4 x 100)

FUEL

ImportedCoal

$50T

$70fT

1st Year

68 88

Levelized

78 107

Sultani Oil Shale

71 83

ImportedOil

$1713

$2413

56

67

76

96

0 10 20 30 40 50

I 60

I 70

I 80

I 90 100 110 120

Mills per kWh

Prefeasibility Study Oil Shale Fueled Power Generation

179581251 cJordarVl 18 3-14-89 rspc1

Summary Financial Analysis Results

Project size

Debt equity ratio

- Investment cost

- Power cost

- 25-year net benefit

- Project implementation

Alternative fuel price

Economic Comparison

Very significant

Not significant

Not significant

Very significant

Critical

Very significant

Prefeasibility Study

Oil Shale Fueled Power Generation

VY0 tDLUAi3

i

Study Conclusions

Feasibility

Timeliness

Expansion conditions

Environmental impacts

Development advantages

Prefeasibility Study

Oil Shale Fueled Power Generation VW41-1AiUA

4

Feasibility

Oil shale fueled power generation is technically and economically justifiedunder certain conditions

N Need for additional generating capacity

exists

- 6 annual peak demand growth - Orderly retirement of olderhigh cost

generating capacity needed

U Higher costs are expected for imported fuels

- 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

-OP b i j~~4shy

-4protntiYPe 4 demo plnt orP42 t~Plant orPootypeProje(-7hould

that Rj

demo 4Therefore-44 JEA anxinus

the

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

27Pag 4- 1 2S c i n 4 4

4i2Sectjo4-18-4 Secio 4-4 014

lt th~ae hi4h -tasisso syste thrug27 ~ 04lag arstl~art-p tasforme ed 2p27132Kvdieanwhy notthroug

EAto- is protmm~~ thegnJgt~~ pracie an ect ~ platqrby

28Pg 4 s heonnenotedto~the 32K rc powr

It not8 Scection rie049teoervnrain prctc de1

rh u n trae f2V3K anerd not throughgeterAntor

27 P3e-1r p ant weung-a

-If I

2tEll10 DRWE-jOi ASOt Mint~~al d~c~e o hepwrgnrto

ELCTRInYJORD UTHORITY-

Ate~

21Pge41 ection 4 04- 5

sindicated~ t hthigh the unit outputredu f hecondenser Injengtd~ibbvePressureed incg desrin hi h riseb vmbi nt emperatureWe bel~ieve

PleaIse provide us with th rscrapcity for th-e three options n nt generating~

21-Iisidca ted that~ thediaatgeofCBi theSheavy fn oe consumnptionPlease~ providethe us withpecntgA

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

400 MW COAL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO 5050

NET GENERATION - MWe 40000 CAPACITY FACTOR - 75 ANNUAL GENERATION MKWhYR 2628 SUB TOTAL PLANT COSTS (TPC) $1000 $620000

FIXED 0 amp M COSTS MH $ MH FIRST YEAR COST$1O00

------- --------- --- ---- --- --- ------------

OPERATING LABOR 351936 $3 $1100 MAINTENANCE LABOR 4000 of 150 OF TPC 3720

MAINTENANCE MATERIAL 6000

ADMIN LABOR of 150

3000 OF TPC

OF 0 amp M LABOR 5580 1446

SUB TOTAL FIXED OampM COSTS $11846

VARIABLE 0 amp M COSTS QUANTITY UNIT COST

VARIABLE MAINTENANCE 2628 MKWh 10 MILLKWH $ 2628 PROCESS WATER 13500000 GALLON 02 SGAL $ 2700 GENERAL PLANT CHEMICALS ALLOW 50 FUEL OIL 1000000 GALLON 035 $GAL $ 350 WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290SPECIAL BOILER MAINT ALLOW 0

SUB TOTAL VARIABLE OampM COSTS $ 8018

TOTAL FIXED amp VARIABLE OampM COSTS $19864 TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $8227 $TN $99139

(INCL INFLATION ADJUSTMENT)

B DEBT EQUITY RATIO =========== 8020

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $17574

WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290

TOTAL FIXED amp VARIABLE OampM COSTS $19864TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $5877 $TN $70814

(INCL INFLATION ADJUSTMENT)

6-21

Table 612 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY

400 MW OIL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO

NET GENERATION -

CAPACITY FACTOR -

ANNUAL GENERATION SUB TOTAL PLANT COSTS (TPC)

FIXED 0 amp M COSTS

OPERATING LABOR MAINTENANCE LABOR 4000 of

MAINTENANCE MATERIAL 6000 of

ADMIN LABOR

SUB TOTAL FIXED OampM COSTS

VARIABLE 0 amp M COSTS

VARIABLE MAINTENANCE PROCESS WATER GENERAL PLANT CHEMICALS FUEL OIL WASTE DISPOSAL (Section 6027) SPECIAL BOILER MAINT

SUB TOTAL VARIABLE OampM COSTS

5050

MWe

MKWhYR $1000

MH

262080

150

150 3000

QUANTITY

2628 MKWh 13500000 GALLON

1000000 GALLON 0 TNYR

TOTAL FIXED amp VARIABLE OampM COSTS FUEL OIL 503000 TNYR

B DEBT EQUITY RATIO =8020

40000 75

268 $443000

FIRST YEAR $ MH COST$1O00

$3 $ 800

OF TPC 2658

OF TPC 3987 OF 0 amp M LABOR 1037

$ 8482

UNIT COST

05 MILLKWH $ 1314 02 $GAL $ 2700

ALLOW 50 035 $GAL $ 350

$1000 $TN $ 0 ALLOW 0

$ 4414

$12896 $19981 $TN $100502

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $12896

WASTE DISPOSAL (Section 6027) 0 TNYR $1000 $TN $ 0

TOTAL FIXED amp VARIABLE OampM COSTS $12896 FUEL OIL 503000 TNYR $14104 $TN $70943

6-23

Page 21: fo; - pdf.usaid.gov

Project Layout 9 fc =f4j

deg2

o r -w (031

5_7EC 45U

iPefeaibiity tud

OlSeFuedP erGr in

179581113i~o(atyvv11

n1- 14 4pc

C)

Sultani Oil Shale Reserves

North South Area Area Total

Mineable shale tonne x 106 320 658 978

Fischer assay oil content wt 744 761 765

Overburden m3 x 106 384 627 1011

Stripping ratio m3m3 2161 1711 1861

bull Based on NRA core drilling and core analysis

Prefeasibility Study Oil Shale Fueled Power Generation

VWO41OFEAMI14

i

Sultani Oil Shale Analyses

Moisture

Ash (less CO 2 in CaCO 3 )

CO 2 (in CaCO 3 )

Carbon (organic)

Hydrogen

Nitrogen

Sulfur

Oxygen (by diff)

Total

High heating value BtuIb

Fischer assay oil content

bull Percent by weight

Design Basis Fuel

320

6680

1387

1132

113

048

255

065

10000

2250

840

Low High Calorific Calorific

Value Fuel Value Fuel

320 320

6730 6625

1414 1337

1020 1250

102 125

058 038

238 271

118 034

10000 10000

2000 2500

750 925

Preteasibility Study Oil Shale Fueled Power Generation

vo0N d-GEAR 1S

50 MW Oil Shale ProcessingPrototype Plant

Mlne Plant

_ 14 0 Haul0___) to Plant 1 Sorage

Portable Crusher

(-)100 mm Storage

(-) 100 mm Hopper UIU 400 th

Feed Bin

J 50

250 tvb

8 -m Circulating Load Impact3or0 0 30 0 0shy+8mm25

30 0L Sampler 0 1 30 0

p3 Day Storage

To Power Plant

Preleasibility StudyOil Shale Fueled Power Generation

17958101 SaJordanli 18 3-14-89 rsipc1

20 MW Oil Shale Demonstration Plant

Mine Plant

Haul00- 01 o

= Pb n Storage Portable _

110 mm Stora e 0

()100 mm r Hopper

U 400V

Feed Bin

CirculatingLoad3 Day Stoge

Prefea~ltSudy Shale Fueled Power Generation

179S 111p 1 11Joda3 yl 3-202-89 8vk2

I

Mine and Shale ProcessingDesign - 2050 MW Project

I Overburden removal (north pit area) 10-meter benches

- Drill and blast

- 10 m3 front-end loader

- 77-ton truck haulage

I Oil shale mining 10-meter benches

- Rippe and auger scraper

- Front-end loader

- Portable in-pit crusher

- 77-ton truck haulage

Oil shale processing

- Feed = minus 100 mm

- Product = minus 8 mm

- Capacity = 250 tph

- Reversible impactor

- Two vibrating screens

1 Prefeasibility Study Oil Shale Fueled Power Generation

V -M 1AMI1ARt46

400 MW Full-Scale Oil Shale ProcessingPlant

Feed MTnus 200 mm Samplerr

1000 bull 10000 Tonnes Live Storage Grade

200 m long(-) 200 mm -- =-- Plow Feeders

00 h 100000 Tonnes Live Storage

Stream 3 - Sampler Bin Stream 2

Stream th 31Da2000

Circulating Load 2i

NFw Feed r -17000t1 170001l 170 t 17000 t 17000 t

1000 th Silo with 7 Impactor (-1)8 mm Reapro- 3 Day Storage at Aver age Loadn

0 20 Feeders 20 m Diameter by 40 m High

JJJTHT To Power Plant

Prefeasibility Study Oil Shale Fueled Power Generation

179589 6aJordarV 1I8 3-14-89 rsipc1

Mine and Shale ProcessingDesign - 4x100 MW Project

m Overburden removal (north area) 10-meter benches

- Drill and blast

- Three 20 m3 shovels

- 136-ton truck haulage

m Oil shale mining 10-meter benches

- Two mechanical surface miners

- 136-ton trucks to pit hopper

- Belt conveyor = 2000 tph

- Traveling stacker

m Oil shale processing

- Feed = minus 200 mm

- Product = minus 8 mm

- Capacity = three 1000 tph units

Prefeasibility Study Oil Shale Fueled Power Generation

VOO79-ampGEAIAt 17

i

Steady-State Production Schedule

Overburden removal bench m3

20 MW demo project 5n MW prototype 4x100 MW full-scale plant

Oil shale mining and shale processing tonnes

20 MW project 50 MW project 4x100 MW project

HourlyDesign Capacity

282 234

1850

HourlyDesign Capacity

250 250

2000

Avg Daily Annual PEQuctiQa Production

1690 507000 4217 13 million

33333 10 million

Max Daily(a) Annual(b) Production Production

1733 390000 4324 973000

34578 78 million

(a) Based on 100 operating factor for power block

(b) Based on 75 operating factor for power block ( 20 MW project = 300 shiftsyr 50 MW project = 900 shiftsyr 400 MW project = 900 shiftsyr)

Prefeasibility Study Oil Shale Fueled Power Generation

Conceptual Power Plant Plans

m Pyroflow boiler

Power generating facilities

m Auxiliaries

S Preleasibility Study Oil ShaJe Fueled Power Generation

vo0o7dEAO 19

Pyroflow Boiler SteamConciflons

Flow rate 226700 kghr (500000 Ibhr)

Pressure 1099 kgcm2 abs (15635 psia)

Temperature 51280C (9550F)

Same for 20 50 and 100 MW designs

Prefeasibility Study Oil ShaJe Fueled Power Generation

vooGALMI 20

HtomCOPUIOTP

- 50005 5op

-- LEVAThUM ORPORAION

0

-VI

DZ 4

Power Block

Fuel handling system

- Day binsscrew feeders

Boiler

- Pyroflow circulating fluid bed combustor

Power generation

- Non reheat condensing steam turbine

- Conventional Rankin steam cycle

Ash handling system (btm ash irom combustor and flyash from bag house)

- Wetted in pug mill to add 20plusmn wt wpter

Plant service water

- Air-cooled condensors and small cooling tower from circulating trim water coolers

Plant raw water

- To cooling tower makeup

- To drinking water system

- To pump seals etc

Plant treated makeup water

- Demineralizer train

Preteasibility Study Oil Shale Fueled Power Generation

i

Onsite Infrastructure

Project office

Control house

U Maintenance shops warehouse

Laboratory

Employee service facility

Site developmentoperations service facilities

- Fire controlsecurity

- Communications

- Lighting

- Roads drainage and sewage

Prefeasibility StudyQ1I Shale Fueled Power Generation

voo4JG m 0 JV

i

BechtellPyropower50 MW Cogeneration Plant - Mt Poso California

W4t Prefeasibility Study --- 7 Oil Shale Fueled Power Generation

179586122aJordarv 118 3-14-89 rsO

Characteristics of Three Size Operations

Oil shale fuel tpy

Mine development excavation bank m3

Spent ash disposal tpy (wetted)

Water consumption 1000 m3yr

Staffing required

Community population

400 MW

20 MW 50 MW (4x1 00)

390000 973000 78 million

500000 1 million 85 million

327000 815000 61 million

538 907 1263

185 324 1046

700 1200 4000

Prefeasibility Study Oil Shale Fueled Power Generation

V000ofllAM1 23

Conceptual Designs Summary

N All BOP facilities involve conventional equipment and technology

100 MW unit operation involves boiler scale-up considerations

N Water consumption estimates

- Requirement for 4x100 MW project is 13 million m3 yr

- Water allocation of 2 million m3yr of water supports 6x100 MW

N Water availability probably limits total power generation from oil shale in Jordan

Prefeasibility Study Oil Shale Fueled Power Generation

V007041GEAOLMI

i

TECHNOLOGY RISK ASSESSMENT

Basic concepts

Key boiler scale-up design issues

Impact of scale-up

U Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Prefeasibility Study O1 Shale Fueled Power Generation

VOOh-7AEAAO 2

Basic Concepts

U CFBC is relatively new in the powerindustry

- Existing plants are small typically 20 to 50 MW

- There is limited operating experience with high-ash fuels

- Existing designs for lignite biomass and coal wastes show good plant performance

I Application of CFBC boiler design to oil shale fuel has defined risk that relates to scale-up of existing design

Similar CFBC technology is used in petroleum refining industry

- FCC cracking plant regenerators burn carbon residue off spent catalyst

- 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

FUEL ANALYSES

High Ash Fuel Projects Total Solids Input Basis

Gilberton Cambria North Branch

Carbon 4653 2749 1822 Hydrogen 153 164 160 Sulfur 073 222 234 Nitrogen 085 051 043 Oxygen 282 218 468 Moisture 1451 514 557 Ash 3303 6 0 6Z16

10000 10000 10000

HHVBtulb 7485 4809 3453

includes limestone feed a3 ash

includes CO2 in Ca~o3

CA89029 CAkw

Oil Shale

1132

113

255

048

065

320

-8062

10000

2250

Key Boiler Scale-Up DesignIssues

m Solids handling

- Feeding shale to combustor

- 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

Voo4tGEAMI 30

i

Mine and Shale Processing

U Fugitive dust emissions are controllable

- Wetting mine roads

- Enclose crushing plant equipment

Noise levels are controllable

- Enclose crushing plant equipment - Muffle truck exhausts

- Engineered waste disposal

Water effluents can be controlled

- Need good mine drainage design - Continue leachability studies on

waste dump piles

Prefeasibilily StudyOil Shale Fueled Po r Generaton

V0079OOG-4O 31

1

Power Plant

II Fugitive dust emissions are controllable

- Baghouse designoperation will minimize particulates in flue gas

- Wetting spent ash before disposal

N Gaseous emissions are controllable

- Pilot test results show acceptable SO2NOxCO in flue gas

- Develop baseline data for Sultani area

Develop air dispersion model for Sultani

Prefeasibility StudyOil Shale Fueled Power Generatio

V00 V-4GEA l32

i

Power Plant (Contd)

Noise levels are controllable

- Enclose boiler plant fans as required - Enclose turbines and pumps as

required

Water effluents are controllable

- Continue leachability studies on spent ash disposal

- Develop aquifer dispersion model

- Develop sewage and garbage disposal plan

Prefeasibility SludyOil Shale Fueled Power Generation

V00-4FAAI 33

Conclusions

No environmental constraints are anticipated on oil shale powerdevelopment

Gas effluents will meet World Bank standards

- Ash disposal is manageable

- The potential for groundwatercontamination appears low

- Water effluents will be minimal

Continued studies to develop air and groundwater baseline data are recommended

S Prefeasibility Study Oil Shale Fueled Power Generation

v0 9ampGLAMR 34

Power Demand vs SupplyAssessment

m Demand growth forecasts

Electrical generating capacity

= Power supply forecasts

= Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Preleasibility Study Oil Shaie Fuelod Power Generation

VO9- uLIROI

1

Power Demand Forecasts

Percent Annual Growth

JEA

Meta systems HaglerBailey and Bechtel National Inc

JEA Peak Demand Growth

1980 (actual) 1985 (actual) 1987 (actual) 1995 (forecast) 2005 (forecast)

1986 1990 to to

1990 2000

97 60

49 39

200 MW 475 MW 593 MW 900 MW

1400 MW

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOO-DLURO2

i

JEA ElectricityGeneratingCapacity

1987 Installed

Capacity (MW) Aqaba 260

22

Zarqa 395

Marka 102

Karak 23

Miscellaneous 67

Subtotal JEA capacity 869

Other capacity - industrial 110

Total 979

Prefeasibility Study Oi1 Shale Fueled Power Generation

V000-6O0LFJRO3 (

Forecast New Power Generating Capacity Required

Fcst 1987 Required

New Peak Available Installed

Demand Capacity Shortfall (a) Capacity (b) (MM (MW) (MW) (MW)

Assumed capacityfactor (65) (75)

1995 requirement 900 636 264 352

2005 requirement 1400 636 764 1019

(a) Excludes proposed additions and retirements (b) Excludes possible power exports or imports

Load shedding or levelizing not considered

Preteasibility Study Oil Shale Fueled Power Generation

Vflcmf-R)LLAO4

i

Supply vs Demand Evaluation

1800

1600

1400 Forecast Peak Demands

1200 -

E Installed Capacity

0 800shy75--

U) Assumed Available Calcit

a 6 Ao600 shy0 o 65

400 shy

200

I I I I I I I I I I I I I I I I I I I I I I I 1 1 1980 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958f738aIJordarV 118 3-14-89 rspCO

Conclusions

Additional power generating capacity is needed to meet forecasted 19952005demand growth

A 400 MW oil shale-to-power project at Sultani can meet a portion of this need

U A second 400 MW oil shale project maybe required if water is available

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOW0O-8LURO5

i

Economic Feasibility

N Order-of-magnitude costs

N Economic analysis

- Jordan study options

- Project size effect

m Comparison with alternative fuels

- Fuel requirement

- Project financing effect

- Alternate fuel price effect

- Estimated cost of electricity

N Summary financial analysis

bull Material was developed by Bechtel Power Company

Prefeasibility Study

go Oil Shale Fueled Power Generation VOOSO-ampDtJROh

ORDER-OF-MAGNITUDE COSTS

U Oil shale fuel

Power plant

I Integrated project- busbar

Preteasibility Study

Oil Shale Fueled Power Generation

VOO9O-ampDLUROS

Oil Shale Fuel Costs

Installed Capital Cost

Mine Development

Mine Equipment

Processing Plant

Spare Parts

Working Capital

Capitalized Interest

Total

Annual Operating Cost

Fuel Cost $UStonne

bull Based on 8020 debtequity ratio

20 MW

4900

11090

6945

1200

1200

4054

29389

5582

1431

US $1000 Factored

50 MW 4x100 MW

7833 30915

12202 66012

8388 50889

1300 5000

2200 10000

5108 39075

37031 201891

11556 53236

1188 684

Prefeasibility Study

Oil Shale Fueled Power Generation

VCO-ampDLUJ1O

Power Plant Costs

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Cost

Power faciities 57500 91800 567800

Owners cost 10200 20400 192700

Total 67700 112200 760500

Annual Operating Cost 2205 3248 17157(excluding fuel cost)

bullBased on 8020 debtequity ratio oil shale fueled

Prefeasibility Study

Oil Shale Fueled Power Generation

V00O8c4LLMO9

i

INTEGRATED PROJECT -BUSBAR COST

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Costs Mine amp shale processingPower block Waste disposal Infrastructure

29359 67700

1664 10000

37031 112200

2381 15000

201891 760500

8714 45000

TOTAL 108753 166612 1016105

Annual Operating Cost Mine amp shale processingPower block Waste disposal Infrastructure (a)

5582 2205

316

11556 3248

710

56430(b) 18186(b) 6004

Subtotal 8103 15514 80620

Capital Charges 139 9410 15596 106000

Total 17513 31110 186620

25-year levelized cost - - 218000

Busbar Cost millskWh First year 128 92 71 25-year levelized 83

(a) Housing and community facilities assumed self-liquidating(b) Includes first-year inflation adjustment

Based on 8020 debtequity ratio

Prefeasibility StudyOil Shale Fueled Power Generaion

VOOOO-8MLtROi0

ECONOMIC ANALYSIS

n Jordan study options

Project size effect

Fuel requirement

Project financing effect

Alternative fuel price effect

Estimated electricity cost

Summary financial analysis results

Prefeasibility Study

Oil Shale Fueled Powr Generation

VOOeO-BOCLLO1 I

i

Jordan Study Options

U Project size

- Demonstration = 20 MW

- Prototype = 50 MW

- Commercial = 400 MW (4x100)

Project financing

- Debtequity 8020

- Debtequity 5050

Imported alternative fuels cost assumptions

A B Crude oil $17bbl $24bbl

$120onne $170tonne

Low sulfur coal $ 50tonne $ 70tonne See Chevron forecast supporting assumptions

Prefeasibility StudyOil Shale Fueled Power Generation

VOOOO-8DLIJRO12

i

Crude Oil Price Trends

60

Source World Energy Outlook Chevron Corporation Oclober 1987

40

High trend

No Ir 20 ~~~~Arabian Light Spot I A u

IILowYUII trend

0 1970 1975 1980 1985 1990 1995

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958246aJodar 118 3-14-89 rsO

2000

Project Size Effect Shale Fuel Option

Project Size

Integrated facilities installed capital cost$ US million

Shale cost $UStonne(8020 debtequity)

Cost of power millskWh(8020 debtequity ratio)

20 MW

109

143

128

50 MW

167

118

92

400 MW (4x1 00)

1016

68

71

Prefeasibility Study Oil Sampae Fueled Power Generation

VOO O-8I0LJRO13

gt1

1

Power Block Investment Cost

3000

$2875 Excluding mining and offsite 2800

2600

2400

2200

2000

$1836 1800

$1613 1600

$1420 1400 1I 1 I

0 100 200 300 400 MWe

August 1988

Preleasibility Study OilShale Fueled Power Generation

179581147aJodar1 18 3-14-89 rspcl

Fuel Requirement - 4x100 MW Project

Coal = 12 million tpy

n Oil = 503000 tpy

Oil shale = 78 million tpy

Preleasibility Study

Oil Shale Fueled Power Generation

IO060-OLLIRO14

Financing Effect -Project

Oil Shale Fuel Option

Mine and shale processing

Power block

Waste disposal

Community facilities

Total

Coal-Fired Power Plant

Oil-Fired Power Plant

400 MW

Capital Cost ($US MM)

DebtEquity

8020 5050

202 187

760 760

9 8

45 45

1016 1000

647 647

463 463

Prefeasibility StudyOil Shale Fueled Power Generation

VOe-BD1JRO15

Financing Effect shy400 MW Project

Operating Costs ($US millionyr)

DebtEquity

8020 5050

Coal $70tonne 282 282

Oil $24bbl 254 254

Oil shale-fueled 218 236

Including fuel

Prefeasibility Study

SOil Shale Fueled Power Generaion

VOOIt JLMO I

Alternate Fuel Price Effect shy4x100 MW Project

Financing Basis DebtEquity Ratio

Alternate Fuel Price

Imported coal $50tonne $70tonne

Imported oil $17bbl ($120tonne) $24bbl ($170tonne)

Cumulative 25-yr Net Benefit

Favoring Oil Shale (US $MM) shy

8020 5050

778 315 2531 2068

(18) (506)1810 1322

Prefeasibility Study

Oil Shale Fueled Power Generation

Voo -I DLU-A 2

i

Comparison of Cumulative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

32 Pay Out Year shy

400 MW PlantOil Shale vs Imported Coal (8020 debtequty)

30

28 -Cumulative fuel cost savings forcoal $70ton

Cumulative fuel cost savings for coaJ $50ton

26---------- Cumulative Incremental capital plus OampM costs

24

22 -

18 -0

W- Cumulative net benefit for shae vs coal $50ton 2B Cumulative net benefit for shale vs coal $70ton

co16C -

14 -

12 -

10 -

09

06 -Payout inyear 1

Payout Inyear 9 for coal $50ton - -- - - -shy

02 0 I

0 1 2 3 4 5 Nowl Yewr in which sauings in fWe colsacm-ewi tat hsawinitl

ca=al wosaand OampM costs

6

_iiM

7 8

9 10

------ - -amp -

11 12 13 14Year of Operation

--

15

- - --shy

16 17

I

18

1

19

I

20

I

21

I

22

I

23

I

24 25

Prefeasibility StudyOil Shale Fueled Power Generation

17958d351aJordanr 3-14-89 rsO

118

Comparison of Cumuiative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

28 Pay Out Year shy

400 MW Plant Oil Shale vs Imported Coal (5050 debtequity)

26shy2

24-

Cumulaive fuel nst savings for coal 0 $70ton Cumulative fuel cost savings for coal $50ton Cumulative Incremental capital plus OampM corts

22 -

20 -

18 -- Cumuladve net benefit for shle vs coal $50ton B Cumuarve net benefit for sale vs coal $70ton

16 -

C 14

12

10

08 -06 - Payout In year 1for coal $50ton

04

Payout Inyear 1

for coal $70ton02~

0 0

-No

02-

1 2

Yew inrY MCM cajlaI rl

3 4 5 6

sngm inW coas 0 ort hghWcentWin

0tOM cori

7

--

8

- -

9 10 11 12 13 14

Year of Operation

15 16 17

I

18

IIII

19 20 21 22 23 24 25

Preieasibility Study Oil Shale Fueled Power Generation

17958451 bJordarV118 3-14-89 rsipcI

Estimated Cost of Power- 400 MW (4 x 100)

FUEL

ImportedCoal

$50T

$70fT

1st Year

68 88

Levelized

78 107

Sultani Oil Shale

71 83

ImportedOil

$1713

$2413

56

67

76

96

0 10 20 30 40 50

I 60

I 70

I 80

I 90 100 110 120

Mills per kWh

Prefeasibility Study Oil Shale Fueled Power Generation

179581251 cJordarVl 18 3-14-89 rspc1

Summary Financial Analysis Results

Project size

Debt equity ratio

- Investment cost

- Power cost

- 25-year net benefit

- Project implementation

Alternative fuel price

Economic Comparison

Very significant

Not significant

Not significant

Very significant

Critical

Very significant

Prefeasibility Study

Oil Shale Fueled Power Generation

VY0 tDLUAi3

i

Study Conclusions

Feasibility

Timeliness

Expansion conditions

Environmental impacts

Development advantages

Prefeasibility Study

Oil Shale Fueled Power Generation VW41-1AiUA

4

Feasibility

Oil shale fueled power generation is technically and economically justifiedunder certain conditions

N Need for additional generating capacity

exists

- 6 annual peak demand growth - Orderly retirement of olderhigh cost

generating capacity needed

U Higher costs are expected for imported fuels

- 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

-OP b i j~~4shy

-4protntiYPe 4 demo plnt orP42 t~Plant orPootypeProje(-7hould

that Rj

demo 4Therefore-44 JEA anxinus

the

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

27Pag 4- 1 2S c i n 4 4

4i2Sectjo4-18-4 Secio 4-4 014

lt th~ae hi4h -tasisso syste thrug27 ~ 04lag arstl~art-p tasforme ed 2p27132Kvdieanwhy notthroug

EAto- is protmm~~ thegnJgt~~ pracie an ect ~ platqrby

28Pg 4 s heonnenotedto~the 32K rc powr

It not8 Scection rie049teoervnrain prctc de1

rh u n trae f2V3K anerd not throughgeterAntor

27 P3e-1r p ant weung-a

-If I

2tEll10 DRWE-jOi ASOt Mint~~al d~c~e o hepwrgnrto

ELCTRInYJORD UTHORITY-

Ate~

21Pge41 ection 4 04- 5

sindicated~ t hthigh the unit outputredu f hecondenser Injengtd~ibbvePressureed incg desrin hi h riseb vmbi nt emperatureWe bel~ieve

PleaIse provide us with th rscrapcity for th-e three options n nt generating~

21-Iisidca ted that~ thediaatgeofCBi theSheavy fn oe consumnptionPlease~ providethe us withpecntgA

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

400 MW COAL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO 5050

NET GENERATION - MWe 40000 CAPACITY FACTOR - 75 ANNUAL GENERATION MKWhYR 2628 SUB TOTAL PLANT COSTS (TPC) $1000 $620000

FIXED 0 amp M COSTS MH $ MH FIRST YEAR COST$1O00

------- --------- --- ---- --- --- ------------

OPERATING LABOR 351936 $3 $1100 MAINTENANCE LABOR 4000 of 150 OF TPC 3720

MAINTENANCE MATERIAL 6000

ADMIN LABOR of 150

3000 OF TPC

OF 0 amp M LABOR 5580 1446

SUB TOTAL FIXED OampM COSTS $11846

VARIABLE 0 amp M COSTS QUANTITY UNIT COST

VARIABLE MAINTENANCE 2628 MKWh 10 MILLKWH $ 2628 PROCESS WATER 13500000 GALLON 02 SGAL $ 2700 GENERAL PLANT CHEMICALS ALLOW 50 FUEL OIL 1000000 GALLON 035 $GAL $ 350 WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290SPECIAL BOILER MAINT ALLOW 0

SUB TOTAL VARIABLE OampM COSTS $ 8018

TOTAL FIXED amp VARIABLE OampM COSTS $19864 TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $8227 $TN $99139

(INCL INFLATION ADJUSTMENT)

B DEBT EQUITY RATIO =========== 8020

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $17574

WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290

TOTAL FIXED amp VARIABLE OampM COSTS $19864TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $5877 $TN $70814

(INCL INFLATION ADJUSTMENT)

6-21

Table 612 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY

400 MW OIL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO

NET GENERATION -

CAPACITY FACTOR -

ANNUAL GENERATION SUB TOTAL PLANT COSTS (TPC)

FIXED 0 amp M COSTS

OPERATING LABOR MAINTENANCE LABOR 4000 of

MAINTENANCE MATERIAL 6000 of

ADMIN LABOR

SUB TOTAL FIXED OampM COSTS

VARIABLE 0 amp M COSTS

VARIABLE MAINTENANCE PROCESS WATER GENERAL PLANT CHEMICALS FUEL OIL WASTE DISPOSAL (Section 6027) SPECIAL BOILER MAINT

SUB TOTAL VARIABLE OampM COSTS

5050

MWe

MKWhYR $1000

MH

262080

150

150 3000

QUANTITY

2628 MKWh 13500000 GALLON

1000000 GALLON 0 TNYR

TOTAL FIXED amp VARIABLE OampM COSTS FUEL OIL 503000 TNYR

B DEBT EQUITY RATIO =8020

40000 75

268 $443000

FIRST YEAR $ MH COST$1O00

$3 $ 800

OF TPC 2658

OF TPC 3987 OF 0 amp M LABOR 1037

$ 8482

UNIT COST

05 MILLKWH $ 1314 02 $GAL $ 2700

ALLOW 50 035 $GAL $ 350

$1000 $TN $ 0 ALLOW 0

$ 4414

$12896 $19981 $TN $100502

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $12896

WASTE DISPOSAL (Section 6027) 0 TNYR $1000 $TN $ 0

TOTAL FIXED amp VARIABLE OampM COSTS $12896 FUEL OIL 503000 TNYR $14104 $TN $70943

6-23

Page 22: fo; - pdf.usaid.gov

Sultani Oil Shale Reserves

North South Area Area Total

Mineable shale tonne x 106 320 658 978

Fischer assay oil content wt 744 761 765

Overburden m3 x 106 384 627 1011

Stripping ratio m3m3 2161 1711 1861

bull Based on NRA core drilling and core analysis

Prefeasibility Study Oil Shale Fueled Power Generation

VWO41OFEAMI14

i

Sultani Oil Shale Analyses

Moisture

Ash (less CO 2 in CaCO 3 )

CO 2 (in CaCO 3 )

Carbon (organic)

Hydrogen

Nitrogen

Sulfur

Oxygen (by diff)

Total

High heating value BtuIb

Fischer assay oil content

bull Percent by weight

Design Basis Fuel

320

6680

1387

1132

113

048

255

065

10000

2250

840

Low High Calorific Calorific

Value Fuel Value Fuel

320 320

6730 6625

1414 1337

1020 1250

102 125

058 038

238 271

118 034

10000 10000

2000 2500

750 925

Preteasibility Study Oil Shale Fueled Power Generation

vo0N d-GEAR 1S

50 MW Oil Shale ProcessingPrototype Plant

Mlne Plant

_ 14 0 Haul0___) to Plant 1 Sorage

Portable Crusher

(-)100 mm Storage

(-) 100 mm Hopper UIU 400 th

Feed Bin

J 50

250 tvb

8 -m Circulating Load Impact3or0 0 30 0 0shy+8mm25

30 0L Sampler 0 1 30 0

p3 Day Storage

To Power Plant

Preleasibility StudyOil Shale Fueled Power Generation

17958101 SaJordanli 18 3-14-89 rsipc1

20 MW Oil Shale Demonstration Plant

Mine Plant

Haul00- 01 o

= Pb n Storage Portable _

110 mm Stora e 0

()100 mm r Hopper

U 400V

Feed Bin

CirculatingLoad3 Day Stoge

Prefea~ltSudy Shale Fueled Power Generation

179S 111p 1 11Joda3 yl 3-202-89 8vk2

I

Mine and Shale ProcessingDesign - 2050 MW Project

I Overburden removal (north pit area) 10-meter benches

- Drill and blast

- 10 m3 front-end loader

- 77-ton truck haulage

I Oil shale mining 10-meter benches

- Rippe and auger scraper

- Front-end loader

- Portable in-pit crusher

- 77-ton truck haulage

Oil shale processing

- Feed = minus 100 mm

- Product = minus 8 mm

- Capacity = 250 tph

- Reversible impactor

- Two vibrating screens

1 Prefeasibility Study Oil Shale Fueled Power Generation

V -M 1AMI1ARt46

400 MW Full-Scale Oil Shale ProcessingPlant

Feed MTnus 200 mm Samplerr

1000 bull 10000 Tonnes Live Storage Grade

200 m long(-) 200 mm -- =-- Plow Feeders

00 h 100000 Tonnes Live Storage

Stream 3 - Sampler Bin Stream 2

Stream th 31Da2000

Circulating Load 2i

NFw Feed r -17000t1 170001l 170 t 17000 t 17000 t

1000 th Silo with 7 Impactor (-1)8 mm Reapro- 3 Day Storage at Aver age Loadn

0 20 Feeders 20 m Diameter by 40 m High

JJJTHT To Power Plant

Prefeasibility Study Oil Shale Fueled Power Generation

179589 6aJordarV 1I8 3-14-89 rsipc1

Mine and Shale ProcessingDesign - 4x100 MW Project

m Overburden removal (north area) 10-meter benches

- Drill and blast

- Three 20 m3 shovels

- 136-ton truck haulage

m Oil shale mining 10-meter benches

- Two mechanical surface miners

- 136-ton trucks to pit hopper

- Belt conveyor = 2000 tph

- Traveling stacker

m Oil shale processing

- Feed = minus 200 mm

- Product = minus 8 mm

- Capacity = three 1000 tph units

Prefeasibility Study Oil Shale Fueled Power Generation

VOO79-ampGEAIAt 17

i

Steady-State Production Schedule

Overburden removal bench m3

20 MW demo project 5n MW prototype 4x100 MW full-scale plant

Oil shale mining and shale processing tonnes

20 MW project 50 MW project 4x100 MW project

HourlyDesign Capacity

282 234

1850

HourlyDesign Capacity

250 250

2000

Avg Daily Annual PEQuctiQa Production

1690 507000 4217 13 million

33333 10 million

Max Daily(a) Annual(b) Production Production

1733 390000 4324 973000

34578 78 million

(a) Based on 100 operating factor for power block

(b) Based on 75 operating factor for power block ( 20 MW project = 300 shiftsyr 50 MW project = 900 shiftsyr 400 MW project = 900 shiftsyr)

Prefeasibility Study Oil Shale Fueled Power Generation

Conceptual Power Plant Plans

m Pyroflow boiler

Power generating facilities

m Auxiliaries

S Preleasibility Study Oil ShaJe Fueled Power Generation

vo0o7dEAO 19

Pyroflow Boiler SteamConciflons

Flow rate 226700 kghr (500000 Ibhr)

Pressure 1099 kgcm2 abs (15635 psia)

Temperature 51280C (9550F)

Same for 20 50 and 100 MW designs

Prefeasibility Study Oil ShaJe Fueled Power Generation

vooGALMI 20

HtomCOPUIOTP

- 50005 5op

-- LEVAThUM ORPORAION

0

-VI

DZ 4

Power Block

Fuel handling system

- Day binsscrew feeders

Boiler

- Pyroflow circulating fluid bed combustor

Power generation

- Non reheat condensing steam turbine

- Conventional Rankin steam cycle

Ash handling system (btm ash irom combustor and flyash from bag house)

- Wetted in pug mill to add 20plusmn wt wpter

Plant service water

- Air-cooled condensors and small cooling tower from circulating trim water coolers

Plant raw water

- To cooling tower makeup

- To drinking water system

- To pump seals etc

Plant treated makeup water

- Demineralizer train

Preteasibility Study Oil Shale Fueled Power Generation

i

Onsite Infrastructure

Project office

Control house

U Maintenance shops warehouse

Laboratory

Employee service facility

Site developmentoperations service facilities

- Fire controlsecurity

- Communications

- Lighting

- Roads drainage and sewage

Prefeasibility StudyQ1I Shale Fueled Power Generation

voo4JG m 0 JV

i

BechtellPyropower50 MW Cogeneration Plant - Mt Poso California

W4t Prefeasibility Study --- 7 Oil Shale Fueled Power Generation

179586122aJordarv 118 3-14-89 rsO

Characteristics of Three Size Operations

Oil shale fuel tpy

Mine development excavation bank m3

Spent ash disposal tpy (wetted)

Water consumption 1000 m3yr

Staffing required

Community population

400 MW

20 MW 50 MW (4x1 00)

390000 973000 78 million

500000 1 million 85 million

327000 815000 61 million

538 907 1263

185 324 1046

700 1200 4000

Prefeasibility Study Oil Shale Fueled Power Generation

V000ofllAM1 23

Conceptual Designs Summary

N All BOP facilities involve conventional equipment and technology

100 MW unit operation involves boiler scale-up considerations

N Water consumption estimates

- Requirement for 4x100 MW project is 13 million m3 yr

- Water allocation of 2 million m3yr of water supports 6x100 MW

N Water availability probably limits total power generation from oil shale in Jordan

Prefeasibility Study Oil Shale Fueled Power Generation

V007041GEAOLMI

i

TECHNOLOGY RISK ASSESSMENT

Basic concepts

Key boiler scale-up design issues

Impact of scale-up

U Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Prefeasibility Study O1 Shale Fueled Power Generation

VOOh-7AEAAO 2

Basic Concepts

U CFBC is relatively new in the powerindustry

- Existing plants are small typically 20 to 50 MW

- There is limited operating experience with high-ash fuels

- Existing designs for lignite biomass and coal wastes show good plant performance

I Application of CFBC boiler design to oil shale fuel has defined risk that relates to scale-up of existing design

Similar CFBC technology is used in petroleum refining industry

- FCC cracking plant regenerators burn carbon residue off spent catalyst

- 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

FUEL ANALYSES

High Ash Fuel Projects Total Solids Input Basis

Gilberton Cambria North Branch

Carbon 4653 2749 1822 Hydrogen 153 164 160 Sulfur 073 222 234 Nitrogen 085 051 043 Oxygen 282 218 468 Moisture 1451 514 557 Ash 3303 6 0 6Z16

10000 10000 10000

HHVBtulb 7485 4809 3453

includes limestone feed a3 ash

includes CO2 in Ca~o3

CA89029 CAkw

Oil Shale

1132

113

255

048

065

320

-8062

10000

2250

Key Boiler Scale-Up DesignIssues

m Solids handling

- Feeding shale to combustor

- 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

Voo4tGEAMI 30

i

Mine and Shale Processing

U Fugitive dust emissions are controllable

- Wetting mine roads

- Enclose crushing plant equipment

Noise levels are controllable

- Enclose crushing plant equipment - Muffle truck exhausts

- Engineered waste disposal

Water effluents can be controlled

- Need good mine drainage design - Continue leachability studies on

waste dump piles

Prefeasibilily StudyOil Shale Fueled Po r Generaton

V0079OOG-4O 31

1

Power Plant

II Fugitive dust emissions are controllable

- Baghouse designoperation will minimize particulates in flue gas

- Wetting spent ash before disposal

N Gaseous emissions are controllable

- Pilot test results show acceptable SO2NOxCO in flue gas

- Develop baseline data for Sultani area

Develop air dispersion model for Sultani

Prefeasibility StudyOil Shale Fueled Power Generatio

V00 V-4GEA l32

i

Power Plant (Contd)

Noise levels are controllable

- Enclose boiler plant fans as required - Enclose turbines and pumps as

required

Water effluents are controllable

- Continue leachability studies on spent ash disposal

- Develop aquifer dispersion model

- Develop sewage and garbage disposal plan

Prefeasibility SludyOil Shale Fueled Power Generation

V00-4FAAI 33

Conclusions

No environmental constraints are anticipated on oil shale powerdevelopment

Gas effluents will meet World Bank standards

- Ash disposal is manageable

- The potential for groundwatercontamination appears low

- Water effluents will be minimal

Continued studies to develop air and groundwater baseline data are recommended

S Prefeasibility Study Oil Shale Fueled Power Generation

v0 9ampGLAMR 34

Power Demand vs SupplyAssessment

m Demand growth forecasts

Electrical generating capacity

= Power supply forecasts

= Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Preleasibility Study Oil Shaie Fuelod Power Generation

VO9- uLIROI

1

Power Demand Forecasts

Percent Annual Growth

JEA

Meta systems HaglerBailey and Bechtel National Inc

JEA Peak Demand Growth

1980 (actual) 1985 (actual) 1987 (actual) 1995 (forecast) 2005 (forecast)

1986 1990 to to

1990 2000

97 60

49 39

200 MW 475 MW 593 MW 900 MW

1400 MW

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOO-DLURO2

i

JEA ElectricityGeneratingCapacity

1987 Installed

Capacity (MW) Aqaba 260

22

Zarqa 395

Marka 102

Karak 23

Miscellaneous 67

Subtotal JEA capacity 869

Other capacity - industrial 110

Total 979

Prefeasibility Study Oi1 Shale Fueled Power Generation

V000-6O0LFJRO3 (

Forecast New Power Generating Capacity Required

Fcst 1987 Required

New Peak Available Installed

Demand Capacity Shortfall (a) Capacity (b) (MM (MW) (MW) (MW)

Assumed capacityfactor (65) (75)

1995 requirement 900 636 264 352

2005 requirement 1400 636 764 1019

(a) Excludes proposed additions and retirements (b) Excludes possible power exports or imports

Load shedding or levelizing not considered

Preteasibility Study Oil Shale Fueled Power Generation

Vflcmf-R)LLAO4

i

Supply vs Demand Evaluation

1800

1600

1400 Forecast Peak Demands

1200 -

E Installed Capacity

0 800shy75--

U) Assumed Available Calcit

a 6 Ao600 shy0 o 65

400 shy

200

I I I I I I I I I I I I I I I I I I I I I I I 1 1 1980 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958f738aIJordarV 118 3-14-89 rspCO

Conclusions

Additional power generating capacity is needed to meet forecasted 19952005demand growth

A 400 MW oil shale-to-power project at Sultani can meet a portion of this need

U A second 400 MW oil shale project maybe required if water is available

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOW0O-8LURO5

i

Economic Feasibility

N Order-of-magnitude costs

N Economic analysis

- Jordan study options

- Project size effect

m Comparison with alternative fuels

- Fuel requirement

- Project financing effect

- Alternate fuel price effect

- Estimated cost of electricity

N Summary financial analysis

bull Material was developed by Bechtel Power Company

Prefeasibility Study

go Oil Shale Fueled Power Generation VOOSO-ampDtJROh

ORDER-OF-MAGNITUDE COSTS

U Oil shale fuel

Power plant

I Integrated project- busbar

Preteasibility Study

Oil Shale Fueled Power Generation

VOO9O-ampDLUROS

Oil Shale Fuel Costs

Installed Capital Cost

Mine Development

Mine Equipment

Processing Plant

Spare Parts

Working Capital

Capitalized Interest

Total

Annual Operating Cost

Fuel Cost $UStonne

bull Based on 8020 debtequity ratio

20 MW

4900

11090

6945

1200

1200

4054

29389

5582

1431

US $1000 Factored

50 MW 4x100 MW

7833 30915

12202 66012

8388 50889

1300 5000

2200 10000

5108 39075

37031 201891

11556 53236

1188 684

Prefeasibility Study

Oil Shale Fueled Power Generation

VCO-ampDLUJ1O

Power Plant Costs

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Cost

Power faciities 57500 91800 567800

Owners cost 10200 20400 192700

Total 67700 112200 760500

Annual Operating Cost 2205 3248 17157(excluding fuel cost)

bullBased on 8020 debtequity ratio oil shale fueled

Prefeasibility Study

Oil Shale Fueled Power Generation

V00O8c4LLMO9

i

INTEGRATED PROJECT -BUSBAR COST

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Costs Mine amp shale processingPower block Waste disposal Infrastructure

29359 67700

1664 10000

37031 112200

2381 15000

201891 760500

8714 45000

TOTAL 108753 166612 1016105

Annual Operating Cost Mine amp shale processingPower block Waste disposal Infrastructure (a)

5582 2205

316

11556 3248

710

56430(b) 18186(b) 6004

Subtotal 8103 15514 80620

Capital Charges 139 9410 15596 106000

Total 17513 31110 186620

25-year levelized cost - - 218000

Busbar Cost millskWh First year 128 92 71 25-year levelized 83

(a) Housing and community facilities assumed self-liquidating(b) Includes first-year inflation adjustment

Based on 8020 debtequity ratio

Prefeasibility StudyOil Shale Fueled Power Generaion

VOOOO-8MLtROi0

ECONOMIC ANALYSIS

n Jordan study options

Project size effect

Fuel requirement

Project financing effect

Alternative fuel price effect

Estimated electricity cost

Summary financial analysis results

Prefeasibility Study

Oil Shale Fueled Powr Generation

VOOeO-BOCLLO1 I

i

Jordan Study Options

U Project size

- Demonstration = 20 MW

- Prototype = 50 MW

- Commercial = 400 MW (4x100)

Project financing

- Debtequity 8020

- Debtequity 5050

Imported alternative fuels cost assumptions

A B Crude oil $17bbl $24bbl

$120onne $170tonne

Low sulfur coal $ 50tonne $ 70tonne See Chevron forecast supporting assumptions

Prefeasibility StudyOil Shale Fueled Power Generation

VOOOO-8DLIJRO12

i

Crude Oil Price Trends

60

Source World Energy Outlook Chevron Corporation Oclober 1987

40

High trend

No Ir 20 ~~~~Arabian Light Spot I A u

IILowYUII trend

0 1970 1975 1980 1985 1990 1995

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958246aJodar 118 3-14-89 rsO

2000

Project Size Effect Shale Fuel Option

Project Size

Integrated facilities installed capital cost$ US million

Shale cost $UStonne(8020 debtequity)

Cost of power millskWh(8020 debtequity ratio)

20 MW

109

143

128

50 MW

167

118

92

400 MW (4x1 00)

1016

68

71

Prefeasibility Study Oil Sampae Fueled Power Generation

VOO O-8I0LJRO13

gt1

1

Power Block Investment Cost

3000

$2875 Excluding mining and offsite 2800

2600

2400

2200

2000

$1836 1800

$1613 1600

$1420 1400 1I 1 I

0 100 200 300 400 MWe

August 1988

Preleasibility Study OilShale Fueled Power Generation

179581147aJodar1 18 3-14-89 rspcl

Fuel Requirement - 4x100 MW Project

Coal = 12 million tpy

n Oil = 503000 tpy

Oil shale = 78 million tpy

Preleasibility Study

Oil Shale Fueled Power Generation

IO060-OLLIRO14

Financing Effect -Project

Oil Shale Fuel Option

Mine and shale processing

Power block

Waste disposal

Community facilities

Total

Coal-Fired Power Plant

Oil-Fired Power Plant

400 MW

Capital Cost ($US MM)

DebtEquity

8020 5050

202 187

760 760

9 8

45 45

1016 1000

647 647

463 463

Prefeasibility StudyOil Shale Fueled Power Generation

VOe-BD1JRO15

Financing Effect shy400 MW Project

Operating Costs ($US millionyr)

DebtEquity

8020 5050

Coal $70tonne 282 282

Oil $24bbl 254 254

Oil shale-fueled 218 236

Including fuel

Prefeasibility Study

SOil Shale Fueled Power Generaion

VOOIt JLMO I

Alternate Fuel Price Effect shy4x100 MW Project

Financing Basis DebtEquity Ratio

Alternate Fuel Price

Imported coal $50tonne $70tonne

Imported oil $17bbl ($120tonne) $24bbl ($170tonne)

Cumulative 25-yr Net Benefit

Favoring Oil Shale (US $MM) shy

8020 5050

778 315 2531 2068

(18) (506)1810 1322

Prefeasibility Study

Oil Shale Fueled Power Generation

Voo -I DLU-A 2

i

Comparison of Cumulative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

32 Pay Out Year shy

400 MW PlantOil Shale vs Imported Coal (8020 debtequty)

30

28 -Cumulative fuel cost savings forcoal $70ton

Cumulative fuel cost savings for coaJ $50ton

26---------- Cumulative Incremental capital plus OampM costs

24

22 -

18 -0

W- Cumulative net benefit for shae vs coal $50ton 2B Cumulative net benefit for shale vs coal $70ton

co16C -

14 -

12 -

10 -

09

06 -Payout inyear 1

Payout Inyear 9 for coal $50ton - -- - - -shy

02 0 I

0 1 2 3 4 5 Nowl Yewr in which sauings in fWe colsacm-ewi tat hsawinitl

ca=al wosaand OampM costs

6

_iiM

7 8

9 10

------ - -amp -

11 12 13 14Year of Operation

--

15

- - --shy

16 17

I

18

1

19

I

20

I

21

I

22

I

23

I

24 25

Prefeasibility StudyOil Shale Fueled Power Generation

17958d351aJordanr 3-14-89 rsO

118

Comparison of Cumuiative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

28 Pay Out Year shy

400 MW Plant Oil Shale vs Imported Coal (5050 debtequity)

26shy2

24-

Cumulaive fuel nst savings for coal 0 $70ton Cumulative fuel cost savings for coal $50ton Cumulative Incremental capital plus OampM corts

22 -

20 -

18 -- Cumuladve net benefit for shle vs coal $50ton B Cumuarve net benefit for sale vs coal $70ton

16 -

C 14

12

10

08 -06 - Payout In year 1for coal $50ton

04

Payout Inyear 1

for coal $70ton02~

0 0

-No

02-

1 2

Yew inrY MCM cajlaI rl

3 4 5 6

sngm inW coas 0 ort hghWcentWin

0tOM cori

7

--

8

- -

9 10 11 12 13 14

Year of Operation

15 16 17

I

18

IIII

19 20 21 22 23 24 25

Preieasibility Study Oil Shale Fueled Power Generation

17958451 bJordarV118 3-14-89 rsipcI

Estimated Cost of Power- 400 MW (4 x 100)

FUEL

ImportedCoal

$50T

$70fT

1st Year

68 88

Levelized

78 107

Sultani Oil Shale

71 83

ImportedOil

$1713

$2413

56

67

76

96

0 10 20 30 40 50

I 60

I 70

I 80

I 90 100 110 120

Mills per kWh

Prefeasibility Study Oil Shale Fueled Power Generation

179581251 cJordarVl 18 3-14-89 rspc1

Summary Financial Analysis Results

Project size

Debt equity ratio

- Investment cost

- Power cost

- 25-year net benefit

- Project implementation

Alternative fuel price

Economic Comparison

Very significant

Not significant

Not significant

Very significant

Critical

Very significant

Prefeasibility Study

Oil Shale Fueled Power Generation

VY0 tDLUAi3

i

Study Conclusions

Feasibility

Timeliness

Expansion conditions

Environmental impacts

Development advantages

Prefeasibility Study

Oil Shale Fueled Power Generation VW41-1AiUA

4

Feasibility

Oil shale fueled power generation is technically and economically justifiedunder certain conditions

N Need for additional generating capacity

exists

- 6 annual peak demand growth - Orderly retirement of olderhigh cost

generating capacity needed

U Higher costs are expected for imported fuels

- 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

-OP b i j~~4shy

-4protntiYPe 4 demo plnt orP42 t~Plant orPootypeProje(-7hould

that Rj

demo 4Therefore-44 JEA anxinus

the

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

27Pag 4- 1 2S c i n 4 4

4i2Sectjo4-18-4 Secio 4-4 014

lt th~ae hi4h -tasisso syste thrug27 ~ 04lag arstl~art-p tasforme ed 2p27132Kvdieanwhy notthroug

EAto- is protmm~~ thegnJgt~~ pracie an ect ~ platqrby

28Pg 4 s heonnenotedto~the 32K rc powr

It not8 Scection rie049teoervnrain prctc de1

rh u n trae f2V3K anerd not throughgeterAntor

27 P3e-1r p ant weung-a

-If I

2tEll10 DRWE-jOi ASOt Mint~~al d~c~e o hepwrgnrto

ELCTRInYJORD UTHORITY-

Ate~

21Pge41 ection 4 04- 5

sindicated~ t hthigh the unit outputredu f hecondenser Injengtd~ibbvePressureed incg desrin hi h riseb vmbi nt emperatureWe bel~ieve

PleaIse provide us with th rscrapcity for th-e three options n nt generating~

21-Iisidca ted that~ thediaatgeofCBi theSheavy fn oe consumnptionPlease~ providethe us withpecntgA

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

400 MW COAL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO 5050

NET GENERATION - MWe 40000 CAPACITY FACTOR - 75 ANNUAL GENERATION MKWhYR 2628 SUB TOTAL PLANT COSTS (TPC) $1000 $620000

FIXED 0 amp M COSTS MH $ MH FIRST YEAR COST$1O00

------- --------- --- ---- --- --- ------------

OPERATING LABOR 351936 $3 $1100 MAINTENANCE LABOR 4000 of 150 OF TPC 3720

MAINTENANCE MATERIAL 6000

ADMIN LABOR of 150

3000 OF TPC

OF 0 amp M LABOR 5580 1446

SUB TOTAL FIXED OampM COSTS $11846

VARIABLE 0 amp M COSTS QUANTITY UNIT COST

VARIABLE MAINTENANCE 2628 MKWh 10 MILLKWH $ 2628 PROCESS WATER 13500000 GALLON 02 SGAL $ 2700 GENERAL PLANT CHEMICALS ALLOW 50 FUEL OIL 1000000 GALLON 035 $GAL $ 350 WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290SPECIAL BOILER MAINT ALLOW 0

SUB TOTAL VARIABLE OampM COSTS $ 8018

TOTAL FIXED amp VARIABLE OampM COSTS $19864 TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $8227 $TN $99139

(INCL INFLATION ADJUSTMENT)

B DEBT EQUITY RATIO =========== 8020

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $17574

WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290

TOTAL FIXED amp VARIABLE OampM COSTS $19864TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $5877 $TN $70814

(INCL INFLATION ADJUSTMENT)

6-21

Table 612 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY

400 MW OIL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO

NET GENERATION -

CAPACITY FACTOR -

ANNUAL GENERATION SUB TOTAL PLANT COSTS (TPC)

FIXED 0 amp M COSTS

OPERATING LABOR MAINTENANCE LABOR 4000 of

MAINTENANCE MATERIAL 6000 of

ADMIN LABOR

SUB TOTAL FIXED OampM COSTS

VARIABLE 0 amp M COSTS

VARIABLE MAINTENANCE PROCESS WATER GENERAL PLANT CHEMICALS FUEL OIL WASTE DISPOSAL (Section 6027) SPECIAL BOILER MAINT

SUB TOTAL VARIABLE OampM COSTS

5050

MWe

MKWhYR $1000

MH

262080

150

150 3000

QUANTITY

2628 MKWh 13500000 GALLON

1000000 GALLON 0 TNYR

TOTAL FIXED amp VARIABLE OampM COSTS FUEL OIL 503000 TNYR

B DEBT EQUITY RATIO =8020

40000 75

268 $443000

FIRST YEAR $ MH COST$1O00

$3 $ 800

OF TPC 2658

OF TPC 3987 OF 0 amp M LABOR 1037

$ 8482

UNIT COST

05 MILLKWH $ 1314 02 $GAL $ 2700

ALLOW 50 035 $GAL $ 350

$1000 $TN $ 0 ALLOW 0

$ 4414

$12896 $19981 $TN $100502

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $12896

WASTE DISPOSAL (Section 6027) 0 TNYR $1000 $TN $ 0

TOTAL FIXED amp VARIABLE OampM COSTS $12896 FUEL OIL 503000 TNYR $14104 $TN $70943

6-23

Page 23: fo; - pdf.usaid.gov

Sultani Oil Shale Analyses

Moisture

Ash (less CO 2 in CaCO 3 )

CO 2 (in CaCO 3 )

Carbon (organic)

Hydrogen

Nitrogen

Sulfur

Oxygen (by diff)

Total

High heating value BtuIb

Fischer assay oil content

bull Percent by weight

Design Basis Fuel

320

6680

1387

1132

113

048

255

065

10000

2250

840

Low High Calorific Calorific

Value Fuel Value Fuel

320 320

6730 6625

1414 1337

1020 1250

102 125

058 038

238 271

118 034

10000 10000

2000 2500

750 925

Preteasibility Study Oil Shale Fueled Power Generation

vo0N d-GEAR 1S

50 MW Oil Shale ProcessingPrototype Plant

Mlne Plant

_ 14 0 Haul0___) to Plant 1 Sorage

Portable Crusher

(-)100 mm Storage

(-) 100 mm Hopper UIU 400 th

Feed Bin

J 50

250 tvb

8 -m Circulating Load Impact3or0 0 30 0 0shy+8mm25

30 0L Sampler 0 1 30 0

p3 Day Storage

To Power Plant

Preleasibility StudyOil Shale Fueled Power Generation

17958101 SaJordanli 18 3-14-89 rsipc1

20 MW Oil Shale Demonstration Plant

Mine Plant

Haul00- 01 o

= Pb n Storage Portable _

110 mm Stora e 0

()100 mm r Hopper

U 400V

Feed Bin

CirculatingLoad3 Day Stoge

Prefea~ltSudy Shale Fueled Power Generation

179S 111p 1 11Joda3 yl 3-202-89 8vk2

I

Mine and Shale ProcessingDesign - 2050 MW Project

I Overburden removal (north pit area) 10-meter benches

- Drill and blast

- 10 m3 front-end loader

- 77-ton truck haulage

I Oil shale mining 10-meter benches

- Rippe and auger scraper

- Front-end loader

- Portable in-pit crusher

- 77-ton truck haulage

Oil shale processing

- Feed = minus 100 mm

- Product = minus 8 mm

- Capacity = 250 tph

- Reversible impactor

- Two vibrating screens

1 Prefeasibility Study Oil Shale Fueled Power Generation

V -M 1AMI1ARt46

400 MW Full-Scale Oil Shale ProcessingPlant

Feed MTnus 200 mm Samplerr

1000 bull 10000 Tonnes Live Storage Grade

200 m long(-) 200 mm -- =-- Plow Feeders

00 h 100000 Tonnes Live Storage

Stream 3 - Sampler Bin Stream 2

Stream th 31Da2000

Circulating Load 2i

NFw Feed r -17000t1 170001l 170 t 17000 t 17000 t

1000 th Silo with 7 Impactor (-1)8 mm Reapro- 3 Day Storage at Aver age Loadn

0 20 Feeders 20 m Diameter by 40 m High

JJJTHT To Power Plant

Prefeasibility Study Oil Shale Fueled Power Generation

179589 6aJordarV 1I8 3-14-89 rsipc1

Mine and Shale ProcessingDesign - 4x100 MW Project

m Overburden removal (north area) 10-meter benches

- Drill and blast

- Three 20 m3 shovels

- 136-ton truck haulage

m Oil shale mining 10-meter benches

- Two mechanical surface miners

- 136-ton trucks to pit hopper

- Belt conveyor = 2000 tph

- Traveling stacker

m Oil shale processing

- Feed = minus 200 mm

- Product = minus 8 mm

- Capacity = three 1000 tph units

Prefeasibility Study Oil Shale Fueled Power Generation

VOO79-ampGEAIAt 17

i

Steady-State Production Schedule

Overburden removal bench m3

20 MW demo project 5n MW prototype 4x100 MW full-scale plant

Oil shale mining and shale processing tonnes

20 MW project 50 MW project 4x100 MW project

HourlyDesign Capacity

282 234

1850

HourlyDesign Capacity

250 250

2000

Avg Daily Annual PEQuctiQa Production

1690 507000 4217 13 million

33333 10 million

Max Daily(a) Annual(b) Production Production

1733 390000 4324 973000

34578 78 million

(a) Based on 100 operating factor for power block

(b) Based on 75 operating factor for power block ( 20 MW project = 300 shiftsyr 50 MW project = 900 shiftsyr 400 MW project = 900 shiftsyr)

Prefeasibility Study Oil Shale Fueled Power Generation

Conceptual Power Plant Plans

m Pyroflow boiler

Power generating facilities

m Auxiliaries

S Preleasibility Study Oil ShaJe Fueled Power Generation

vo0o7dEAO 19

Pyroflow Boiler SteamConciflons

Flow rate 226700 kghr (500000 Ibhr)

Pressure 1099 kgcm2 abs (15635 psia)

Temperature 51280C (9550F)

Same for 20 50 and 100 MW designs

Prefeasibility Study Oil ShaJe Fueled Power Generation

vooGALMI 20

HtomCOPUIOTP

- 50005 5op

-- LEVAThUM ORPORAION

0

-VI

DZ 4

Power Block

Fuel handling system

- Day binsscrew feeders

Boiler

- Pyroflow circulating fluid bed combustor

Power generation

- Non reheat condensing steam turbine

- Conventional Rankin steam cycle

Ash handling system (btm ash irom combustor and flyash from bag house)

- Wetted in pug mill to add 20plusmn wt wpter

Plant service water

- Air-cooled condensors and small cooling tower from circulating trim water coolers

Plant raw water

- To cooling tower makeup

- To drinking water system

- To pump seals etc

Plant treated makeup water

- Demineralizer train

Preteasibility Study Oil Shale Fueled Power Generation

i

Onsite Infrastructure

Project office

Control house

U Maintenance shops warehouse

Laboratory

Employee service facility

Site developmentoperations service facilities

- Fire controlsecurity

- Communications

- Lighting

- Roads drainage and sewage

Prefeasibility StudyQ1I Shale Fueled Power Generation

voo4JG m 0 JV

i

BechtellPyropower50 MW Cogeneration Plant - Mt Poso California

W4t Prefeasibility Study --- 7 Oil Shale Fueled Power Generation

179586122aJordarv 118 3-14-89 rsO

Characteristics of Three Size Operations

Oil shale fuel tpy

Mine development excavation bank m3

Spent ash disposal tpy (wetted)

Water consumption 1000 m3yr

Staffing required

Community population

400 MW

20 MW 50 MW (4x1 00)

390000 973000 78 million

500000 1 million 85 million

327000 815000 61 million

538 907 1263

185 324 1046

700 1200 4000

Prefeasibility Study Oil Shale Fueled Power Generation

V000ofllAM1 23

Conceptual Designs Summary

N All BOP facilities involve conventional equipment and technology

100 MW unit operation involves boiler scale-up considerations

N Water consumption estimates

- Requirement for 4x100 MW project is 13 million m3 yr

- Water allocation of 2 million m3yr of water supports 6x100 MW

N Water availability probably limits total power generation from oil shale in Jordan

Prefeasibility Study Oil Shale Fueled Power Generation

V007041GEAOLMI

i

TECHNOLOGY RISK ASSESSMENT

Basic concepts

Key boiler scale-up design issues

Impact of scale-up

U Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Prefeasibility Study O1 Shale Fueled Power Generation

VOOh-7AEAAO 2

Basic Concepts

U CFBC is relatively new in the powerindustry

- Existing plants are small typically 20 to 50 MW

- There is limited operating experience with high-ash fuels

- Existing designs for lignite biomass and coal wastes show good plant performance

I Application of CFBC boiler design to oil shale fuel has defined risk that relates to scale-up of existing design

Similar CFBC technology is used in petroleum refining industry

- FCC cracking plant regenerators burn carbon residue off spent catalyst

- 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

FUEL ANALYSES

High Ash Fuel Projects Total Solids Input Basis

Gilberton Cambria North Branch

Carbon 4653 2749 1822 Hydrogen 153 164 160 Sulfur 073 222 234 Nitrogen 085 051 043 Oxygen 282 218 468 Moisture 1451 514 557 Ash 3303 6 0 6Z16

10000 10000 10000

HHVBtulb 7485 4809 3453

includes limestone feed a3 ash

includes CO2 in Ca~o3

CA89029 CAkw

Oil Shale

1132

113

255

048

065

320

-8062

10000

2250

Key Boiler Scale-Up DesignIssues

m Solids handling

- Feeding shale to combustor

- 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

Voo4tGEAMI 30

i

Mine and Shale Processing

U Fugitive dust emissions are controllable

- Wetting mine roads

- Enclose crushing plant equipment

Noise levels are controllable

- Enclose crushing plant equipment - Muffle truck exhausts

- Engineered waste disposal

Water effluents can be controlled

- Need good mine drainage design - Continue leachability studies on

waste dump piles

Prefeasibilily StudyOil Shale Fueled Po r Generaton

V0079OOG-4O 31

1

Power Plant

II Fugitive dust emissions are controllable

- Baghouse designoperation will minimize particulates in flue gas

- Wetting spent ash before disposal

N Gaseous emissions are controllable

- Pilot test results show acceptable SO2NOxCO in flue gas

- Develop baseline data for Sultani area

Develop air dispersion model for Sultani

Prefeasibility StudyOil Shale Fueled Power Generatio

V00 V-4GEA l32

i

Power Plant (Contd)

Noise levels are controllable

- Enclose boiler plant fans as required - Enclose turbines and pumps as

required

Water effluents are controllable

- Continue leachability studies on spent ash disposal

- Develop aquifer dispersion model

- Develop sewage and garbage disposal plan

Prefeasibility SludyOil Shale Fueled Power Generation

V00-4FAAI 33

Conclusions

No environmental constraints are anticipated on oil shale powerdevelopment

Gas effluents will meet World Bank standards

- Ash disposal is manageable

- The potential for groundwatercontamination appears low

- Water effluents will be minimal

Continued studies to develop air and groundwater baseline data are recommended

S Prefeasibility Study Oil Shale Fueled Power Generation

v0 9ampGLAMR 34

Power Demand vs SupplyAssessment

m Demand growth forecasts

Electrical generating capacity

= Power supply forecasts

= Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Preleasibility Study Oil Shaie Fuelod Power Generation

VO9- uLIROI

1

Power Demand Forecasts

Percent Annual Growth

JEA

Meta systems HaglerBailey and Bechtel National Inc

JEA Peak Demand Growth

1980 (actual) 1985 (actual) 1987 (actual) 1995 (forecast) 2005 (forecast)

1986 1990 to to

1990 2000

97 60

49 39

200 MW 475 MW 593 MW 900 MW

1400 MW

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOO-DLURO2

i

JEA ElectricityGeneratingCapacity

1987 Installed

Capacity (MW) Aqaba 260

22

Zarqa 395

Marka 102

Karak 23

Miscellaneous 67

Subtotal JEA capacity 869

Other capacity - industrial 110

Total 979

Prefeasibility Study Oi1 Shale Fueled Power Generation

V000-6O0LFJRO3 (

Forecast New Power Generating Capacity Required

Fcst 1987 Required

New Peak Available Installed

Demand Capacity Shortfall (a) Capacity (b) (MM (MW) (MW) (MW)

Assumed capacityfactor (65) (75)

1995 requirement 900 636 264 352

2005 requirement 1400 636 764 1019

(a) Excludes proposed additions and retirements (b) Excludes possible power exports or imports

Load shedding or levelizing not considered

Preteasibility Study Oil Shale Fueled Power Generation

Vflcmf-R)LLAO4

i

Supply vs Demand Evaluation

1800

1600

1400 Forecast Peak Demands

1200 -

E Installed Capacity

0 800shy75--

U) Assumed Available Calcit

a 6 Ao600 shy0 o 65

400 shy

200

I I I I I I I I I I I I I I I I I I I I I I I 1 1 1980 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958f738aIJordarV 118 3-14-89 rspCO

Conclusions

Additional power generating capacity is needed to meet forecasted 19952005demand growth

A 400 MW oil shale-to-power project at Sultani can meet a portion of this need

U A second 400 MW oil shale project maybe required if water is available

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOW0O-8LURO5

i

Economic Feasibility

N Order-of-magnitude costs

N Economic analysis

- Jordan study options

- Project size effect

m Comparison with alternative fuels

- Fuel requirement

- Project financing effect

- Alternate fuel price effect

- Estimated cost of electricity

N Summary financial analysis

bull Material was developed by Bechtel Power Company

Prefeasibility Study

go Oil Shale Fueled Power Generation VOOSO-ampDtJROh

ORDER-OF-MAGNITUDE COSTS

U Oil shale fuel

Power plant

I Integrated project- busbar

Preteasibility Study

Oil Shale Fueled Power Generation

VOO9O-ampDLUROS

Oil Shale Fuel Costs

Installed Capital Cost

Mine Development

Mine Equipment

Processing Plant

Spare Parts

Working Capital

Capitalized Interest

Total

Annual Operating Cost

Fuel Cost $UStonne

bull Based on 8020 debtequity ratio

20 MW

4900

11090

6945

1200

1200

4054

29389

5582

1431

US $1000 Factored

50 MW 4x100 MW

7833 30915

12202 66012

8388 50889

1300 5000

2200 10000

5108 39075

37031 201891

11556 53236

1188 684

Prefeasibility Study

Oil Shale Fueled Power Generation

VCO-ampDLUJ1O

Power Plant Costs

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Cost

Power faciities 57500 91800 567800

Owners cost 10200 20400 192700

Total 67700 112200 760500

Annual Operating Cost 2205 3248 17157(excluding fuel cost)

bullBased on 8020 debtequity ratio oil shale fueled

Prefeasibility Study

Oil Shale Fueled Power Generation

V00O8c4LLMO9

i

INTEGRATED PROJECT -BUSBAR COST

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Costs Mine amp shale processingPower block Waste disposal Infrastructure

29359 67700

1664 10000

37031 112200

2381 15000

201891 760500

8714 45000

TOTAL 108753 166612 1016105

Annual Operating Cost Mine amp shale processingPower block Waste disposal Infrastructure (a)

5582 2205

316

11556 3248

710

56430(b) 18186(b) 6004

Subtotal 8103 15514 80620

Capital Charges 139 9410 15596 106000

Total 17513 31110 186620

25-year levelized cost - - 218000

Busbar Cost millskWh First year 128 92 71 25-year levelized 83

(a) Housing and community facilities assumed self-liquidating(b) Includes first-year inflation adjustment

Based on 8020 debtequity ratio

Prefeasibility StudyOil Shale Fueled Power Generaion

VOOOO-8MLtROi0

ECONOMIC ANALYSIS

n Jordan study options

Project size effect

Fuel requirement

Project financing effect

Alternative fuel price effect

Estimated electricity cost

Summary financial analysis results

Prefeasibility Study

Oil Shale Fueled Powr Generation

VOOeO-BOCLLO1 I

i

Jordan Study Options

U Project size

- Demonstration = 20 MW

- Prototype = 50 MW

- Commercial = 400 MW (4x100)

Project financing

- Debtequity 8020

- Debtequity 5050

Imported alternative fuels cost assumptions

A B Crude oil $17bbl $24bbl

$120onne $170tonne

Low sulfur coal $ 50tonne $ 70tonne See Chevron forecast supporting assumptions

Prefeasibility StudyOil Shale Fueled Power Generation

VOOOO-8DLIJRO12

i

Crude Oil Price Trends

60

Source World Energy Outlook Chevron Corporation Oclober 1987

40

High trend

No Ir 20 ~~~~Arabian Light Spot I A u

IILowYUII trend

0 1970 1975 1980 1985 1990 1995

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958246aJodar 118 3-14-89 rsO

2000

Project Size Effect Shale Fuel Option

Project Size

Integrated facilities installed capital cost$ US million

Shale cost $UStonne(8020 debtequity)

Cost of power millskWh(8020 debtequity ratio)

20 MW

109

143

128

50 MW

167

118

92

400 MW (4x1 00)

1016

68

71

Prefeasibility Study Oil Sampae Fueled Power Generation

VOO O-8I0LJRO13

gt1

1

Power Block Investment Cost

3000

$2875 Excluding mining and offsite 2800

2600

2400

2200

2000

$1836 1800

$1613 1600

$1420 1400 1I 1 I

0 100 200 300 400 MWe

August 1988

Preleasibility Study OilShale Fueled Power Generation

179581147aJodar1 18 3-14-89 rspcl

Fuel Requirement - 4x100 MW Project

Coal = 12 million tpy

n Oil = 503000 tpy

Oil shale = 78 million tpy

Preleasibility Study

Oil Shale Fueled Power Generation

IO060-OLLIRO14

Financing Effect -Project

Oil Shale Fuel Option

Mine and shale processing

Power block

Waste disposal

Community facilities

Total

Coal-Fired Power Plant

Oil-Fired Power Plant

400 MW

Capital Cost ($US MM)

DebtEquity

8020 5050

202 187

760 760

9 8

45 45

1016 1000

647 647

463 463

Prefeasibility StudyOil Shale Fueled Power Generation

VOe-BD1JRO15

Financing Effect shy400 MW Project

Operating Costs ($US millionyr)

DebtEquity

8020 5050

Coal $70tonne 282 282

Oil $24bbl 254 254

Oil shale-fueled 218 236

Including fuel

Prefeasibility Study

SOil Shale Fueled Power Generaion

VOOIt JLMO I

Alternate Fuel Price Effect shy4x100 MW Project

Financing Basis DebtEquity Ratio

Alternate Fuel Price

Imported coal $50tonne $70tonne

Imported oil $17bbl ($120tonne) $24bbl ($170tonne)

Cumulative 25-yr Net Benefit

Favoring Oil Shale (US $MM) shy

8020 5050

778 315 2531 2068

(18) (506)1810 1322

Prefeasibility Study

Oil Shale Fueled Power Generation

Voo -I DLU-A 2

i

Comparison of Cumulative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

32 Pay Out Year shy

400 MW PlantOil Shale vs Imported Coal (8020 debtequty)

30

28 -Cumulative fuel cost savings forcoal $70ton

Cumulative fuel cost savings for coaJ $50ton

26---------- Cumulative Incremental capital plus OampM costs

24

22 -

18 -0

W- Cumulative net benefit for shae vs coal $50ton 2B Cumulative net benefit for shale vs coal $70ton

co16C -

14 -

12 -

10 -

09

06 -Payout inyear 1

Payout Inyear 9 for coal $50ton - -- - - -shy

02 0 I

0 1 2 3 4 5 Nowl Yewr in which sauings in fWe colsacm-ewi tat hsawinitl

ca=al wosaand OampM costs

6

_iiM

7 8

9 10

------ - -amp -

11 12 13 14Year of Operation

--

15

- - --shy

16 17

I

18

1

19

I

20

I

21

I

22

I

23

I

24 25

Prefeasibility StudyOil Shale Fueled Power Generation

17958d351aJordanr 3-14-89 rsO

118

Comparison of Cumuiative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

28 Pay Out Year shy

400 MW Plant Oil Shale vs Imported Coal (5050 debtequity)

26shy2

24-

Cumulaive fuel nst savings for coal 0 $70ton Cumulative fuel cost savings for coal $50ton Cumulative Incremental capital plus OampM corts

22 -

20 -

18 -- Cumuladve net benefit for shle vs coal $50ton B Cumuarve net benefit for sale vs coal $70ton

16 -

C 14

12

10

08 -06 - Payout In year 1for coal $50ton

04

Payout Inyear 1

for coal $70ton02~

0 0

-No

02-

1 2

Yew inrY MCM cajlaI rl

3 4 5 6

sngm inW coas 0 ort hghWcentWin

0tOM cori

7

--

8

- -

9 10 11 12 13 14

Year of Operation

15 16 17

I

18

IIII

19 20 21 22 23 24 25

Preieasibility Study Oil Shale Fueled Power Generation

17958451 bJordarV118 3-14-89 rsipcI

Estimated Cost of Power- 400 MW (4 x 100)

FUEL

ImportedCoal

$50T

$70fT

1st Year

68 88

Levelized

78 107

Sultani Oil Shale

71 83

ImportedOil

$1713

$2413

56

67

76

96

0 10 20 30 40 50

I 60

I 70

I 80

I 90 100 110 120

Mills per kWh

Prefeasibility Study Oil Shale Fueled Power Generation

179581251 cJordarVl 18 3-14-89 rspc1

Summary Financial Analysis Results

Project size

Debt equity ratio

- Investment cost

- Power cost

- 25-year net benefit

- Project implementation

Alternative fuel price

Economic Comparison

Very significant

Not significant

Not significant

Very significant

Critical

Very significant

Prefeasibility Study

Oil Shale Fueled Power Generation

VY0 tDLUAi3

i

Study Conclusions

Feasibility

Timeliness

Expansion conditions

Environmental impacts

Development advantages

Prefeasibility Study

Oil Shale Fueled Power Generation VW41-1AiUA

4

Feasibility

Oil shale fueled power generation is technically and economically justifiedunder certain conditions

N Need for additional generating capacity

exists

- 6 annual peak demand growth - Orderly retirement of olderhigh cost

generating capacity needed

U Higher costs are expected for imported fuels

- 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

-OP b i j~~4shy

-4protntiYPe 4 demo plnt orP42 t~Plant orPootypeProje(-7hould

that Rj

demo 4Therefore-44 JEA anxinus

the

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

27Pag 4- 1 2S c i n 4 4

4i2Sectjo4-18-4 Secio 4-4 014

lt th~ae hi4h -tasisso syste thrug27 ~ 04lag arstl~art-p tasforme ed 2p27132Kvdieanwhy notthroug

EAto- is protmm~~ thegnJgt~~ pracie an ect ~ platqrby

28Pg 4 s heonnenotedto~the 32K rc powr

It not8 Scection rie049teoervnrain prctc de1

rh u n trae f2V3K anerd not throughgeterAntor

27 P3e-1r p ant weung-a

-If I

2tEll10 DRWE-jOi ASOt Mint~~al d~c~e o hepwrgnrto

ELCTRInYJORD UTHORITY-

Ate~

21Pge41 ection 4 04- 5

sindicated~ t hthigh the unit outputredu f hecondenser Injengtd~ibbvePressureed incg desrin hi h riseb vmbi nt emperatureWe bel~ieve

PleaIse provide us with th rscrapcity for th-e three options n nt generating~

21-Iisidca ted that~ thediaatgeofCBi theSheavy fn oe consumnptionPlease~ providethe us withpecntgA

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

400 MW COAL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO 5050

NET GENERATION - MWe 40000 CAPACITY FACTOR - 75 ANNUAL GENERATION MKWhYR 2628 SUB TOTAL PLANT COSTS (TPC) $1000 $620000

FIXED 0 amp M COSTS MH $ MH FIRST YEAR COST$1O00

------- --------- --- ---- --- --- ------------

OPERATING LABOR 351936 $3 $1100 MAINTENANCE LABOR 4000 of 150 OF TPC 3720

MAINTENANCE MATERIAL 6000

ADMIN LABOR of 150

3000 OF TPC

OF 0 amp M LABOR 5580 1446

SUB TOTAL FIXED OampM COSTS $11846

VARIABLE 0 amp M COSTS QUANTITY UNIT COST

VARIABLE MAINTENANCE 2628 MKWh 10 MILLKWH $ 2628 PROCESS WATER 13500000 GALLON 02 SGAL $ 2700 GENERAL PLANT CHEMICALS ALLOW 50 FUEL OIL 1000000 GALLON 035 $GAL $ 350 WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290SPECIAL BOILER MAINT ALLOW 0

SUB TOTAL VARIABLE OampM COSTS $ 8018

TOTAL FIXED amp VARIABLE OampM COSTS $19864 TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $8227 $TN $99139

(INCL INFLATION ADJUSTMENT)

B DEBT EQUITY RATIO =========== 8020

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $17574

WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290

TOTAL FIXED amp VARIABLE OampM COSTS $19864TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $5877 $TN $70814

(INCL INFLATION ADJUSTMENT)

6-21

Table 612 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY

400 MW OIL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO

NET GENERATION -

CAPACITY FACTOR -

ANNUAL GENERATION SUB TOTAL PLANT COSTS (TPC)

FIXED 0 amp M COSTS

OPERATING LABOR MAINTENANCE LABOR 4000 of

MAINTENANCE MATERIAL 6000 of

ADMIN LABOR

SUB TOTAL FIXED OampM COSTS

VARIABLE 0 amp M COSTS

VARIABLE MAINTENANCE PROCESS WATER GENERAL PLANT CHEMICALS FUEL OIL WASTE DISPOSAL (Section 6027) SPECIAL BOILER MAINT

SUB TOTAL VARIABLE OampM COSTS

5050

MWe

MKWhYR $1000

MH

262080

150

150 3000

QUANTITY

2628 MKWh 13500000 GALLON

1000000 GALLON 0 TNYR

TOTAL FIXED amp VARIABLE OampM COSTS FUEL OIL 503000 TNYR

B DEBT EQUITY RATIO =8020

40000 75

268 $443000

FIRST YEAR $ MH COST$1O00

$3 $ 800

OF TPC 2658

OF TPC 3987 OF 0 amp M LABOR 1037

$ 8482

UNIT COST

05 MILLKWH $ 1314 02 $GAL $ 2700

ALLOW 50 035 $GAL $ 350

$1000 $TN $ 0 ALLOW 0

$ 4414

$12896 $19981 $TN $100502

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $12896

WASTE DISPOSAL (Section 6027) 0 TNYR $1000 $TN $ 0

TOTAL FIXED amp VARIABLE OampM COSTS $12896 FUEL OIL 503000 TNYR $14104 $TN $70943

6-23

Page 24: fo; - pdf.usaid.gov

50 MW Oil Shale ProcessingPrototype Plant

Mlne Plant

_ 14 0 Haul0___) to Plant 1 Sorage

Portable Crusher

(-)100 mm Storage

(-) 100 mm Hopper UIU 400 th

Feed Bin

J 50

250 tvb

8 -m Circulating Load Impact3or0 0 30 0 0shy+8mm25

30 0L Sampler 0 1 30 0

p3 Day Storage

To Power Plant

Preleasibility StudyOil Shale Fueled Power Generation

17958101 SaJordanli 18 3-14-89 rsipc1

20 MW Oil Shale Demonstration Plant

Mine Plant

Haul00- 01 o

= Pb n Storage Portable _

110 mm Stora e 0

()100 mm r Hopper

U 400V

Feed Bin

CirculatingLoad3 Day Stoge

Prefea~ltSudy Shale Fueled Power Generation

179S 111p 1 11Joda3 yl 3-202-89 8vk2

I

Mine and Shale ProcessingDesign - 2050 MW Project

I Overburden removal (north pit area) 10-meter benches

- Drill and blast

- 10 m3 front-end loader

- 77-ton truck haulage

I Oil shale mining 10-meter benches

- Rippe and auger scraper

- Front-end loader

- Portable in-pit crusher

- 77-ton truck haulage

Oil shale processing

- Feed = minus 100 mm

- Product = minus 8 mm

- Capacity = 250 tph

- Reversible impactor

- Two vibrating screens

1 Prefeasibility Study Oil Shale Fueled Power Generation

V -M 1AMI1ARt46

400 MW Full-Scale Oil Shale ProcessingPlant

Feed MTnus 200 mm Samplerr

1000 bull 10000 Tonnes Live Storage Grade

200 m long(-) 200 mm -- =-- Plow Feeders

00 h 100000 Tonnes Live Storage

Stream 3 - Sampler Bin Stream 2

Stream th 31Da2000

Circulating Load 2i

NFw Feed r -17000t1 170001l 170 t 17000 t 17000 t

1000 th Silo with 7 Impactor (-1)8 mm Reapro- 3 Day Storage at Aver age Loadn

0 20 Feeders 20 m Diameter by 40 m High

JJJTHT To Power Plant

Prefeasibility Study Oil Shale Fueled Power Generation

179589 6aJordarV 1I8 3-14-89 rsipc1

Mine and Shale ProcessingDesign - 4x100 MW Project

m Overburden removal (north area) 10-meter benches

- Drill and blast

- Three 20 m3 shovels

- 136-ton truck haulage

m Oil shale mining 10-meter benches

- Two mechanical surface miners

- 136-ton trucks to pit hopper

- Belt conveyor = 2000 tph

- Traveling stacker

m Oil shale processing

- Feed = minus 200 mm

- Product = minus 8 mm

- Capacity = three 1000 tph units

Prefeasibility Study Oil Shale Fueled Power Generation

VOO79-ampGEAIAt 17

i

Steady-State Production Schedule

Overburden removal bench m3

20 MW demo project 5n MW prototype 4x100 MW full-scale plant

Oil shale mining and shale processing tonnes

20 MW project 50 MW project 4x100 MW project

HourlyDesign Capacity

282 234

1850

HourlyDesign Capacity

250 250

2000

Avg Daily Annual PEQuctiQa Production

1690 507000 4217 13 million

33333 10 million

Max Daily(a) Annual(b) Production Production

1733 390000 4324 973000

34578 78 million

(a) Based on 100 operating factor for power block

(b) Based on 75 operating factor for power block ( 20 MW project = 300 shiftsyr 50 MW project = 900 shiftsyr 400 MW project = 900 shiftsyr)

Prefeasibility Study Oil Shale Fueled Power Generation

Conceptual Power Plant Plans

m Pyroflow boiler

Power generating facilities

m Auxiliaries

S Preleasibility Study Oil ShaJe Fueled Power Generation

vo0o7dEAO 19

Pyroflow Boiler SteamConciflons

Flow rate 226700 kghr (500000 Ibhr)

Pressure 1099 kgcm2 abs (15635 psia)

Temperature 51280C (9550F)

Same for 20 50 and 100 MW designs

Prefeasibility Study Oil ShaJe Fueled Power Generation

vooGALMI 20

HtomCOPUIOTP

- 50005 5op

-- LEVAThUM ORPORAION

0

-VI

DZ 4

Power Block

Fuel handling system

- Day binsscrew feeders

Boiler

- Pyroflow circulating fluid bed combustor

Power generation

- Non reheat condensing steam turbine

- Conventional Rankin steam cycle

Ash handling system (btm ash irom combustor and flyash from bag house)

- Wetted in pug mill to add 20plusmn wt wpter

Plant service water

- Air-cooled condensors and small cooling tower from circulating trim water coolers

Plant raw water

- To cooling tower makeup

- To drinking water system

- To pump seals etc

Plant treated makeup water

- Demineralizer train

Preteasibility Study Oil Shale Fueled Power Generation

i

Onsite Infrastructure

Project office

Control house

U Maintenance shops warehouse

Laboratory

Employee service facility

Site developmentoperations service facilities

- Fire controlsecurity

- Communications

- Lighting

- Roads drainage and sewage

Prefeasibility StudyQ1I Shale Fueled Power Generation

voo4JG m 0 JV

i

BechtellPyropower50 MW Cogeneration Plant - Mt Poso California

W4t Prefeasibility Study --- 7 Oil Shale Fueled Power Generation

179586122aJordarv 118 3-14-89 rsO

Characteristics of Three Size Operations

Oil shale fuel tpy

Mine development excavation bank m3

Spent ash disposal tpy (wetted)

Water consumption 1000 m3yr

Staffing required

Community population

400 MW

20 MW 50 MW (4x1 00)

390000 973000 78 million

500000 1 million 85 million

327000 815000 61 million

538 907 1263

185 324 1046

700 1200 4000

Prefeasibility Study Oil Shale Fueled Power Generation

V000ofllAM1 23

Conceptual Designs Summary

N All BOP facilities involve conventional equipment and technology

100 MW unit operation involves boiler scale-up considerations

N Water consumption estimates

- Requirement for 4x100 MW project is 13 million m3 yr

- Water allocation of 2 million m3yr of water supports 6x100 MW

N Water availability probably limits total power generation from oil shale in Jordan

Prefeasibility Study Oil Shale Fueled Power Generation

V007041GEAOLMI

i

TECHNOLOGY RISK ASSESSMENT

Basic concepts

Key boiler scale-up design issues

Impact of scale-up

U Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Prefeasibility Study O1 Shale Fueled Power Generation

VOOh-7AEAAO 2

Basic Concepts

U CFBC is relatively new in the powerindustry

- Existing plants are small typically 20 to 50 MW

- There is limited operating experience with high-ash fuels

- Existing designs for lignite biomass and coal wastes show good plant performance

I Application of CFBC boiler design to oil shale fuel has defined risk that relates to scale-up of existing design

Similar CFBC technology is used in petroleum refining industry

- FCC cracking plant regenerators burn carbon residue off spent catalyst

- 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

FUEL ANALYSES

High Ash Fuel Projects Total Solids Input Basis

Gilberton Cambria North Branch

Carbon 4653 2749 1822 Hydrogen 153 164 160 Sulfur 073 222 234 Nitrogen 085 051 043 Oxygen 282 218 468 Moisture 1451 514 557 Ash 3303 6 0 6Z16

10000 10000 10000

HHVBtulb 7485 4809 3453

includes limestone feed a3 ash

includes CO2 in Ca~o3

CA89029 CAkw

Oil Shale

1132

113

255

048

065

320

-8062

10000

2250

Key Boiler Scale-Up DesignIssues

m Solids handling

- Feeding shale to combustor

- 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

Voo4tGEAMI 30

i

Mine and Shale Processing

U Fugitive dust emissions are controllable

- Wetting mine roads

- Enclose crushing plant equipment

Noise levels are controllable

- Enclose crushing plant equipment - Muffle truck exhausts

- Engineered waste disposal

Water effluents can be controlled

- Need good mine drainage design - Continue leachability studies on

waste dump piles

Prefeasibilily StudyOil Shale Fueled Po r Generaton

V0079OOG-4O 31

1

Power Plant

II Fugitive dust emissions are controllable

- Baghouse designoperation will minimize particulates in flue gas

- Wetting spent ash before disposal

N Gaseous emissions are controllable

- Pilot test results show acceptable SO2NOxCO in flue gas

- Develop baseline data for Sultani area

Develop air dispersion model for Sultani

Prefeasibility StudyOil Shale Fueled Power Generatio

V00 V-4GEA l32

i

Power Plant (Contd)

Noise levels are controllable

- Enclose boiler plant fans as required - Enclose turbines and pumps as

required

Water effluents are controllable

- Continue leachability studies on spent ash disposal

- Develop aquifer dispersion model

- Develop sewage and garbage disposal plan

Prefeasibility SludyOil Shale Fueled Power Generation

V00-4FAAI 33

Conclusions

No environmental constraints are anticipated on oil shale powerdevelopment

Gas effluents will meet World Bank standards

- Ash disposal is manageable

- The potential for groundwatercontamination appears low

- Water effluents will be minimal

Continued studies to develop air and groundwater baseline data are recommended

S Prefeasibility Study Oil Shale Fueled Power Generation

v0 9ampGLAMR 34

Power Demand vs SupplyAssessment

m Demand growth forecasts

Electrical generating capacity

= Power supply forecasts

= Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Preleasibility Study Oil Shaie Fuelod Power Generation

VO9- uLIROI

1

Power Demand Forecasts

Percent Annual Growth

JEA

Meta systems HaglerBailey and Bechtel National Inc

JEA Peak Demand Growth

1980 (actual) 1985 (actual) 1987 (actual) 1995 (forecast) 2005 (forecast)

1986 1990 to to

1990 2000

97 60

49 39

200 MW 475 MW 593 MW 900 MW

1400 MW

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOO-DLURO2

i

JEA ElectricityGeneratingCapacity

1987 Installed

Capacity (MW) Aqaba 260

22

Zarqa 395

Marka 102

Karak 23

Miscellaneous 67

Subtotal JEA capacity 869

Other capacity - industrial 110

Total 979

Prefeasibility Study Oi1 Shale Fueled Power Generation

V000-6O0LFJRO3 (

Forecast New Power Generating Capacity Required

Fcst 1987 Required

New Peak Available Installed

Demand Capacity Shortfall (a) Capacity (b) (MM (MW) (MW) (MW)

Assumed capacityfactor (65) (75)

1995 requirement 900 636 264 352

2005 requirement 1400 636 764 1019

(a) Excludes proposed additions and retirements (b) Excludes possible power exports or imports

Load shedding or levelizing not considered

Preteasibility Study Oil Shale Fueled Power Generation

Vflcmf-R)LLAO4

i

Supply vs Demand Evaluation

1800

1600

1400 Forecast Peak Demands

1200 -

E Installed Capacity

0 800shy75--

U) Assumed Available Calcit

a 6 Ao600 shy0 o 65

400 shy

200

I I I I I I I I I I I I I I I I I I I I I I I 1 1 1980 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958f738aIJordarV 118 3-14-89 rspCO

Conclusions

Additional power generating capacity is needed to meet forecasted 19952005demand growth

A 400 MW oil shale-to-power project at Sultani can meet a portion of this need

U A second 400 MW oil shale project maybe required if water is available

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOW0O-8LURO5

i

Economic Feasibility

N Order-of-magnitude costs

N Economic analysis

- Jordan study options

- Project size effect

m Comparison with alternative fuels

- Fuel requirement

- Project financing effect

- Alternate fuel price effect

- Estimated cost of electricity

N Summary financial analysis

bull Material was developed by Bechtel Power Company

Prefeasibility Study

go Oil Shale Fueled Power Generation VOOSO-ampDtJROh

ORDER-OF-MAGNITUDE COSTS

U Oil shale fuel

Power plant

I Integrated project- busbar

Preteasibility Study

Oil Shale Fueled Power Generation

VOO9O-ampDLUROS

Oil Shale Fuel Costs

Installed Capital Cost

Mine Development

Mine Equipment

Processing Plant

Spare Parts

Working Capital

Capitalized Interest

Total

Annual Operating Cost

Fuel Cost $UStonne

bull Based on 8020 debtequity ratio

20 MW

4900

11090

6945

1200

1200

4054

29389

5582

1431

US $1000 Factored

50 MW 4x100 MW

7833 30915

12202 66012

8388 50889

1300 5000

2200 10000

5108 39075

37031 201891

11556 53236

1188 684

Prefeasibility Study

Oil Shale Fueled Power Generation

VCO-ampDLUJ1O

Power Plant Costs

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Cost

Power faciities 57500 91800 567800

Owners cost 10200 20400 192700

Total 67700 112200 760500

Annual Operating Cost 2205 3248 17157(excluding fuel cost)

bullBased on 8020 debtequity ratio oil shale fueled

Prefeasibility Study

Oil Shale Fueled Power Generation

V00O8c4LLMO9

i

INTEGRATED PROJECT -BUSBAR COST

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Costs Mine amp shale processingPower block Waste disposal Infrastructure

29359 67700

1664 10000

37031 112200

2381 15000

201891 760500

8714 45000

TOTAL 108753 166612 1016105

Annual Operating Cost Mine amp shale processingPower block Waste disposal Infrastructure (a)

5582 2205

316

11556 3248

710

56430(b) 18186(b) 6004

Subtotal 8103 15514 80620

Capital Charges 139 9410 15596 106000

Total 17513 31110 186620

25-year levelized cost - - 218000

Busbar Cost millskWh First year 128 92 71 25-year levelized 83

(a) Housing and community facilities assumed self-liquidating(b) Includes first-year inflation adjustment

Based on 8020 debtequity ratio

Prefeasibility StudyOil Shale Fueled Power Generaion

VOOOO-8MLtROi0

ECONOMIC ANALYSIS

n Jordan study options

Project size effect

Fuel requirement

Project financing effect

Alternative fuel price effect

Estimated electricity cost

Summary financial analysis results

Prefeasibility Study

Oil Shale Fueled Powr Generation

VOOeO-BOCLLO1 I

i

Jordan Study Options

U Project size

- Demonstration = 20 MW

- Prototype = 50 MW

- Commercial = 400 MW (4x100)

Project financing

- Debtequity 8020

- Debtequity 5050

Imported alternative fuels cost assumptions

A B Crude oil $17bbl $24bbl

$120onne $170tonne

Low sulfur coal $ 50tonne $ 70tonne See Chevron forecast supporting assumptions

Prefeasibility StudyOil Shale Fueled Power Generation

VOOOO-8DLIJRO12

i

Crude Oil Price Trends

60

Source World Energy Outlook Chevron Corporation Oclober 1987

40

High trend

No Ir 20 ~~~~Arabian Light Spot I A u

IILowYUII trend

0 1970 1975 1980 1985 1990 1995

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958246aJodar 118 3-14-89 rsO

2000

Project Size Effect Shale Fuel Option

Project Size

Integrated facilities installed capital cost$ US million

Shale cost $UStonne(8020 debtequity)

Cost of power millskWh(8020 debtequity ratio)

20 MW

109

143

128

50 MW

167

118

92

400 MW (4x1 00)

1016

68

71

Prefeasibility Study Oil Sampae Fueled Power Generation

VOO O-8I0LJRO13

gt1

1

Power Block Investment Cost

3000

$2875 Excluding mining and offsite 2800

2600

2400

2200

2000

$1836 1800

$1613 1600

$1420 1400 1I 1 I

0 100 200 300 400 MWe

August 1988

Preleasibility Study OilShale Fueled Power Generation

179581147aJodar1 18 3-14-89 rspcl

Fuel Requirement - 4x100 MW Project

Coal = 12 million tpy

n Oil = 503000 tpy

Oil shale = 78 million tpy

Preleasibility Study

Oil Shale Fueled Power Generation

IO060-OLLIRO14

Financing Effect -Project

Oil Shale Fuel Option

Mine and shale processing

Power block

Waste disposal

Community facilities

Total

Coal-Fired Power Plant

Oil-Fired Power Plant

400 MW

Capital Cost ($US MM)

DebtEquity

8020 5050

202 187

760 760

9 8

45 45

1016 1000

647 647

463 463

Prefeasibility StudyOil Shale Fueled Power Generation

VOe-BD1JRO15

Financing Effect shy400 MW Project

Operating Costs ($US millionyr)

DebtEquity

8020 5050

Coal $70tonne 282 282

Oil $24bbl 254 254

Oil shale-fueled 218 236

Including fuel

Prefeasibility Study

SOil Shale Fueled Power Generaion

VOOIt JLMO I

Alternate Fuel Price Effect shy4x100 MW Project

Financing Basis DebtEquity Ratio

Alternate Fuel Price

Imported coal $50tonne $70tonne

Imported oil $17bbl ($120tonne) $24bbl ($170tonne)

Cumulative 25-yr Net Benefit

Favoring Oil Shale (US $MM) shy

8020 5050

778 315 2531 2068

(18) (506)1810 1322

Prefeasibility Study

Oil Shale Fueled Power Generation

Voo -I DLU-A 2

i

Comparison of Cumulative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

32 Pay Out Year shy

400 MW PlantOil Shale vs Imported Coal (8020 debtequty)

30

28 -Cumulative fuel cost savings forcoal $70ton

Cumulative fuel cost savings for coaJ $50ton

26---------- Cumulative Incremental capital plus OampM costs

24

22 -

18 -0

W- Cumulative net benefit for shae vs coal $50ton 2B Cumulative net benefit for shale vs coal $70ton

co16C -

14 -

12 -

10 -

09

06 -Payout inyear 1

Payout Inyear 9 for coal $50ton - -- - - -shy

02 0 I

0 1 2 3 4 5 Nowl Yewr in which sauings in fWe colsacm-ewi tat hsawinitl

ca=al wosaand OampM costs

6

_iiM

7 8

9 10

------ - -amp -

11 12 13 14Year of Operation

--

15

- - --shy

16 17

I

18

1

19

I

20

I

21

I

22

I

23

I

24 25

Prefeasibility StudyOil Shale Fueled Power Generation

17958d351aJordanr 3-14-89 rsO

118

Comparison of Cumuiative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

28 Pay Out Year shy

400 MW Plant Oil Shale vs Imported Coal (5050 debtequity)

26shy2

24-

Cumulaive fuel nst savings for coal 0 $70ton Cumulative fuel cost savings for coal $50ton Cumulative Incremental capital plus OampM corts

22 -

20 -

18 -- Cumuladve net benefit for shle vs coal $50ton B Cumuarve net benefit for sale vs coal $70ton

16 -

C 14

12

10

08 -06 - Payout In year 1for coal $50ton

04

Payout Inyear 1

for coal $70ton02~

0 0

-No

02-

1 2

Yew inrY MCM cajlaI rl

3 4 5 6

sngm inW coas 0 ort hghWcentWin

0tOM cori

7

--

8

- -

9 10 11 12 13 14

Year of Operation

15 16 17

I

18

IIII

19 20 21 22 23 24 25

Preieasibility Study Oil Shale Fueled Power Generation

17958451 bJordarV118 3-14-89 rsipcI

Estimated Cost of Power- 400 MW (4 x 100)

FUEL

ImportedCoal

$50T

$70fT

1st Year

68 88

Levelized

78 107

Sultani Oil Shale

71 83

ImportedOil

$1713

$2413

56

67

76

96

0 10 20 30 40 50

I 60

I 70

I 80

I 90 100 110 120

Mills per kWh

Prefeasibility Study Oil Shale Fueled Power Generation

179581251 cJordarVl 18 3-14-89 rspc1

Summary Financial Analysis Results

Project size

Debt equity ratio

- Investment cost

- Power cost

- 25-year net benefit

- Project implementation

Alternative fuel price

Economic Comparison

Very significant

Not significant

Not significant

Very significant

Critical

Very significant

Prefeasibility Study

Oil Shale Fueled Power Generation

VY0 tDLUAi3

i

Study Conclusions

Feasibility

Timeliness

Expansion conditions

Environmental impacts

Development advantages

Prefeasibility Study

Oil Shale Fueled Power Generation VW41-1AiUA

4

Feasibility

Oil shale fueled power generation is technically and economically justifiedunder certain conditions

N Need for additional generating capacity

exists

- 6 annual peak demand growth - Orderly retirement of olderhigh cost

generating capacity needed

U Higher costs are expected for imported fuels

- 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

-OP b i j~~4shy

-4protntiYPe 4 demo plnt orP42 t~Plant orPootypeProje(-7hould

that Rj

demo 4Therefore-44 JEA anxinus

the

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

27Pag 4- 1 2S c i n 4 4

4i2Sectjo4-18-4 Secio 4-4 014

lt th~ae hi4h -tasisso syste thrug27 ~ 04lag arstl~art-p tasforme ed 2p27132Kvdieanwhy notthroug

EAto- is protmm~~ thegnJgt~~ pracie an ect ~ platqrby

28Pg 4 s heonnenotedto~the 32K rc powr

It not8 Scection rie049teoervnrain prctc de1

rh u n trae f2V3K anerd not throughgeterAntor

27 P3e-1r p ant weung-a

-If I

2tEll10 DRWE-jOi ASOt Mint~~al d~c~e o hepwrgnrto

ELCTRInYJORD UTHORITY-

Ate~

21Pge41 ection 4 04- 5

sindicated~ t hthigh the unit outputredu f hecondenser Injengtd~ibbvePressureed incg desrin hi h riseb vmbi nt emperatureWe bel~ieve

PleaIse provide us with th rscrapcity for th-e three options n nt generating~

21-Iisidca ted that~ thediaatgeofCBi theSheavy fn oe consumnptionPlease~ providethe us withpecntgA

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

400 MW COAL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO 5050

NET GENERATION - MWe 40000 CAPACITY FACTOR - 75 ANNUAL GENERATION MKWhYR 2628 SUB TOTAL PLANT COSTS (TPC) $1000 $620000

FIXED 0 amp M COSTS MH $ MH FIRST YEAR COST$1O00

------- --------- --- ---- --- --- ------------

OPERATING LABOR 351936 $3 $1100 MAINTENANCE LABOR 4000 of 150 OF TPC 3720

MAINTENANCE MATERIAL 6000

ADMIN LABOR of 150

3000 OF TPC

OF 0 amp M LABOR 5580 1446

SUB TOTAL FIXED OampM COSTS $11846

VARIABLE 0 amp M COSTS QUANTITY UNIT COST

VARIABLE MAINTENANCE 2628 MKWh 10 MILLKWH $ 2628 PROCESS WATER 13500000 GALLON 02 SGAL $ 2700 GENERAL PLANT CHEMICALS ALLOW 50 FUEL OIL 1000000 GALLON 035 $GAL $ 350 WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290SPECIAL BOILER MAINT ALLOW 0

SUB TOTAL VARIABLE OampM COSTS $ 8018

TOTAL FIXED amp VARIABLE OampM COSTS $19864 TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $8227 $TN $99139

(INCL INFLATION ADJUSTMENT)

B DEBT EQUITY RATIO =========== 8020

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $17574

WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290

TOTAL FIXED amp VARIABLE OampM COSTS $19864TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $5877 $TN $70814

(INCL INFLATION ADJUSTMENT)

6-21

Table 612 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY

400 MW OIL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO

NET GENERATION -

CAPACITY FACTOR -

ANNUAL GENERATION SUB TOTAL PLANT COSTS (TPC)

FIXED 0 amp M COSTS

OPERATING LABOR MAINTENANCE LABOR 4000 of

MAINTENANCE MATERIAL 6000 of

ADMIN LABOR

SUB TOTAL FIXED OampM COSTS

VARIABLE 0 amp M COSTS

VARIABLE MAINTENANCE PROCESS WATER GENERAL PLANT CHEMICALS FUEL OIL WASTE DISPOSAL (Section 6027) SPECIAL BOILER MAINT

SUB TOTAL VARIABLE OampM COSTS

5050

MWe

MKWhYR $1000

MH

262080

150

150 3000

QUANTITY

2628 MKWh 13500000 GALLON

1000000 GALLON 0 TNYR

TOTAL FIXED amp VARIABLE OampM COSTS FUEL OIL 503000 TNYR

B DEBT EQUITY RATIO =8020

40000 75

268 $443000

FIRST YEAR $ MH COST$1O00

$3 $ 800

OF TPC 2658

OF TPC 3987 OF 0 amp M LABOR 1037

$ 8482

UNIT COST

05 MILLKWH $ 1314 02 $GAL $ 2700

ALLOW 50 035 $GAL $ 350

$1000 $TN $ 0 ALLOW 0

$ 4414

$12896 $19981 $TN $100502

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $12896

WASTE DISPOSAL (Section 6027) 0 TNYR $1000 $TN $ 0

TOTAL FIXED amp VARIABLE OampM COSTS $12896 FUEL OIL 503000 TNYR $14104 $TN $70943

6-23

Page 25: fo; - pdf.usaid.gov

20 MW Oil Shale Demonstration Plant

Mine Plant

Haul00- 01 o

= Pb n Storage Portable _

110 mm Stora e 0

()100 mm r Hopper

U 400V

Feed Bin

CirculatingLoad3 Day Stoge

Prefea~ltSudy Shale Fueled Power Generation

179S 111p 1 11Joda3 yl 3-202-89 8vk2

I

Mine and Shale ProcessingDesign - 2050 MW Project

I Overburden removal (north pit area) 10-meter benches

- Drill and blast

- 10 m3 front-end loader

- 77-ton truck haulage

I Oil shale mining 10-meter benches

- Rippe and auger scraper

- Front-end loader

- Portable in-pit crusher

- 77-ton truck haulage

Oil shale processing

- Feed = minus 100 mm

- Product = minus 8 mm

- Capacity = 250 tph

- Reversible impactor

- Two vibrating screens

1 Prefeasibility Study Oil Shale Fueled Power Generation

V -M 1AMI1ARt46

400 MW Full-Scale Oil Shale ProcessingPlant

Feed MTnus 200 mm Samplerr

1000 bull 10000 Tonnes Live Storage Grade

200 m long(-) 200 mm -- =-- Plow Feeders

00 h 100000 Tonnes Live Storage

Stream 3 - Sampler Bin Stream 2

Stream th 31Da2000

Circulating Load 2i

NFw Feed r -17000t1 170001l 170 t 17000 t 17000 t

1000 th Silo with 7 Impactor (-1)8 mm Reapro- 3 Day Storage at Aver age Loadn

0 20 Feeders 20 m Diameter by 40 m High

JJJTHT To Power Plant

Prefeasibility Study Oil Shale Fueled Power Generation

179589 6aJordarV 1I8 3-14-89 rsipc1

Mine and Shale ProcessingDesign - 4x100 MW Project

m Overburden removal (north area) 10-meter benches

- Drill and blast

- Three 20 m3 shovels

- 136-ton truck haulage

m Oil shale mining 10-meter benches

- Two mechanical surface miners

- 136-ton trucks to pit hopper

- Belt conveyor = 2000 tph

- Traveling stacker

m Oil shale processing

- Feed = minus 200 mm

- Product = minus 8 mm

- Capacity = three 1000 tph units

Prefeasibility Study Oil Shale Fueled Power Generation

VOO79-ampGEAIAt 17

i

Steady-State Production Schedule

Overburden removal bench m3

20 MW demo project 5n MW prototype 4x100 MW full-scale plant

Oil shale mining and shale processing tonnes

20 MW project 50 MW project 4x100 MW project

HourlyDesign Capacity

282 234

1850

HourlyDesign Capacity

250 250

2000

Avg Daily Annual PEQuctiQa Production

1690 507000 4217 13 million

33333 10 million

Max Daily(a) Annual(b) Production Production

1733 390000 4324 973000

34578 78 million

(a) Based on 100 operating factor for power block

(b) Based on 75 operating factor for power block ( 20 MW project = 300 shiftsyr 50 MW project = 900 shiftsyr 400 MW project = 900 shiftsyr)

Prefeasibility Study Oil Shale Fueled Power Generation

Conceptual Power Plant Plans

m Pyroflow boiler

Power generating facilities

m Auxiliaries

S Preleasibility Study Oil ShaJe Fueled Power Generation

vo0o7dEAO 19

Pyroflow Boiler SteamConciflons

Flow rate 226700 kghr (500000 Ibhr)

Pressure 1099 kgcm2 abs (15635 psia)

Temperature 51280C (9550F)

Same for 20 50 and 100 MW designs

Prefeasibility Study Oil ShaJe Fueled Power Generation

vooGALMI 20

HtomCOPUIOTP

- 50005 5op

-- LEVAThUM ORPORAION

0

-VI

DZ 4

Power Block

Fuel handling system

- Day binsscrew feeders

Boiler

- Pyroflow circulating fluid bed combustor

Power generation

- Non reheat condensing steam turbine

- Conventional Rankin steam cycle

Ash handling system (btm ash irom combustor and flyash from bag house)

- Wetted in pug mill to add 20plusmn wt wpter

Plant service water

- Air-cooled condensors and small cooling tower from circulating trim water coolers

Plant raw water

- To cooling tower makeup

- To drinking water system

- To pump seals etc

Plant treated makeup water

- Demineralizer train

Preteasibility Study Oil Shale Fueled Power Generation

i

Onsite Infrastructure

Project office

Control house

U Maintenance shops warehouse

Laboratory

Employee service facility

Site developmentoperations service facilities

- Fire controlsecurity

- Communications

- Lighting

- Roads drainage and sewage

Prefeasibility StudyQ1I Shale Fueled Power Generation

voo4JG m 0 JV

i

BechtellPyropower50 MW Cogeneration Plant - Mt Poso California

W4t Prefeasibility Study --- 7 Oil Shale Fueled Power Generation

179586122aJordarv 118 3-14-89 rsO

Characteristics of Three Size Operations

Oil shale fuel tpy

Mine development excavation bank m3

Spent ash disposal tpy (wetted)

Water consumption 1000 m3yr

Staffing required

Community population

400 MW

20 MW 50 MW (4x1 00)

390000 973000 78 million

500000 1 million 85 million

327000 815000 61 million

538 907 1263

185 324 1046

700 1200 4000

Prefeasibility Study Oil Shale Fueled Power Generation

V000ofllAM1 23

Conceptual Designs Summary

N All BOP facilities involve conventional equipment and technology

100 MW unit operation involves boiler scale-up considerations

N Water consumption estimates

- Requirement for 4x100 MW project is 13 million m3 yr

- Water allocation of 2 million m3yr of water supports 6x100 MW

N Water availability probably limits total power generation from oil shale in Jordan

Prefeasibility Study Oil Shale Fueled Power Generation

V007041GEAOLMI

i

TECHNOLOGY RISK ASSESSMENT

Basic concepts

Key boiler scale-up design issues

Impact of scale-up

U Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Prefeasibility Study O1 Shale Fueled Power Generation

VOOh-7AEAAO 2

Basic Concepts

U CFBC is relatively new in the powerindustry

- Existing plants are small typically 20 to 50 MW

- There is limited operating experience with high-ash fuels

- Existing designs for lignite biomass and coal wastes show good plant performance

I Application of CFBC boiler design to oil shale fuel has defined risk that relates to scale-up of existing design

Similar CFBC technology is used in petroleum refining industry

- FCC cracking plant regenerators burn carbon residue off spent catalyst

- 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

FUEL ANALYSES

High Ash Fuel Projects Total Solids Input Basis

Gilberton Cambria North Branch

Carbon 4653 2749 1822 Hydrogen 153 164 160 Sulfur 073 222 234 Nitrogen 085 051 043 Oxygen 282 218 468 Moisture 1451 514 557 Ash 3303 6 0 6Z16

10000 10000 10000

HHVBtulb 7485 4809 3453

includes limestone feed a3 ash

includes CO2 in Ca~o3

CA89029 CAkw

Oil Shale

1132

113

255

048

065

320

-8062

10000

2250

Key Boiler Scale-Up DesignIssues

m Solids handling

- Feeding shale to combustor

- 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

Voo4tGEAMI 30

i

Mine and Shale Processing

U Fugitive dust emissions are controllable

- Wetting mine roads

- Enclose crushing plant equipment

Noise levels are controllable

- Enclose crushing plant equipment - Muffle truck exhausts

- Engineered waste disposal

Water effluents can be controlled

- Need good mine drainage design - Continue leachability studies on

waste dump piles

Prefeasibilily StudyOil Shale Fueled Po r Generaton

V0079OOG-4O 31

1

Power Plant

II Fugitive dust emissions are controllable

- Baghouse designoperation will minimize particulates in flue gas

- Wetting spent ash before disposal

N Gaseous emissions are controllable

- Pilot test results show acceptable SO2NOxCO in flue gas

- Develop baseline data for Sultani area

Develop air dispersion model for Sultani

Prefeasibility StudyOil Shale Fueled Power Generatio

V00 V-4GEA l32

i

Power Plant (Contd)

Noise levels are controllable

- Enclose boiler plant fans as required - Enclose turbines and pumps as

required

Water effluents are controllable

- Continue leachability studies on spent ash disposal

- Develop aquifer dispersion model

- Develop sewage and garbage disposal plan

Prefeasibility SludyOil Shale Fueled Power Generation

V00-4FAAI 33

Conclusions

No environmental constraints are anticipated on oil shale powerdevelopment

Gas effluents will meet World Bank standards

- Ash disposal is manageable

- The potential for groundwatercontamination appears low

- Water effluents will be minimal

Continued studies to develop air and groundwater baseline data are recommended

S Prefeasibility Study Oil Shale Fueled Power Generation

v0 9ampGLAMR 34

Power Demand vs SupplyAssessment

m Demand growth forecasts

Electrical generating capacity

= Power supply forecasts

= Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Preleasibility Study Oil Shaie Fuelod Power Generation

VO9- uLIROI

1

Power Demand Forecasts

Percent Annual Growth

JEA

Meta systems HaglerBailey and Bechtel National Inc

JEA Peak Demand Growth

1980 (actual) 1985 (actual) 1987 (actual) 1995 (forecast) 2005 (forecast)

1986 1990 to to

1990 2000

97 60

49 39

200 MW 475 MW 593 MW 900 MW

1400 MW

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOO-DLURO2

i

JEA ElectricityGeneratingCapacity

1987 Installed

Capacity (MW) Aqaba 260

22

Zarqa 395

Marka 102

Karak 23

Miscellaneous 67

Subtotal JEA capacity 869

Other capacity - industrial 110

Total 979

Prefeasibility Study Oi1 Shale Fueled Power Generation

V000-6O0LFJRO3 (

Forecast New Power Generating Capacity Required

Fcst 1987 Required

New Peak Available Installed

Demand Capacity Shortfall (a) Capacity (b) (MM (MW) (MW) (MW)

Assumed capacityfactor (65) (75)

1995 requirement 900 636 264 352

2005 requirement 1400 636 764 1019

(a) Excludes proposed additions and retirements (b) Excludes possible power exports or imports

Load shedding or levelizing not considered

Preteasibility Study Oil Shale Fueled Power Generation

Vflcmf-R)LLAO4

i

Supply vs Demand Evaluation

1800

1600

1400 Forecast Peak Demands

1200 -

E Installed Capacity

0 800shy75--

U) Assumed Available Calcit

a 6 Ao600 shy0 o 65

400 shy

200

I I I I I I I I I I I I I I I I I I I I I I I 1 1 1980 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958f738aIJordarV 118 3-14-89 rspCO

Conclusions

Additional power generating capacity is needed to meet forecasted 19952005demand growth

A 400 MW oil shale-to-power project at Sultani can meet a portion of this need

U A second 400 MW oil shale project maybe required if water is available

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOW0O-8LURO5

i

Economic Feasibility

N Order-of-magnitude costs

N Economic analysis

- Jordan study options

- Project size effect

m Comparison with alternative fuels

- Fuel requirement

- Project financing effect

- Alternate fuel price effect

- Estimated cost of electricity

N Summary financial analysis

bull Material was developed by Bechtel Power Company

Prefeasibility Study

go Oil Shale Fueled Power Generation VOOSO-ampDtJROh

ORDER-OF-MAGNITUDE COSTS

U Oil shale fuel

Power plant

I Integrated project- busbar

Preteasibility Study

Oil Shale Fueled Power Generation

VOO9O-ampDLUROS

Oil Shale Fuel Costs

Installed Capital Cost

Mine Development

Mine Equipment

Processing Plant

Spare Parts

Working Capital

Capitalized Interest

Total

Annual Operating Cost

Fuel Cost $UStonne

bull Based on 8020 debtequity ratio

20 MW

4900

11090

6945

1200

1200

4054

29389

5582

1431

US $1000 Factored

50 MW 4x100 MW

7833 30915

12202 66012

8388 50889

1300 5000

2200 10000

5108 39075

37031 201891

11556 53236

1188 684

Prefeasibility Study

Oil Shale Fueled Power Generation

VCO-ampDLUJ1O

Power Plant Costs

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Cost

Power faciities 57500 91800 567800

Owners cost 10200 20400 192700

Total 67700 112200 760500

Annual Operating Cost 2205 3248 17157(excluding fuel cost)

bullBased on 8020 debtequity ratio oil shale fueled

Prefeasibility Study

Oil Shale Fueled Power Generation

V00O8c4LLMO9

i

INTEGRATED PROJECT -BUSBAR COST

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Costs Mine amp shale processingPower block Waste disposal Infrastructure

29359 67700

1664 10000

37031 112200

2381 15000

201891 760500

8714 45000

TOTAL 108753 166612 1016105

Annual Operating Cost Mine amp shale processingPower block Waste disposal Infrastructure (a)

5582 2205

316

11556 3248

710

56430(b) 18186(b) 6004

Subtotal 8103 15514 80620

Capital Charges 139 9410 15596 106000

Total 17513 31110 186620

25-year levelized cost - - 218000

Busbar Cost millskWh First year 128 92 71 25-year levelized 83

(a) Housing and community facilities assumed self-liquidating(b) Includes first-year inflation adjustment

Based on 8020 debtequity ratio

Prefeasibility StudyOil Shale Fueled Power Generaion

VOOOO-8MLtROi0

ECONOMIC ANALYSIS

n Jordan study options

Project size effect

Fuel requirement

Project financing effect

Alternative fuel price effect

Estimated electricity cost

Summary financial analysis results

Prefeasibility Study

Oil Shale Fueled Powr Generation

VOOeO-BOCLLO1 I

i

Jordan Study Options

U Project size

- Demonstration = 20 MW

- Prototype = 50 MW

- Commercial = 400 MW (4x100)

Project financing

- Debtequity 8020

- Debtequity 5050

Imported alternative fuels cost assumptions

A B Crude oil $17bbl $24bbl

$120onne $170tonne

Low sulfur coal $ 50tonne $ 70tonne See Chevron forecast supporting assumptions

Prefeasibility StudyOil Shale Fueled Power Generation

VOOOO-8DLIJRO12

i

Crude Oil Price Trends

60

Source World Energy Outlook Chevron Corporation Oclober 1987

40

High trend

No Ir 20 ~~~~Arabian Light Spot I A u

IILowYUII trend

0 1970 1975 1980 1985 1990 1995

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958246aJodar 118 3-14-89 rsO

2000

Project Size Effect Shale Fuel Option

Project Size

Integrated facilities installed capital cost$ US million

Shale cost $UStonne(8020 debtequity)

Cost of power millskWh(8020 debtequity ratio)

20 MW

109

143

128

50 MW

167

118

92

400 MW (4x1 00)

1016

68

71

Prefeasibility Study Oil Sampae Fueled Power Generation

VOO O-8I0LJRO13

gt1

1

Power Block Investment Cost

3000

$2875 Excluding mining and offsite 2800

2600

2400

2200

2000

$1836 1800

$1613 1600

$1420 1400 1I 1 I

0 100 200 300 400 MWe

August 1988

Preleasibility Study OilShale Fueled Power Generation

179581147aJodar1 18 3-14-89 rspcl

Fuel Requirement - 4x100 MW Project

Coal = 12 million tpy

n Oil = 503000 tpy

Oil shale = 78 million tpy

Preleasibility Study

Oil Shale Fueled Power Generation

IO060-OLLIRO14

Financing Effect -Project

Oil Shale Fuel Option

Mine and shale processing

Power block

Waste disposal

Community facilities

Total

Coal-Fired Power Plant

Oil-Fired Power Plant

400 MW

Capital Cost ($US MM)

DebtEquity

8020 5050

202 187

760 760

9 8

45 45

1016 1000

647 647

463 463

Prefeasibility StudyOil Shale Fueled Power Generation

VOe-BD1JRO15

Financing Effect shy400 MW Project

Operating Costs ($US millionyr)

DebtEquity

8020 5050

Coal $70tonne 282 282

Oil $24bbl 254 254

Oil shale-fueled 218 236

Including fuel

Prefeasibility Study

SOil Shale Fueled Power Generaion

VOOIt JLMO I

Alternate Fuel Price Effect shy4x100 MW Project

Financing Basis DebtEquity Ratio

Alternate Fuel Price

Imported coal $50tonne $70tonne

Imported oil $17bbl ($120tonne) $24bbl ($170tonne)

Cumulative 25-yr Net Benefit

Favoring Oil Shale (US $MM) shy

8020 5050

778 315 2531 2068

(18) (506)1810 1322

Prefeasibility Study

Oil Shale Fueled Power Generation

Voo -I DLU-A 2

i

Comparison of Cumulative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

32 Pay Out Year shy

400 MW PlantOil Shale vs Imported Coal (8020 debtequty)

30

28 -Cumulative fuel cost savings forcoal $70ton

Cumulative fuel cost savings for coaJ $50ton

26---------- Cumulative Incremental capital plus OampM costs

24

22 -

18 -0

W- Cumulative net benefit for shae vs coal $50ton 2B Cumulative net benefit for shale vs coal $70ton

co16C -

14 -

12 -

10 -

09

06 -Payout inyear 1

Payout Inyear 9 for coal $50ton - -- - - -shy

02 0 I

0 1 2 3 4 5 Nowl Yewr in which sauings in fWe colsacm-ewi tat hsawinitl

ca=al wosaand OampM costs

6

_iiM

7 8

9 10

------ - -amp -

11 12 13 14Year of Operation

--

15

- - --shy

16 17

I

18

1

19

I

20

I

21

I

22

I

23

I

24 25

Prefeasibility StudyOil Shale Fueled Power Generation

17958d351aJordanr 3-14-89 rsO

118

Comparison of Cumuiative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

28 Pay Out Year shy

400 MW Plant Oil Shale vs Imported Coal (5050 debtequity)

26shy2

24-

Cumulaive fuel nst savings for coal 0 $70ton Cumulative fuel cost savings for coal $50ton Cumulative Incremental capital plus OampM corts

22 -

20 -

18 -- Cumuladve net benefit for shle vs coal $50ton B Cumuarve net benefit for sale vs coal $70ton

16 -

C 14

12

10

08 -06 - Payout In year 1for coal $50ton

04

Payout Inyear 1

for coal $70ton02~

0 0

-No

02-

1 2

Yew inrY MCM cajlaI rl

3 4 5 6

sngm inW coas 0 ort hghWcentWin

0tOM cori

7

--

8

- -

9 10 11 12 13 14

Year of Operation

15 16 17

I

18

IIII

19 20 21 22 23 24 25

Preieasibility Study Oil Shale Fueled Power Generation

17958451 bJordarV118 3-14-89 rsipcI

Estimated Cost of Power- 400 MW (4 x 100)

FUEL

ImportedCoal

$50T

$70fT

1st Year

68 88

Levelized

78 107

Sultani Oil Shale

71 83

ImportedOil

$1713

$2413

56

67

76

96

0 10 20 30 40 50

I 60

I 70

I 80

I 90 100 110 120

Mills per kWh

Prefeasibility Study Oil Shale Fueled Power Generation

179581251 cJordarVl 18 3-14-89 rspc1

Summary Financial Analysis Results

Project size

Debt equity ratio

- Investment cost

- Power cost

- 25-year net benefit

- Project implementation

Alternative fuel price

Economic Comparison

Very significant

Not significant

Not significant

Very significant

Critical

Very significant

Prefeasibility Study

Oil Shale Fueled Power Generation

VY0 tDLUAi3

i

Study Conclusions

Feasibility

Timeliness

Expansion conditions

Environmental impacts

Development advantages

Prefeasibility Study

Oil Shale Fueled Power Generation VW41-1AiUA

4

Feasibility

Oil shale fueled power generation is technically and economically justifiedunder certain conditions

N Need for additional generating capacity

exists

- 6 annual peak demand growth - Orderly retirement of olderhigh cost

generating capacity needed

U Higher costs are expected for imported fuels

- 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

-OP b i j~~4shy

-4protntiYPe 4 demo plnt orP42 t~Plant orPootypeProje(-7hould

that Rj

demo 4Therefore-44 JEA anxinus

the

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

27Pag 4- 1 2S c i n 4 4

4i2Sectjo4-18-4 Secio 4-4 014

lt th~ae hi4h -tasisso syste thrug27 ~ 04lag arstl~art-p tasforme ed 2p27132Kvdieanwhy notthroug

EAto- is protmm~~ thegnJgt~~ pracie an ect ~ platqrby

28Pg 4 s heonnenotedto~the 32K rc powr

It not8 Scection rie049teoervnrain prctc de1

rh u n trae f2V3K anerd not throughgeterAntor

27 P3e-1r p ant weung-a

-If I

2tEll10 DRWE-jOi ASOt Mint~~al d~c~e o hepwrgnrto

ELCTRInYJORD UTHORITY-

Ate~

21Pge41 ection 4 04- 5

sindicated~ t hthigh the unit outputredu f hecondenser Injengtd~ibbvePressureed incg desrin hi h riseb vmbi nt emperatureWe bel~ieve

PleaIse provide us with th rscrapcity for th-e three options n nt generating~

21-Iisidca ted that~ thediaatgeofCBi theSheavy fn oe consumnptionPlease~ providethe us withpecntgA

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

400 MW COAL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO 5050

NET GENERATION - MWe 40000 CAPACITY FACTOR - 75 ANNUAL GENERATION MKWhYR 2628 SUB TOTAL PLANT COSTS (TPC) $1000 $620000

FIXED 0 amp M COSTS MH $ MH FIRST YEAR COST$1O00

------- --------- --- ---- --- --- ------------

OPERATING LABOR 351936 $3 $1100 MAINTENANCE LABOR 4000 of 150 OF TPC 3720

MAINTENANCE MATERIAL 6000

ADMIN LABOR of 150

3000 OF TPC

OF 0 amp M LABOR 5580 1446

SUB TOTAL FIXED OampM COSTS $11846

VARIABLE 0 amp M COSTS QUANTITY UNIT COST

VARIABLE MAINTENANCE 2628 MKWh 10 MILLKWH $ 2628 PROCESS WATER 13500000 GALLON 02 SGAL $ 2700 GENERAL PLANT CHEMICALS ALLOW 50 FUEL OIL 1000000 GALLON 035 $GAL $ 350 WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290SPECIAL BOILER MAINT ALLOW 0

SUB TOTAL VARIABLE OampM COSTS $ 8018

TOTAL FIXED amp VARIABLE OampM COSTS $19864 TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $8227 $TN $99139

(INCL INFLATION ADJUSTMENT)

B DEBT EQUITY RATIO =========== 8020

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $17574

WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290

TOTAL FIXED amp VARIABLE OampM COSTS $19864TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $5877 $TN $70814

(INCL INFLATION ADJUSTMENT)

6-21

Table 612 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY

400 MW OIL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO

NET GENERATION -

CAPACITY FACTOR -

ANNUAL GENERATION SUB TOTAL PLANT COSTS (TPC)

FIXED 0 amp M COSTS

OPERATING LABOR MAINTENANCE LABOR 4000 of

MAINTENANCE MATERIAL 6000 of

ADMIN LABOR

SUB TOTAL FIXED OampM COSTS

VARIABLE 0 amp M COSTS

VARIABLE MAINTENANCE PROCESS WATER GENERAL PLANT CHEMICALS FUEL OIL WASTE DISPOSAL (Section 6027) SPECIAL BOILER MAINT

SUB TOTAL VARIABLE OampM COSTS

5050

MWe

MKWhYR $1000

MH

262080

150

150 3000

QUANTITY

2628 MKWh 13500000 GALLON

1000000 GALLON 0 TNYR

TOTAL FIXED amp VARIABLE OampM COSTS FUEL OIL 503000 TNYR

B DEBT EQUITY RATIO =8020

40000 75

268 $443000

FIRST YEAR $ MH COST$1O00

$3 $ 800

OF TPC 2658

OF TPC 3987 OF 0 amp M LABOR 1037

$ 8482

UNIT COST

05 MILLKWH $ 1314 02 $GAL $ 2700

ALLOW 50 035 $GAL $ 350

$1000 $TN $ 0 ALLOW 0

$ 4414

$12896 $19981 $TN $100502

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $12896

WASTE DISPOSAL (Section 6027) 0 TNYR $1000 $TN $ 0

TOTAL FIXED amp VARIABLE OampM COSTS $12896 FUEL OIL 503000 TNYR $14104 $TN $70943

6-23

Page 26: fo; - pdf.usaid.gov

Mine and Shale ProcessingDesign - 2050 MW Project

I Overburden removal (north pit area) 10-meter benches

- Drill and blast

- 10 m3 front-end loader

- 77-ton truck haulage

I Oil shale mining 10-meter benches

- Rippe and auger scraper

- Front-end loader

- Portable in-pit crusher

- 77-ton truck haulage

Oil shale processing

- Feed = minus 100 mm

- Product = minus 8 mm

- Capacity = 250 tph

- Reversible impactor

- Two vibrating screens

1 Prefeasibility Study Oil Shale Fueled Power Generation

V -M 1AMI1ARt46

400 MW Full-Scale Oil Shale ProcessingPlant

Feed MTnus 200 mm Samplerr

1000 bull 10000 Tonnes Live Storage Grade

200 m long(-) 200 mm -- =-- Plow Feeders

00 h 100000 Tonnes Live Storage

Stream 3 - Sampler Bin Stream 2

Stream th 31Da2000

Circulating Load 2i

NFw Feed r -17000t1 170001l 170 t 17000 t 17000 t

1000 th Silo with 7 Impactor (-1)8 mm Reapro- 3 Day Storage at Aver age Loadn

0 20 Feeders 20 m Diameter by 40 m High

JJJTHT To Power Plant

Prefeasibility Study Oil Shale Fueled Power Generation

179589 6aJordarV 1I8 3-14-89 rsipc1

Mine and Shale ProcessingDesign - 4x100 MW Project

m Overburden removal (north area) 10-meter benches

- Drill and blast

- Three 20 m3 shovels

- 136-ton truck haulage

m Oil shale mining 10-meter benches

- Two mechanical surface miners

- 136-ton trucks to pit hopper

- Belt conveyor = 2000 tph

- Traveling stacker

m Oil shale processing

- Feed = minus 200 mm

- Product = minus 8 mm

- Capacity = three 1000 tph units

Prefeasibility Study Oil Shale Fueled Power Generation

VOO79-ampGEAIAt 17

i

Steady-State Production Schedule

Overburden removal bench m3

20 MW demo project 5n MW prototype 4x100 MW full-scale plant

Oil shale mining and shale processing tonnes

20 MW project 50 MW project 4x100 MW project

HourlyDesign Capacity

282 234

1850

HourlyDesign Capacity

250 250

2000

Avg Daily Annual PEQuctiQa Production

1690 507000 4217 13 million

33333 10 million

Max Daily(a) Annual(b) Production Production

1733 390000 4324 973000

34578 78 million

(a) Based on 100 operating factor for power block

(b) Based on 75 operating factor for power block ( 20 MW project = 300 shiftsyr 50 MW project = 900 shiftsyr 400 MW project = 900 shiftsyr)

Prefeasibility Study Oil Shale Fueled Power Generation

Conceptual Power Plant Plans

m Pyroflow boiler

Power generating facilities

m Auxiliaries

S Preleasibility Study Oil ShaJe Fueled Power Generation

vo0o7dEAO 19

Pyroflow Boiler SteamConciflons

Flow rate 226700 kghr (500000 Ibhr)

Pressure 1099 kgcm2 abs (15635 psia)

Temperature 51280C (9550F)

Same for 20 50 and 100 MW designs

Prefeasibility Study Oil ShaJe Fueled Power Generation

vooGALMI 20

HtomCOPUIOTP

- 50005 5op

-- LEVAThUM ORPORAION

0

-VI

DZ 4

Power Block

Fuel handling system

- Day binsscrew feeders

Boiler

- Pyroflow circulating fluid bed combustor

Power generation

- Non reheat condensing steam turbine

- Conventional Rankin steam cycle

Ash handling system (btm ash irom combustor and flyash from bag house)

- Wetted in pug mill to add 20plusmn wt wpter

Plant service water

- Air-cooled condensors and small cooling tower from circulating trim water coolers

Plant raw water

- To cooling tower makeup

- To drinking water system

- To pump seals etc

Plant treated makeup water

- Demineralizer train

Preteasibility Study Oil Shale Fueled Power Generation

i

Onsite Infrastructure

Project office

Control house

U Maintenance shops warehouse

Laboratory

Employee service facility

Site developmentoperations service facilities

- Fire controlsecurity

- Communications

- Lighting

- Roads drainage and sewage

Prefeasibility StudyQ1I Shale Fueled Power Generation

voo4JG m 0 JV

i

BechtellPyropower50 MW Cogeneration Plant - Mt Poso California

W4t Prefeasibility Study --- 7 Oil Shale Fueled Power Generation

179586122aJordarv 118 3-14-89 rsO

Characteristics of Three Size Operations

Oil shale fuel tpy

Mine development excavation bank m3

Spent ash disposal tpy (wetted)

Water consumption 1000 m3yr

Staffing required

Community population

400 MW

20 MW 50 MW (4x1 00)

390000 973000 78 million

500000 1 million 85 million

327000 815000 61 million

538 907 1263

185 324 1046

700 1200 4000

Prefeasibility Study Oil Shale Fueled Power Generation

V000ofllAM1 23

Conceptual Designs Summary

N All BOP facilities involve conventional equipment and technology

100 MW unit operation involves boiler scale-up considerations

N Water consumption estimates

- Requirement for 4x100 MW project is 13 million m3 yr

- Water allocation of 2 million m3yr of water supports 6x100 MW

N Water availability probably limits total power generation from oil shale in Jordan

Prefeasibility Study Oil Shale Fueled Power Generation

V007041GEAOLMI

i

TECHNOLOGY RISK ASSESSMENT

Basic concepts

Key boiler scale-up design issues

Impact of scale-up

U Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Prefeasibility Study O1 Shale Fueled Power Generation

VOOh-7AEAAO 2

Basic Concepts

U CFBC is relatively new in the powerindustry

- Existing plants are small typically 20 to 50 MW

- There is limited operating experience with high-ash fuels

- Existing designs for lignite biomass and coal wastes show good plant performance

I Application of CFBC boiler design to oil shale fuel has defined risk that relates to scale-up of existing design

Similar CFBC technology is used in petroleum refining industry

- FCC cracking plant regenerators burn carbon residue off spent catalyst

- 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

FUEL ANALYSES

High Ash Fuel Projects Total Solids Input Basis

Gilberton Cambria North Branch

Carbon 4653 2749 1822 Hydrogen 153 164 160 Sulfur 073 222 234 Nitrogen 085 051 043 Oxygen 282 218 468 Moisture 1451 514 557 Ash 3303 6 0 6Z16

10000 10000 10000

HHVBtulb 7485 4809 3453

includes limestone feed a3 ash

includes CO2 in Ca~o3

CA89029 CAkw

Oil Shale

1132

113

255

048

065

320

-8062

10000

2250

Key Boiler Scale-Up DesignIssues

m Solids handling

- Feeding shale to combustor

- 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

Voo4tGEAMI 30

i

Mine and Shale Processing

U Fugitive dust emissions are controllable

- Wetting mine roads

- Enclose crushing plant equipment

Noise levels are controllable

- Enclose crushing plant equipment - Muffle truck exhausts

- Engineered waste disposal

Water effluents can be controlled

- Need good mine drainage design - Continue leachability studies on

waste dump piles

Prefeasibilily StudyOil Shale Fueled Po r Generaton

V0079OOG-4O 31

1

Power Plant

II Fugitive dust emissions are controllable

- Baghouse designoperation will minimize particulates in flue gas

- Wetting spent ash before disposal

N Gaseous emissions are controllable

- Pilot test results show acceptable SO2NOxCO in flue gas

- Develop baseline data for Sultani area

Develop air dispersion model for Sultani

Prefeasibility StudyOil Shale Fueled Power Generatio

V00 V-4GEA l32

i

Power Plant (Contd)

Noise levels are controllable

- Enclose boiler plant fans as required - Enclose turbines and pumps as

required

Water effluents are controllable

- Continue leachability studies on spent ash disposal

- Develop aquifer dispersion model

- Develop sewage and garbage disposal plan

Prefeasibility SludyOil Shale Fueled Power Generation

V00-4FAAI 33

Conclusions

No environmental constraints are anticipated on oil shale powerdevelopment

Gas effluents will meet World Bank standards

- Ash disposal is manageable

- The potential for groundwatercontamination appears low

- Water effluents will be minimal

Continued studies to develop air and groundwater baseline data are recommended

S Prefeasibility Study Oil Shale Fueled Power Generation

v0 9ampGLAMR 34

Power Demand vs SupplyAssessment

m Demand growth forecasts

Electrical generating capacity

= Power supply forecasts

= Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Preleasibility Study Oil Shaie Fuelod Power Generation

VO9- uLIROI

1

Power Demand Forecasts

Percent Annual Growth

JEA

Meta systems HaglerBailey and Bechtel National Inc

JEA Peak Demand Growth

1980 (actual) 1985 (actual) 1987 (actual) 1995 (forecast) 2005 (forecast)

1986 1990 to to

1990 2000

97 60

49 39

200 MW 475 MW 593 MW 900 MW

1400 MW

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOO-DLURO2

i

JEA ElectricityGeneratingCapacity

1987 Installed

Capacity (MW) Aqaba 260

22

Zarqa 395

Marka 102

Karak 23

Miscellaneous 67

Subtotal JEA capacity 869

Other capacity - industrial 110

Total 979

Prefeasibility Study Oi1 Shale Fueled Power Generation

V000-6O0LFJRO3 (

Forecast New Power Generating Capacity Required

Fcst 1987 Required

New Peak Available Installed

Demand Capacity Shortfall (a) Capacity (b) (MM (MW) (MW) (MW)

Assumed capacityfactor (65) (75)

1995 requirement 900 636 264 352

2005 requirement 1400 636 764 1019

(a) Excludes proposed additions and retirements (b) Excludes possible power exports or imports

Load shedding or levelizing not considered

Preteasibility Study Oil Shale Fueled Power Generation

Vflcmf-R)LLAO4

i

Supply vs Demand Evaluation

1800

1600

1400 Forecast Peak Demands

1200 -

E Installed Capacity

0 800shy75--

U) Assumed Available Calcit

a 6 Ao600 shy0 o 65

400 shy

200

I I I I I I I I I I I I I I I I I I I I I I I 1 1 1980 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958f738aIJordarV 118 3-14-89 rspCO

Conclusions

Additional power generating capacity is needed to meet forecasted 19952005demand growth

A 400 MW oil shale-to-power project at Sultani can meet a portion of this need

U A second 400 MW oil shale project maybe required if water is available

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOW0O-8LURO5

i

Economic Feasibility

N Order-of-magnitude costs

N Economic analysis

- Jordan study options

- Project size effect

m Comparison with alternative fuels

- Fuel requirement

- Project financing effect

- Alternate fuel price effect

- Estimated cost of electricity

N Summary financial analysis

bull Material was developed by Bechtel Power Company

Prefeasibility Study

go Oil Shale Fueled Power Generation VOOSO-ampDtJROh

ORDER-OF-MAGNITUDE COSTS

U Oil shale fuel

Power plant

I Integrated project- busbar

Preteasibility Study

Oil Shale Fueled Power Generation

VOO9O-ampDLUROS

Oil Shale Fuel Costs

Installed Capital Cost

Mine Development

Mine Equipment

Processing Plant

Spare Parts

Working Capital

Capitalized Interest

Total

Annual Operating Cost

Fuel Cost $UStonne

bull Based on 8020 debtequity ratio

20 MW

4900

11090

6945

1200

1200

4054

29389

5582

1431

US $1000 Factored

50 MW 4x100 MW

7833 30915

12202 66012

8388 50889

1300 5000

2200 10000

5108 39075

37031 201891

11556 53236

1188 684

Prefeasibility Study

Oil Shale Fueled Power Generation

VCO-ampDLUJ1O

Power Plant Costs

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Cost

Power faciities 57500 91800 567800

Owners cost 10200 20400 192700

Total 67700 112200 760500

Annual Operating Cost 2205 3248 17157(excluding fuel cost)

bullBased on 8020 debtequity ratio oil shale fueled

Prefeasibility Study

Oil Shale Fueled Power Generation

V00O8c4LLMO9

i

INTEGRATED PROJECT -BUSBAR COST

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Costs Mine amp shale processingPower block Waste disposal Infrastructure

29359 67700

1664 10000

37031 112200

2381 15000

201891 760500

8714 45000

TOTAL 108753 166612 1016105

Annual Operating Cost Mine amp shale processingPower block Waste disposal Infrastructure (a)

5582 2205

316

11556 3248

710

56430(b) 18186(b) 6004

Subtotal 8103 15514 80620

Capital Charges 139 9410 15596 106000

Total 17513 31110 186620

25-year levelized cost - - 218000

Busbar Cost millskWh First year 128 92 71 25-year levelized 83

(a) Housing and community facilities assumed self-liquidating(b) Includes first-year inflation adjustment

Based on 8020 debtequity ratio

Prefeasibility StudyOil Shale Fueled Power Generaion

VOOOO-8MLtROi0

ECONOMIC ANALYSIS

n Jordan study options

Project size effect

Fuel requirement

Project financing effect

Alternative fuel price effect

Estimated electricity cost

Summary financial analysis results

Prefeasibility Study

Oil Shale Fueled Powr Generation

VOOeO-BOCLLO1 I

i

Jordan Study Options

U Project size

- Demonstration = 20 MW

- Prototype = 50 MW

- Commercial = 400 MW (4x100)

Project financing

- Debtequity 8020

- Debtequity 5050

Imported alternative fuels cost assumptions

A B Crude oil $17bbl $24bbl

$120onne $170tonne

Low sulfur coal $ 50tonne $ 70tonne See Chevron forecast supporting assumptions

Prefeasibility StudyOil Shale Fueled Power Generation

VOOOO-8DLIJRO12

i

Crude Oil Price Trends

60

Source World Energy Outlook Chevron Corporation Oclober 1987

40

High trend

No Ir 20 ~~~~Arabian Light Spot I A u

IILowYUII trend

0 1970 1975 1980 1985 1990 1995

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958246aJodar 118 3-14-89 rsO

2000

Project Size Effect Shale Fuel Option

Project Size

Integrated facilities installed capital cost$ US million

Shale cost $UStonne(8020 debtequity)

Cost of power millskWh(8020 debtequity ratio)

20 MW

109

143

128

50 MW

167

118

92

400 MW (4x1 00)

1016

68

71

Prefeasibility Study Oil Sampae Fueled Power Generation

VOO O-8I0LJRO13

gt1

1

Power Block Investment Cost

3000

$2875 Excluding mining and offsite 2800

2600

2400

2200

2000

$1836 1800

$1613 1600

$1420 1400 1I 1 I

0 100 200 300 400 MWe

August 1988

Preleasibility Study OilShale Fueled Power Generation

179581147aJodar1 18 3-14-89 rspcl

Fuel Requirement - 4x100 MW Project

Coal = 12 million tpy

n Oil = 503000 tpy

Oil shale = 78 million tpy

Preleasibility Study

Oil Shale Fueled Power Generation

IO060-OLLIRO14

Financing Effect -Project

Oil Shale Fuel Option

Mine and shale processing

Power block

Waste disposal

Community facilities

Total

Coal-Fired Power Plant

Oil-Fired Power Plant

400 MW

Capital Cost ($US MM)

DebtEquity

8020 5050

202 187

760 760

9 8

45 45

1016 1000

647 647

463 463

Prefeasibility StudyOil Shale Fueled Power Generation

VOe-BD1JRO15

Financing Effect shy400 MW Project

Operating Costs ($US millionyr)

DebtEquity

8020 5050

Coal $70tonne 282 282

Oil $24bbl 254 254

Oil shale-fueled 218 236

Including fuel

Prefeasibility Study

SOil Shale Fueled Power Generaion

VOOIt JLMO I

Alternate Fuel Price Effect shy4x100 MW Project

Financing Basis DebtEquity Ratio

Alternate Fuel Price

Imported coal $50tonne $70tonne

Imported oil $17bbl ($120tonne) $24bbl ($170tonne)

Cumulative 25-yr Net Benefit

Favoring Oil Shale (US $MM) shy

8020 5050

778 315 2531 2068

(18) (506)1810 1322

Prefeasibility Study

Oil Shale Fueled Power Generation

Voo -I DLU-A 2

i

Comparison of Cumulative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

32 Pay Out Year shy

400 MW PlantOil Shale vs Imported Coal (8020 debtequty)

30

28 -Cumulative fuel cost savings forcoal $70ton

Cumulative fuel cost savings for coaJ $50ton

26---------- Cumulative Incremental capital plus OampM costs

24

22 -

18 -0

W- Cumulative net benefit for shae vs coal $50ton 2B Cumulative net benefit for shale vs coal $70ton

co16C -

14 -

12 -

10 -

09

06 -Payout inyear 1

Payout Inyear 9 for coal $50ton - -- - - -shy

02 0 I

0 1 2 3 4 5 Nowl Yewr in which sauings in fWe colsacm-ewi tat hsawinitl

ca=al wosaand OampM costs

6

_iiM

7 8

9 10

------ - -amp -

11 12 13 14Year of Operation

--

15

- - --shy

16 17

I

18

1

19

I

20

I

21

I

22

I

23

I

24 25

Prefeasibility StudyOil Shale Fueled Power Generation

17958d351aJordanr 3-14-89 rsO

118

Comparison of Cumuiative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

28 Pay Out Year shy

400 MW Plant Oil Shale vs Imported Coal (5050 debtequity)

26shy2

24-

Cumulaive fuel nst savings for coal 0 $70ton Cumulative fuel cost savings for coal $50ton Cumulative Incremental capital plus OampM corts

22 -

20 -

18 -- Cumuladve net benefit for shle vs coal $50ton B Cumuarve net benefit for sale vs coal $70ton

16 -

C 14

12

10

08 -06 - Payout In year 1for coal $50ton

04

Payout Inyear 1

for coal $70ton02~

0 0

-No

02-

1 2

Yew inrY MCM cajlaI rl

3 4 5 6

sngm inW coas 0 ort hghWcentWin

0tOM cori

7

--

8

- -

9 10 11 12 13 14

Year of Operation

15 16 17

I

18

IIII

19 20 21 22 23 24 25

Preieasibility Study Oil Shale Fueled Power Generation

17958451 bJordarV118 3-14-89 rsipcI

Estimated Cost of Power- 400 MW (4 x 100)

FUEL

ImportedCoal

$50T

$70fT

1st Year

68 88

Levelized

78 107

Sultani Oil Shale

71 83

ImportedOil

$1713

$2413

56

67

76

96

0 10 20 30 40 50

I 60

I 70

I 80

I 90 100 110 120

Mills per kWh

Prefeasibility Study Oil Shale Fueled Power Generation

179581251 cJordarVl 18 3-14-89 rspc1

Summary Financial Analysis Results

Project size

Debt equity ratio

- Investment cost

- Power cost

- 25-year net benefit

- Project implementation

Alternative fuel price

Economic Comparison

Very significant

Not significant

Not significant

Very significant

Critical

Very significant

Prefeasibility Study

Oil Shale Fueled Power Generation

VY0 tDLUAi3

i

Study Conclusions

Feasibility

Timeliness

Expansion conditions

Environmental impacts

Development advantages

Prefeasibility Study

Oil Shale Fueled Power Generation VW41-1AiUA

4

Feasibility

Oil shale fueled power generation is technically and economically justifiedunder certain conditions

N Need for additional generating capacity

exists

- 6 annual peak demand growth - Orderly retirement of olderhigh cost

generating capacity needed

U Higher costs are expected for imported fuels

- 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

-OP b i j~~4shy

-4protntiYPe 4 demo plnt orP42 t~Plant orPootypeProje(-7hould

that Rj

demo 4Therefore-44 JEA anxinus

the

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

27Pag 4- 1 2S c i n 4 4

4i2Sectjo4-18-4 Secio 4-4 014

lt th~ae hi4h -tasisso syste thrug27 ~ 04lag arstl~art-p tasforme ed 2p27132Kvdieanwhy notthroug

EAto- is protmm~~ thegnJgt~~ pracie an ect ~ platqrby

28Pg 4 s heonnenotedto~the 32K rc powr

It not8 Scection rie049teoervnrain prctc de1

rh u n trae f2V3K anerd not throughgeterAntor

27 P3e-1r p ant weung-a

-If I

2tEll10 DRWE-jOi ASOt Mint~~al d~c~e o hepwrgnrto

ELCTRInYJORD UTHORITY-

Ate~

21Pge41 ection 4 04- 5

sindicated~ t hthigh the unit outputredu f hecondenser Injengtd~ibbvePressureed incg desrin hi h riseb vmbi nt emperatureWe bel~ieve

PleaIse provide us with th rscrapcity for th-e three options n nt generating~

21-Iisidca ted that~ thediaatgeofCBi theSheavy fn oe consumnptionPlease~ providethe us withpecntgA

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

400 MW COAL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO 5050

NET GENERATION - MWe 40000 CAPACITY FACTOR - 75 ANNUAL GENERATION MKWhYR 2628 SUB TOTAL PLANT COSTS (TPC) $1000 $620000

FIXED 0 amp M COSTS MH $ MH FIRST YEAR COST$1O00

------- --------- --- ---- --- --- ------------

OPERATING LABOR 351936 $3 $1100 MAINTENANCE LABOR 4000 of 150 OF TPC 3720

MAINTENANCE MATERIAL 6000

ADMIN LABOR of 150

3000 OF TPC

OF 0 amp M LABOR 5580 1446

SUB TOTAL FIXED OampM COSTS $11846

VARIABLE 0 amp M COSTS QUANTITY UNIT COST

VARIABLE MAINTENANCE 2628 MKWh 10 MILLKWH $ 2628 PROCESS WATER 13500000 GALLON 02 SGAL $ 2700 GENERAL PLANT CHEMICALS ALLOW 50 FUEL OIL 1000000 GALLON 035 $GAL $ 350 WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290SPECIAL BOILER MAINT ALLOW 0

SUB TOTAL VARIABLE OampM COSTS $ 8018

TOTAL FIXED amp VARIABLE OampM COSTS $19864 TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $8227 $TN $99139

(INCL INFLATION ADJUSTMENT)

B DEBT EQUITY RATIO =========== 8020

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $17574

WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290

TOTAL FIXED amp VARIABLE OampM COSTS $19864TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $5877 $TN $70814

(INCL INFLATION ADJUSTMENT)

6-21

Table 612 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY

400 MW OIL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO

NET GENERATION -

CAPACITY FACTOR -

ANNUAL GENERATION SUB TOTAL PLANT COSTS (TPC)

FIXED 0 amp M COSTS

OPERATING LABOR MAINTENANCE LABOR 4000 of

MAINTENANCE MATERIAL 6000 of

ADMIN LABOR

SUB TOTAL FIXED OampM COSTS

VARIABLE 0 amp M COSTS

VARIABLE MAINTENANCE PROCESS WATER GENERAL PLANT CHEMICALS FUEL OIL WASTE DISPOSAL (Section 6027) SPECIAL BOILER MAINT

SUB TOTAL VARIABLE OampM COSTS

5050

MWe

MKWhYR $1000

MH

262080

150

150 3000

QUANTITY

2628 MKWh 13500000 GALLON

1000000 GALLON 0 TNYR

TOTAL FIXED amp VARIABLE OampM COSTS FUEL OIL 503000 TNYR

B DEBT EQUITY RATIO =8020

40000 75

268 $443000

FIRST YEAR $ MH COST$1O00

$3 $ 800

OF TPC 2658

OF TPC 3987 OF 0 amp M LABOR 1037

$ 8482

UNIT COST

05 MILLKWH $ 1314 02 $GAL $ 2700

ALLOW 50 035 $GAL $ 350

$1000 $TN $ 0 ALLOW 0

$ 4414

$12896 $19981 $TN $100502

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $12896

WASTE DISPOSAL (Section 6027) 0 TNYR $1000 $TN $ 0

TOTAL FIXED amp VARIABLE OampM COSTS $12896 FUEL OIL 503000 TNYR $14104 $TN $70943

6-23

Page 27: fo; - pdf.usaid.gov

400 MW Full-Scale Oil Shale ProcessingPlant

Feed MTnus 200 mm Samplerr

1000 bull 10000 Tonnes Live Storage Grade

200 m long(-) 200 mm -- =-- Plow Feeders

00 h 100000 Tonnes Live Storage

Stream 3 - Sampler Bin Stream 2

Stream th 31Da2000

Circulating Load 2i

NFw Feed r -17000t1 170001l 170 t 17000 t 17000 t

1000 th Silo with 7 Impactor (-1)8 mm Reapro- 3 Day Storage at Aver age Loadn

0 20 Feeders 20 m Diameter by 40 m High

JJJTHT To Power Plant

Prefeasibility Study Oil Shale Fueled Power Generation

179589 6aJordarV 1I8 3-14-89 rsipc1

Mine and Shale ProcessingDesign - 4x100 MW Project

m Overburden removal (north area) 10-meter benches

- Drill and blast

- Three 20 m3 shovels

- 136-ton truck haulage

m Oil shale mining 10-meter benches

- Two mechanical surface miners

- 136-ton trucks to pit hopper

- Belt conveyor = 2000 tph

- Traveling stacker

m Oil shale processing

- Feed = minus 200 mm

- Product = minus 8 mm

- Capacity = three 1000 tph units

Prefeasibility Study Oil Shale Fueled Power Generation

VOO79-ampGEAIAt 17

i

Steady-State Production Schedule

Overburden removal bench m3

20 MW demo project 5n MW prototype 4x100 MW full-scale plant

Oil shale mining and shale processing tonnes

20 MW project 50 MW project 4x100 MW project

HourlyDesign Capacity

282 234

1850

HourlyDesign Capacity

250 250

2000

Avg Daily Annual PEQuctiQa Production

1690 507000 4217 13 million

33333 10 million

Max Daily(a) Annual(b) Production Production

1733 390000 4324 973000

34578 78 million

(a) Based on 100 operating factor for power block

(b) Based on 75 operating factor for power block ( 20 MW project = 300 shiftsyr 50 MW project = 900 shiftsyr 400 MW project = 900 shiftsyr)

Prefeasibility Study Oil Shale Fueled Power Generation

Conceptual Power Plant Plans

m Pyroflow boiler

Power generating facilities

m Auxiliaries

S Preleasibility Study Oil ShaJe Fueled Power Generation

vo0o7dEAO 19

Pyroflow Boiler SteamConciflons

Flow rate 226700 kghr (500000 Ibhr)

Pressure 1099 kgcm2 abs (15635 psia)

Temperature 51280C (9550F)

Same for 20 50 and 100 MW designs

Prefeasibility Study Oil ShaJe Fueled Power Generation

vooGALMI 20

HtomCOPUIOTP

- 50005 5op

-- LEVAThUM ORPORAION

0

-VI

DZ 4

Power Block

Fuel handling system

- Day binsscrew feeders

Boiler

- Pyroflow circulating fluid bed combustor

Power generation

- Non reheat condensing steam turbine

- Conventional Rankin steam cycle

Ash handling system (btm ash irom combustor and flyash from bag house)

- Wetted in pug mill to add 20plusmn wt wpter

Plant service water

- Air-cooled condensors and small cooling tower from circulating trim water coolers

Plant raw water

- To cooling tower makeup

- To drinking water system

- To pump seals etc

Plant treated makeup water

- Demineralizer train

Preteasibility Study Oil Shale Fueled Power Generation

i

Onsite Infrastructure

Project office

Control house

U Maintenance shops warehouse

Laboratory

Employee service facility

Site developmentoperations service facilities

- Fire controlsecurity

- Communications

- Lighting

- Roads drainage and sewage

Prefeasibility StudyQ1I Shale Fueled Power Generation

voo4JG m 0 JV

i

BechtellPyropower50 MW Cogeneration Plant - Mt Poso California

W4t Prefeasibility Study --- 7 Oil Shale Fueled Power Generation

179586122aJordarv 118 3-14-89 rsO

Characteristics of Three Size Operations

Oil shale fuel tpy

Mine development excavation bank m3

Spent ash disposal tpy (wetted)

Water consumption 1000 m3yr

Staffing required

Community population

400 MW

20 MW 50 MW (4x1 00)

390000 973000 78 million

500000 1 million 85 million

327000 815000 61 million

538 907 1263

185 324 1046

700 1200 4000

Prefeasibility Study Oil Shale Fueled Power Generation

V000ofllAM1 23

Conceptual Designs Summary

N All BOP facilities involve conventional equipment and technology

100 MW unit operation involves boiler scale-up considerations

N Water consumption estimates

- Requirement for 4x100 MW project is 13 million m3 yr

- Water allocation of 2 million m3yr of water supports 6x100 MW

N Water availability probably limits total power generation from oil shale in Jordan

Prefeasibility Study Oil Shale Fueled Power Generation

V007041GEAOLMI

i

TECHNOLOGY RISK ASSESSMENT

Basic concepts

Key boiler scale-up design issues

Impact of scale-up

U Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Prefeasibility Study O1 Shale Fueled Power Generation

VOOh-7AEAAO 2

Basic Concepts

U CFBC is relatively new in the powerindustry

- Existing plants are small typically 20 to 50 MW

- There is limited operating experience with high-ash fuels

- Existing designs for lignite biomass and coal wastes show good plant performance

I Application of CFBC boiler design to oil shale fuel has defined risk that relates to scale-up of existing design

Similar CFBC technology is used in petroleum refining industry

- FCC cracking plant regenerators burn carbon residue off spent catalyst

- 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

FUEL ANALYSES

High Ash Fuel Projects Total Solids Input Basis

Gilberton Cambria North Branch

Carbon 4653 2749 1822 Hydrogen 153 164 160 Sulfur 073 222 234 Nitrogen 085 051 043 Oxygen 282 218 468 Moisture 1451 514 557 Ash 3303 6 0 6Z16

10000 10000 10000

HHVBtulb 7485 4809 3453

includes limestone feed a3 ash

includes CO2 in Ca~o3

CA89029 CAkw

Oil Shale

1132

113

255

048

065

320

-8062

10000

2250

Key Boiler Scale-Up DesignIssues

m Solids handling

- Feeding shale to combustor

- 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

Voo4tGEAMI 30

i

Mine and Shale Processing

U Fugitive dust emissions are controllable

- Wetting mine roads

- Enclose crushing plant equipment

Noise levels are controllable

- Enclose crushing plant equipment - Muffle truck exhausts

- Engineered waste disposal

Water effluents can be controlled

- Need good mine drainage design - Continue leachability studies on

waste dump piles

Prefeasibilily StudyOil Shale Fueled Po r Generaton

V0079OOG-4O 31

1

Power Plant

II Fugitive dust emissions are controllable

- Baghouse designoperation will minimize particulates in flue gas

- Wetting spent ash before disposal

N Gaseous emissions are controllable

- Pilot test results show acceptable SO2NOxCO in flue gas

- Develop baseline data for Sultani area

Develop air dispersion model for Sultani

Prefeasibility StudyOil Shale Fueled Power Generatio

V00 V-4GEA l32

i

Power Plant (Contd)

Noise levels are controllable

- Enclose boiler plant fans as required - Enclose turbines and pumps as

required

Water effluents are controllable

- Continue leachability studies on spent ash disposal

- Develop aquifer dispersion model

- Develop sewage and garbage disposal plan

Prefeasibility SludyOil Shale Fueled Power Generation

V00-4FAAI 33

Conclusions

No environmental constraints are anticipated on oil shale powerdevelopment

Gas effluents will meet World Bank standards

- Ash disposal is manageable

- The potential for groundwatercontamination appears low

- Water effluents will be minimal

Continued studies to develop air and groundwater baseline data are recommended

S Prefeasibility Study Oil Shale Fueled Power Generation

v0 9ampGLAMR 34

Power Demand vs SupplyAssessment

m Demand growth forecasts

Electrical generating capacity

= Power supply forecasts

= Conclusions

Material developed by Oak Ridge National Laboratory (ORNL) and Bechtel

Preleasibility Study Oil Shaie Fuelod Power Generation

VO9- uLIROI

1

Power Demand Forecasts

Percent Annual Growth

JEA

Meta systems HaglerBailey and Bechtel National Inc

JEA Peak Demand Growth

1980 (actual) 1985 (actual) 1987 (actual) 1995 (forecast) 2005 (forecast)

1986 1990 to to

1990 2000

97 60

49 39

200 MW 475 MW 593 MW 900 MW

1400 MW

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOO-DLURO2

i

JEA ElectricityGeneratingCapacity

1987 Installed

Capacity (MW) Aqaba 260

22

Zarqa 395

Marka 102

Karak 23

Miscellaneous 67

Subtotal JEA capacity 869

Other capacity - industrial 110

Total 979

Prefeasibility Study Oi1 Shale Fueled Power Generation

V000-6O0LFJRO3 (

Forecast New Power Generating Capacity Required

Fcst 1987 Required

New Peak Available Installed

Demand Capacity Shortfall (a) Capacity (b) (MM (MW) (MW) (MW)

Assumed capacityfactor (65) (75)

1995 requirement 900 636 264 352

2005 requirement 1400 636 764 1019

(a) Excludes proposed additions and retirements (b) Excludes possible power exports or imports

Load shedding or levelizing not considered

Preteasibility Study Oil Shale Fueled Power Generation

Vflcmf-R)LLAO4

i

Supply vs Demand Evaluation

1800

1600

1400 Forecast Peak Demands

1200 -

E Installed Capacity

0 800shy75--

U) Assumed Available Calcit

a 6 Ao600 shy0 o 65

400 shy

200

I I I I I I I I I I I I I I I I I I I I I I I 1 1 1980 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958f738aIJordarV 118 3-14-89 rspCO

Conclusions

Additional power generating capacity is needed to meet forecasted 19952005demand growth

A 400 MW oil shale-to-power project at Sultani can meet a portion of this need

U A second 400 MW oil shale project maybe required if water is available

Prefeasibility Study

Oil Shale Fueled Power Generation

VOOW0O-8LURO5

i

Economic Feasibility

N Order-of-magnitude costs

N Economic analysis

- Jordan study options

- Project size effect

m Comparison with alternative fuels

- Fuel requirement

- Project financing effect

- Alternate fuel price effect

- Estimated cost of electricity

N Summary financial analysis

bull Material was developed by Bechtel Power Company

Prefeasibility Study

go Oil Shale Fueled Power Generation VOOSO-ampDtJROh

ORDER-OF-MAGNITUDE COSTS

U Oil shale fuel

Power plant

I Integrated project- busbar

Preteasibility Study

Oil Shale Fueled Power Generation

VOO9O-ampDLUROS

Oil Shale Fuel Costs

Installed Capital Cost

Mine Development

Mine Equipment

Processing Plant

Spare Parts

Working Capital

Capitalized Interest

Total

Annual Operating Cost

Fuel Cost $UStonne

bull Based on 8020 debtequity ratio

20 MW

4900

11090

6945

1200

1200

4054

29389

5582

1431

US $1000 Factored

50 MW 4x100 MW

7833 30915

12202 66012

8388 50889

1300 5000

2200 10000

5108 39075

37031 201891

11556 53236

1188 684

Prefeasibility Study

Oil Shale Fueled Power Generation

VCO-ampDLUJ1O

Power Plant Costs

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Cost

Power faciities 57500 91800 567800

Owners cost 10200 20400 192700

Total 67700 112200 760500

Annual Operating Cost 2205 3248 17157(excluding fuel cost)

bullBased on 8020 debtequity ratio oil shale fueled

Prefeasibility Study

Oil Shale Fueled Power Generation

V00O8c4LLMO9

i

INTEGRATED PROJECT -BUSBAR COST

US $1000 20 MW 50 MW 4x100 MW

Installed Capital Costs Mine amp shale processingPower block Waste disposal Infrastructure

29359 67700

1664 10000

37031 112200

2381 15000

201891 760500

8714 45000

TOTAL 108753 166612 1016105

Annual Operating Cost Mine amp shale processingPower block Waste disposal Infrastructure (a)

5582 2205

316

11556 3248

710

56430(b) 18186(b) 6004

Subtotal 8103 15514 80620

Capital Charges 139 9410 15596 106000

Total 17513 31110 186620

25-year levelized cost - - 218000

Busbar Cost millskWh First year 128 92 71 25-year levelized 83

(a) Housing and community facilities assumed self-liquidating(b) Includes first-year inflation adjustment

Based on 8020 debtequity ratio

Prefeasibility StudyOil Shale Fueled Power Generaion

VOOOO-8MLtROi0

ECONOMIC ANALYSIS

n Jordan study options

Project size effect

Fuel requirement

Project financing effect

Alternative fuel price effect

Estimated electricity cost

Summary financial analysis results

Prefeasibility Study

Oil Shale Fueled Powr Generation

VOOeO-BOCLLO1 I

i

Jordan Study Options

U Project size

- Demonstration = 20 MW

- Prototype = 50 MW

- Commercial = 400 MW (4x100)

Project financing

- Debtequity 8020

- Debtequity 5050

Imported alternative fuels cost assumptions

A B Crude oil $17bbl $24bbl

$120onne $170tonne

Low sulfur coal $ 50tonne $ 70tonne See Chevron forecast supporting assumptions

Prefeasibility StudyOil Shale Fueled Power Generation

VOOOO-8DLIJRO12

i

Crude Oil Price Trends

60

Source World Energy Outlook Chevron Corporation Oclober 1987

40

High trend

No Ir 20 ~~~~Arabian Light Spot I A u

IILowYUII trend

0 1970 1975 1980 1985 1990 1995

Year

Prefeasibility Study Oil Shale Fueled Power Generation

17958246aJodar 118 3-14-89 rsO

2000

Project Size Effect Shale Fuel Option

Project Size

Integrated facilities installed capital cost$ US million

Shale cost $UStonne(8020 debtequity)

Cost of power millskWh(8020 debtequity ratio)

20 MW

109

143

128

50 MW

167

118

92

400 MW (4x1 00)

1016

68

71

Prefeasibility Study Oil Sampae Fueled Power Generation

VOO O-8I0LJRO13

gt1

1

Power Block Investment Cost

3000

$2875 Excluding mining and offsite 2800

2600

2400

2200

2000

$1836 1800

$1613 1600

$1420 1400 1I 1 I

0 100 200 300 400 MWe

August 1988

Preleasibility Study OilShale Fueled Power Generation

179581147aJodar1 18 3-14-89 rspcl

Fuel Requirement - 4x100 MW Project

Coal = 12 million tpy

n Oil = 503000 tpy

Oil shale = 78 million tpy

Preleasibility Study

Oil Shale Fueled Power Generation

IO060-OLLIRO14

Financing Effect -Project

Oil Shale Fuel Option

Mine and shale processing

Power block

Waste disposal

Community facilities

Total

Coal-Fired Power Plant

Oil-Fired Power Plant

400 MW

Capital Cost ($US MM)

DebtEquity

8020 5050

202 187

760 760

9 8

45 45

1016 1000

647 647

463 463

Prefeasibility StudyOil Shale Fueled Power Generation

VOe-BD1JRO15

Financing Effect shy400 MW Project

Operating Costs ($US millionyr)

DebtEquity

8020 5050

Coal $70tonne 282 282

Oil $24bbl 254 254

Oil shale-fueled 218 236

Including fuel

Prefeasibility Study

SOil Shale Fueled Power Generaion

VOOIt JLMO I

Alternate Fuel Price Effect shy4x100 MW Project

Financing Basis DebtEquity Ratio

Alternate Fuel Price

Imported coal $50tonne $70tonne

Imported oil $17bbl ($120tonne) $24bbl ($170tonne)

Cumulative 25-yr Net Benefit

Favoring Oil Shale (US $MM) shy

8020 5050

778 315 2531 2068

(18) (506)1810 1322

Prefeasibility Study

Oil Shale Fueled Power Generation

Voo -I DLU-A 2

i

Comparison of Cumulative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

32 Pay Out Year shy

400 MW PlantOil Shale vs Imported Coal (8020 debtequty)

30

28 -Cumulative fuel cost savings forcoal $70ton

Cumulative fuel cost savings for coaJ $50ton

26---------- Cumulative Incremental capital plus OampM costs

24

22 -

18 -0

W- Cumulative net benefit for shae vs coal $50ton 2B Cumulative net benefit for shale vs coal $70ton

co16C -

14 -

12 -

10 -

09

06 -Payout inyear 1

Payout Inyear 9 for coal $50ton - -- - - -shy

02 0 I

0 1 2 3 4 5 Nowl Yewr in which sauings in fWe colsacm-ewi tat hsawinitl

ca=al wosaand OampM costs

6

_iiM

7 8

9 10

------ - -amp -

11 12 13 14Year of Operation

--

15

- - --shy

16 17

I

18

1

19

I

20

I

21

I

22

I

23

I

24 25

Prefeasibility StudyOil Shale Fueled Power Generation

17958d351aJordanr 3-14-89 rsO

118

Comparison of Cumuiative Capital Plus OampM vs Fuel Costs for Oil Shale vs Coal

28 Pay Out Year shy

400 MW Plant Oil Shale vs Imported Coal (5050 debtequity)

26shy2

24-

Cumulaive fuel nst savings for coal 0 $70ton Cumulative fuel cost savings for coal $50ton Cumulative Incremental capital plus OampM corts

22 -

20 -

18 -- Cumuladve net benefit for shle vs coal $50ton B Cumuarve net benefit for sale vs coal $70ton

16 -

C 14

12

10

08 -06 - Payout In year 1for coal $50ton

04

Payout Inyear 1

for coal $70ton02~

0 0

-No

02-

1 2

Yew inrY MCM cajlaI rl

3 4 5 6

sngm inW coas 0 ort hghWcentWin

0tOM cori

7

--

8

- -

9 10 11 12 13 14

Year of Operation

15 16 17

I

18

IIII

19 20 21 22 23 24 25

Preieasibility Study Oil Shale Fueled Power Generation

17958451 bJordarV118 3-14-89 rsipcI

Estimated Cost of Power- 400 MW (4 x 100)

FUEL

ImportedCoal

$50T

$70fT

1st Year

68 88

Levelized

78 107

Sultani Oil Shale

71 83

ImportedOil

$1713

$2413

56

67

76

96

0 10 20 30 40 50

I 60

I 70

I 80

I 90 100 110 120

Mills per kWh

Prefeasibility Study Oil Shale Fueled Power Generation

179581251 cJordarVl 18 3-14-89 rspc1

Summary Financial Analysis Results

Project size

Debt equity ratio

- Investment cost

- Power cost

- 25-year net benefit

- Project implementation

Alternative fuel price

Economic Comparison

Very significant

Not significant

Not significant

Very significant

Critical

Very significant

Prefeasibility Study

Oil Shale Fueled Power Generation

VY0 tDLUAi3

i

Study Conclusions

Feasibility

Timeliness

Expansion conditions

Environmental impacts

Development advantages

Prefeasibility Study

Oil Shale Fueled Power Generation VW41-1AiUA

4

Feasibility

Oil shale fueled power generation is technically and economically justifiedunder certain conditions

N Need for additional generating capacity

exists

- 6 annual peak demand growth - Orderly retirement of olderhigh cost

generating capacity needed

U Higher costs are expected for imported fuels

- 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

-OP b i j~~4shy

-4protntiYPe 4 demo plnt orP42 t~Plant orPootypeProje(-7hould

that Rj

demo 4Therefore-44 JEA anxinus

the

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

27Pag 4- 1 2S c i n 4 4

4i2Sectjo4-18-4 Secio 4-4 014

lt th~ae hi4h -tasisso syste thrug27 ~ 04lag arstl~art-p tasforme ed 2p27132Kvdieanwhy notthroug

EAto- is protmm~~ thegnJgt~~ pracie an ect ~ platqrby

28Pg 4 s heonnenotedto~the 32K rc powr

It not8 Scection rie049teoervnrain prctc de1

rh u n trae f2V3K anerd not throughgeterAntor

27 P3e-1r p ant weung-a

-If I

2tEll10 DRWE-jOi ASOt Mint~~al d~c~e o hepwrgnrto

ELCTRInYJORD UTHORITY-

Ate~

21Pge41 ection 4 04- 5

sindicated~ t hthigh the unit outputredu f hecondenser Injengtd~ibbvePressureed incg desrin hi h riseb vmbi nt emperatureWe bel~ieve

PleaIse provide us with th rscrapcity for th-e three options n nt generating~

21-Iisidca ted that~ thediaatgeofCBi theSheavy fn oe consumnptionPlease~ providethe us withpecntgA

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

400 MW COAL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO 5050

NET GENERATION - MWe 40000 CAPACITY FACTOR - 75 ANNUAL GENERATION MKWhYR 2628 SUB TOTAL PLANT COSTS (TPC) $1000 $620000

FIXED 0 amp M COSTS MH $ MH FIRST YEAR COST$1O00

------- --------- --- ---- --- --- ------------

OPERATING LABOR 351936 $3 $1100 MAINTENANCE LABOR 4000 of 150 OF TPC 3720

MAINTENANCE MATERIAL 6000

ADMIN LABOR of 150

3000 OF TPC

OF 0 amp M LABOR 5580 1446

SUB TOTAL FIXED OampM COSTS $11846

VARIABLE 0 amp M COSTS QUANTITY UNIT COST

VARIABLE MAINTENANCE 2628 MKWh 10 MILLKWH $ 2628 PROCESS WATER 13500000 GALLON 02 SGAL $ 2700 GENERAL PLANT CHEMICALS ALLOW 50 FUEL OIL 1000000 GALLON 035 $GAL $ 350 WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290SPECIAL BOILER MAINT ALLOW 0

SUB TOTAL VARIABLE OampM COSTS $ 8018

TOTAL FIXED amp VARIABLE OampM COSTS $19864 TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $8227 $TN $99139

(INCL INFLATION ADJUSTMENT)

B DEBT EQUITY RATIO =========== 8020

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $17574

WASTE DISPOSAL (Section 6027) 228950 TNYR $1000 $TN $ 2290

TOTAL FIXED amp VARIABLE OampM COSTS $19864TOTAL FIXED amp VARIABLE OampM COSTS (WITH INFLATION) $21056 COAL FUEL 1205000 TNYR $5877 $TN $70814

(INCL INFLATION ADJUSTMENT)

6-21

Table 612 JORDAN OIL SHALE TO POWER PREFEASIBILITY STUDY

400 MW OIL FIRED PLANT OPERATION amp MAINTENANCE COST - 1ST YEAR

A DEBT EQUITY RATIO

NET GENERATION -

CAPACITY FACTOR -

ANNUAL GENERATION SUB TOTAL PLANT COSTS (TPC)

FIXED 0 amp M COSTS

OPERATING LABOR MAINTENANCE LABOR 4000 of

MAINTENANCE MATERIAL 6000 of

ADMIN LABOR

SUB TOTAL FIXED OampM COSTS

VARIABLE 0 amp M COSTS

VARIABLE MAINTENANCE PROCESS WATER GENERAL PLANT CHEMICALS FUEL OIL WASTE DISPOSAL (Section 6027) SPECIAL BOILER MAINT

SUB TOTAL VARIABLE OampM COSTS

5050

MWe

MKWhYR $1000

MH

262080

150

150 3000

QUANTITY

2628 MKWh 13500000 GALLON

1000000 GALLON 0 TNYR

TOTAL FIXED amp VARIABLE OampM COSTS FUEL OIL 503000 TNYR

B DEBT EQUITY RATIO =8020

40000 75

268 $443000

FIRST YEAR $ MH COST$1O00

$3 $ 800

OF TPC 2658

OF TPC 3987 OF 0 amp M LABOR 1037

$ 8482

UNIT COST

05 MILLKWH $ 1314 02 $GAL $ 2700

ALLOW 50 035 $GAL $ 350

$1000 $TN $ 0 ALLOW 0

$ 4414

$12896 $19981 $TN $100502

TOTAL FIXED amp VARIABLE OampM COSTS (WO ASH DISPOSAL) $12896

WASTE DISPOSAL (Section 6027) 0 TNYR $1000 $TN $ 0

TOTAL FIXED amp VARIABLE OampM COSTS $12896 FUEL OIL 503000 TNYR $14104 $TN $70943

6-23

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