Sherco 1 & 2 BART Analysis Revision · 2012. 10. 4. · Retrofit Technology ("BART") submittal for...

7
(l Xcel Energy'" 414 Nicollet Mall Minneapolis, Minnesota 55401-1993 November 13, 2008 Mr. Todd Biewen Manager, Air Assessment and Environmental Management Section JvIinnesota Pollution Control Agency 520 Lafayette Road North St. Paul, Minnesota 55155-4194 RE: Northern States Power Company, a Minnesota Company Sherburne County Generating Plant Units 1 and 2 Best Available Retrofit Technology Analysis, Revision 1 Dear Mr. Biewen: This letter is in response to your letter dated August 28,2008, in which you asked for written notification of Xcel Energy's intentions regarding revising the October 2006 Best Available Retrofit Technology ("BART") submittal for Sherburne County Generating Plant ("Sherco") Units 1 and 2. On September 17, 2008, Xcel Energy notified you of our plans to submit a revision to the Sherco Unit 1 and 2 BART analysis, primarily to account for cost changes that have occurred since the original submittal. After much effort analyzing cost data, we have decided that providing revised cost data would not change the basic conclusions of our analysis. Therefore, this letter provides discussions on relative cost changes since our October 2006 submittal, on our BART proposal for sulfur dioxide (SOz) and on our BART proposal for oxides of nitrogen (NOx). General Cost Information According to industry publications, the cost of building power plants in North America has risen by 130 percent since 2000 (see attadunent). One price index shows that a majority of that cost increase (69 percent) has occurred stIce 2005. This means that the cost of new construction has increased dramatically since Xcel Energy made a BART submittal in October 2006 using a 2005 cost basis. Therefore, the new equipment options discussed in the analysis, such as new semi- dry FGD, new wet FGD, new SNCR and new SCR, would see significantly higher costs than were presented in the October 2006 submittal. The retrofit options to the existing wet scrubbers would also see increased costs, however, they would be of a lesser magnitude than the new technology options. In order to accurately present costs for each evaluated option, it would be necessary to reanalyze each and every option using the same base assumptions. Xcd Energy cannot complete that analysis within the schedule laid out by Minnesota Pollution Control Agency (MPCA) staff. If :tYfPCA staff needs that analysis in order to proceed with the submittal of the State Implementation Plan (SIP), Xcd Energy is open to pursuing this reanalysis. However, Xcd Energy believes that the original analysis accompanied by the contents of this letter should be enough information to allow submittal of the SIP to proceed on schedule.

Transcript of Sherco 1 & 2 BART Analysis Revision · 2012. 10. 4. · Retrofit Technology ("BART") submittal for...

Page 1: Sherco 1 & 2 BART Analysis Revision · 2012. 10. 4. · Retrofit Technology ("BART") submittal for Sherburne County Generating Plant ("Sherco") Units 1 and 2. On September 17, 2008,

(l XcelEnergy'"414 Nicollet Mall

Minneapolis, Minnesota 55401-1993

November 13, 2008

Mr. Todd BiewenManager, Air Assessment and Environmental Management SectionJvIinnesota Pollution Control Agency520 Lafayette Road NorthSt. Paul, Minnesota 55155-4194

RE: Northern States Power Company, a Minnesota CompanySherburne County Generating Plant Units 1 and 2Best Available Retrofit Technology Analysis, Revision 1

Dear Mr. Biewen:

This letter is in response to your letter dated August 28,2008, in which you asked for writtennotification of Xcel Energy's intentions regarding revising the October 2006 Best AvailableRetrofit Technology ("BART") submittal for Sherburne County Generating Plant ("Sherco")Units 1 and 2. On September 17, 2008, Xcel Energy notified you of our plans to submit arevision to the Sherco Unit 1 and 2 BART analysis, primarily to account for cost changes thathave occurred since the original submittal. After much effort analyzing cost data, we havedecided that providing revised cost data would not change the basic conclusions of our analysis.Therefore, this letter provides discussions on relative cost changes since our October 2006submittal, on our BART proposal for sulfur dioxide (SOz) and on our BART proposal for oxidesof nitrogen (NOx).

General Cost InformationAccording to industry publications, the cost of building power plants in North America has risenby 130 percent since 2000 (see attadunent). One price index shows that a majority of that costincrease (69 percent) has occurred stIce 2005. This means that the cost of new construction hasincreased dramatically since Xcel Energy made a BART submittal in October 2006 using a 2005cost basis. Therefore, the new equipment options discussed in the analysis, such as new semi­dry FGD, new wet FGD, new SNCR and new SCR, would see significantly higher costs thanwere presented in the October 2006 submittal. The retrofit options to the existing wetscrubbers would also see increased costs, however, they would be of a lesser magnitude than thenew technology options. In order to accurately present costs for each evaluated option, it wouldbe necessary to reanalyze each and every option using the same base assumptions. Xcd Energycannot complete that analysis within the schedule laid out by Minnesota Pollution ControlAgency (MPCA) staff. If :tYfPCA staff needs that analysis in order to proceed with the submittalof the State Implementation Plan (SIP), Xcd Energy is open to pursuing this reanalysis.However, Xcd Energy believes that the original analysis accompanied by the contents of thisletter should be enough information to allow submittal of the SIP to proceed on schedule.

Page 2: Sherco 1 & 2 BART Analysis Revision · 2012. 10. 4. · Retrofit Technology ("BART") submittal for Sherburne County Generating Plant ("Sherco") Units 1 and 2. On September 17, 2008,

Mr. Todd Biewen LetterNovember 13, 2008Page 2

Sulfur Dioxide (SO~

Since the October 2006 BART submittal, Xcel Energy has conducted a more detailedengineering analysis for the new dry FGD option. As one would expect, this analysis producedbetter quality cost data than that previously submitted in 2006. This analysis refined the scopeof what would be required to install new dry FGD on Units 1 and 2. In addition, the costsincluded the as-built cost escalation for installation in 2012 and 2013. Lastly, tlus analysisincluded more up-to-date commodity and labor estimates for the construction timeline of 201 0­2013. In the end, the revised dry FGD cost estimate was more than double the original dryFGD cost estimate. Xcel Energy is uncomfortable using this data in the BART analysis for thesimple reason that it uses a different basis than all other options evaluated. The comparisonwould not be made on an equivalent basis and, then, would not aid in making a final BARTdetennllation.

Instead, Xcel Energy believes that the conclusions of the original BART analysis submittal forS02 controls are unchanged by the revised cost figures. Xcel Energy continues to propose toretrofit the existing wet scrubbers with sparger tubes. The proposed emissions rate is 0.12 IbS02/mmBtu at the stack, on a 30-day rolling average. Xcel Energy will determine throughtesting of individual scrubber modules whether lime injection is needed to achieve this emissionrate.

The only non-cost change to our original filing is the tinling of the sparger retrofits. In theoriginal BART analysis, Xcel Energy proposed completion of the retrofits on Units 1 and 2 bythe end of 2012 in anticipation that the U.S. Environmental Protection Agency (EPA) wouldcomplete its approval of the Minnesota SIP in 2008, tl1ereby requiring compliance within 5 yearsof SIP approval. It now appears that the Minnesota SIP will be submitted in 2009, with EPAcompleting its approval in 2009 or 2010. If BART retrofits must be completed within 5 years ofEPA approval of the SIP, the new compliance date under this scenario becomes either 2014 or2015, respectively. Xcel Energy proposes to complete tl1ese retrofits in accordance with tlusnew BART compliance date.

Oxides of Nitrogen (NOx)Section 4.BA. of the BART analysis contains cost information for various NOx control options.The analysis included cost information for the selective catalytic reduction (SCR) options forUnits 1 and 2. New cost information for the SCR option was presented in Xcel Energy'sresponse to Information Request No.4 in i\tLinnesota Public Utilities Commission (MPUC)Docket number E002/M-07-02. This information showed slightly lugher SCR system coststhan were found in the original BART analysis. As the costs were not substantially higher thanthose previously presented, no revisions have been made to the NOx section of the BARTanalysis.

Page 3: Sherco 1 & 2 BART Analysis Revision · 2012. 10. 4. · Retrofit Technology ("BART") submittal for Sherburne County Generating Plant ("Sherco") Units 1 and 2. On September 17, 2008,

Mr. Todd Biewen LetterNovember 13, 2008Page 3

The conclusions of the original BART analysis submittal for NOx are unchanged by the SCRdiscussion presented above. Xcel Energy continues to propose new low NOx burners, aseparated/close coupled overfire air system and a combustion optimization system for Unit 1and a combustion optimization system for Unit 2 to meet BART. The proposed emissions rateis 0.15 lb NOx/mmBtu at the stack, on a 30-day rolling average. This rate meets thepresumptive BART limit for tangentially fired boilers burning sub-bituminous coal. Theseretrofits have already been completed.

In summary, Xcd Energy believes that the conclusions reached within the original BARTanalysis are unchanged, even with the dramatic cost increases since 2005. In fact theseconclusions become even clearer when looking at the increased costs of installing new S02 orNOx control equipment. The only change from the original analysis is the compliance date forthe proposed S02 modifications.

Please contact me at (612) 330-7879 if you have any questions or wish to discuss this responsefurther.

Sincerely,

72~(~£Rick RosvoldAir Quality Manager

attachment

cc: Environmental Services Record CenterDean MetcalfNancy GlassAnne Jackson - MPCA

Gary Juip - ShercoMary Dieltz - ShercoGreg Ford - E&CRon Elsner - E&C

R:\ES-Chestnut\ES_Air_Qualiry\AIR QUALlTY\BARHBART Revision Cover Letler_II-13-2008.doc

Page 4: Sherco 1 & 2 BART Analysis Revision · 2012. 10. 4. · Retrofit Technology ("BART") submittal for Sherburne County Generating Plant ("Sherco") Units 1 and 2. On September 17, 2008,

CERAThe Source

for Crilical Information and Insight '"

News ReleaseFOR IMMEDIATE RELEASE

Contact:Bethany Genier+1 [email protected]

Construction Costs for New Power Plants Continue to Escalate:IHS CERA Power Capital Costs IndexCosts have risen 130% since 2000; poised to rise higher in the coming year

CAMBRIDGE, MA (May 27,2008) - The costs of building new power plants have more than

doubled since 2000, according to the most recent IHS CERA Power Capital Costs Index (PCCI).

The latest IHS CERA PCCI shows that the cost of new power plant construction in North America

has risen 130 percent in the last eight years. A majority of this cost increase has occurred since

2005, with the index rising 69 percent since then.

Source' C.mbridge Energy Research Aosoc:i31es.

IHS/CERA Power Capital Costs IndexWith and Without Nuclear

Q12oo8:'.<l 231

110 L-__-

9OL..----JL.----l'-----'_--L_--L_--L._--I-_....L._.....2000 2001 2002 2003 2004 2005 2006 2007 2008 2009

250

230

210

190Cost

Index 170(2000=100)

150

130

The IHS CERA PCCI - which

tracks the costs of building coal,

gas, wind and nuclear power

plants indexed to the year 2000 ­

is a proprietary measure of project

cost inflation similar in concept to

the Consumer Price Index (CPI).

The IHS CERA PCCI now

registers 231 index points,

indicating a power plant that cost

$1 billion in 2000 would, on

average, cost $2.31 billion today.

Page 5: Sherco 1 & 2 BART Analysis Revision · 2012. 10. 4. · Retrofit Technology ("BART") submittal for Sherburne County Generating Plant ("Sherco") Units 1 and 2. On September 17, 2008,

The latest IHS CERA PCCI indicates a one percent drop in the first quarter of 2008. However, the

miniscule drop in the index does not signal a change in the long-term factors that have been driving

up costs. The decrease was driven solely by one narrow factor-an easing of nuclear equipment

costs as a result of market volatility which has been driven by high global demand. Recent results of

the IHS CERA PCCI show that the costs for all other power plants, such as those powered by coal,

gas and wind, continued to rise.

• Wind has shown the largest increase at six percent since the third quarter of 2007 and 108

percent since 2000 in response to increased demand for wind turbines which has pushed up

equipment costs and time to deliver, and is compounded with increasing labor and

construction costs.

• Gas has increased by three percent since the third quarter of 2007 and 92 percent since

2000. This has been driven by manufacturers' response to increased demand for gas

turbine costs, as costs increase and lead times continue to extend for equipment delivery.

Additional escalation can be attributed to continued increases in labor, engineering and

construction costs.

• Coal has increased in cost by 2.3 percent since the third quarter of 2007 and 78 percent

since 2000. Strong international demand for boilers has sustained high cost levels. There

has also been high demand for scrubbers in the United States as clean air provisions push

utilities to retrofit their coal facilities in order to comply with the 2010 regulations.

"While the index has shown a small drop in the past six months, there are no signs that this is the

start of a downward trend," said Candida Scott, CERA senior director of cost and technology. "The

fundamentals that have driven costs upward for the past eight years-supply constraints, increasing

wages and rising materials costs-remain in place and will continue during 2008."

Additional factors, such as rising prices for commodities such as steel, nickel and copper, could

soon drive costs up further, added Paul Bachmuth, CERA associate director of capital cost power.

"Renegotiated prices for iron ore contracts and supply disruptions of coking coal raise serious

concern for cost increases in steel in excess of 50 percent in 2008 if all costs are passed through to

2

Page 6: Sherco 1 & 2 BART Analysis Revision · 2012. 10. 4. · Retrofit Technology ("BART") submittal for Sherburne County Generating Plant ("Sherco") Units 1 and 2. On September 17, 2008,

the end consumer," Bachmuth said. "Combined with the escalating cost of diesel impacting

transportation for all materials, the power industry is set to see costs rise higher in 2008."

"Timely decisions on fuel choice-what type of power plants to build and when to build them-are

critical to keep the lights on, limit power price increases and manage carbon emissions," added

Jone-Lin Wang, CERA managing director of global power group. "Understanding what's driving the

dramatic cost escalation will go a long way toward making efficient decisions,"

Continuing Pressures

Demand for new power generation facilities remains high worldwide, leading to continued tightness

in equipment markets. Cost increases, supply issues and longer delivery times are exacerbated as

manufacturers struggle to keep up with demand. The weakening U.S. dollar also increases the

costs of global procurement for equipment and materials.

The number of engineers in the workforce is also declining as older workers retire and are not being

replaced. The resulting shortages in plant design teams add additional delays to construction

schedules. The current increase in construction for nuclear power generation and the dearth of

experienced nuclear engineers in North America has been a key driver behind cost escalation.

Recent cancellations of proposed coal plants in the United States due to uncertainty over

environmental regulations has provided some slowing in cost increases in the U.S. coal industry.

However, international competition for coal boilers, particularly in Southeast Asia, is keeping the

equipment order books very active.

Concerns over a looming U.S. recession and subsequent cut backs in residential construction have

offered little relaxation to power construction. The residential slump does not free up the skilled

workers required in the power industry and there is no overlap of the specialist metals and

equipment required.

Energy Industry Capital Costs

The IHS CERA PCCI complements the IHS CERA Upstream Capital Costs Index (UCCI) and lHS

CERA Downstream Capital Cost Index (DCCI) which measures the cost of construction of new oil

and gas production projects such as platforms and pipelines and construction of new refineries and

3

Page 7: Sherco 1 & 2 BART Analysis Revision · 2012. 10. 4. · Retrofit Technology ("BART") submittal for Sherburne County Generating Plant ("Sherco") Units 1 and 2. On September 17, 2008,

petrochemical plants. Both indices demonstrate the dramatic impact rapidly rising costs are having

on the energy industry.

####

About the IHS CERA Power Capital Costs Index (PCCI)

The IHS CERA PCCI tracks the costs of equipment, facilities, materials and personnel (both skilledand unskilled) used in the construction of a geographically diversified portfolio of more than 30power generation construction projects throughout North America. It is similar to the consumer priceindex (CPI) in that it provides a clear, transparent benchmark tool for tracking and forecasting acomplex and dynamic environment. The IHS CERA PCCI can be tracked on the IHS Index WebSite at www.ihsindexes.com. The IHS CERA PCCI is a work product of CERA's Capital CostsAnalysis Forum for Power (CCAF-P) in partnership with PowerAdvocate. For information on theCapital Costs Analysis Forum for Power, contact Candida Scott at [email protected].

About CERA (www.cera.com)Cambridge Energy Research Associates (CERA), an IHS company, is a leading advisor to energycompanies, consumers, financial institutions, technology providers and governments. CERA(www.cera.com) delivers strategic knowledge and independent analysis on energy markets,geopolitics, industry trends, and strategy. CERA is based in Cambridge, MA, and has offices inBangkok, Beijing, Calgary, Dubai, Johannesburg, Mexico City, Moscow, Mumbai, Oslo, Paris, Riode Janeiro, San Francisco, Tokyo and Washington, DC.

About IHS (www.ihs.com)IHS (NYSE: IHS) is a leading global source of critical information and insight for customers in abroad range of industries. Our customer product and service solutions span four major areas ofinformation: energy, product lifecycle management, environmental and security. By focusing on ourcustomers first, we deliver data and expertise that enable innovative and successful decision­making. Customers range from governments and multinational companies to smaller companiesand technical professionals in more than 180 countries. IHS has been in business since 1959 andemploys more than 3,500 people in 35 locations around the world.

© 2008, IHS is a registered trademark of IHS Inc. CERA is a registered trademark of Cambridge EnergyResearch Associates, Inc. Copyright ©2008 /J-fS Inc. All rights reserved.

4