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RATE TO BE DETERMINED
SECURITY
REQUIREMENTS CONTRACT (FIRST
THROUGH THE METER)
SECURITY INTEREST IN
EQUIPMENT
EXECUTIVE SUMMARY
SSC assists its clients, such as BSC, in off-balance sheet financing and
development of capital projects. SSC will develop, finance, own, and sell the
electrical output of a Top Gas Recovery Turbine to SPD. Zimmermann & Jansen,
GMBH, a leading supplier and engineering firm, will be the general contractor for
the Top Gas Recovery Turbine Project.
The “L” Blast Furnace at SPD is a high capacity blast furnace. The furnace’s
world class technology includes hydraulically actuated bleeders, a Paul Wurth
bell-less charging system, a Bishoff gas cleaning system, and Hoogovens
Stoves. The furnace produces high- energy high-pressure byproduct gas. The
mechanical energy of the gas pressure is currently dropped through a pressure
regulating device within the system. The Top Gas Recovery Turbine Project
installs a pressure recovery turbine designed to convert the lost mechanical
energy into marketable electrical energy. The cost to install this project is
$11,200,000. The value of generated electricity is $3,347,000 annually.
SSC will own and contract the turbine’s output to SPD. Features of this loan
proposal include:
• The lender will be granted specific security in the components of the
project that will be isolated from the blanket security interests of BSC
primary lenders and debt instrument holders.
• Zimmermann & Jansen, GMBH has been selected as the general
contractor for this project. This firm has earned a worldwide reputation for
quality engineering with
• the steel industry and has a proven track record with the installation of Top
Gas Recovery Turbines throughout Europe.
• This system provides a 32.5% electrical load reduction from current blast
furnace operation.
This proposal is for a construction loan of $11,200,000 to be made to SSC for the
purpose of financing the cost of design, installation, and related costs of a Top
Gas Recovery Turbine Project.
The following pages contain information about principle participants, project
descriptions, an analysis of the financial benefit, and other supporting technical
and financial information.
Michael Ratteree
SSC Energy Development
17608 Burnham, Ste. 100
St. Louis, MO 63005
Telephone: (636) 519-7080
Fax: (636) 519-1101
EXECUTIVE SUMMARY
SSC assists its clients, such as BSC, in off-balance sheet financing and
development of capital projects. SSC will develop, finance, own, and sell the
electrical output of a Top Gas Recovery Turbine to SPD. Zimmermann & Jansen,
GMBH, a leading supplier and engineering firm, will be the general contractor for
the Top Gas Recovery Turbine Project.
The “L” Blast Furnace at SPD is a high capacity blast furnace. The furnace’s
world class technology includes hydraulically actuated bleeders, a Paul Wurth
bell-less charging system, a Bishoff gas cleaning system, and Hoogovens
Stoves. The furnace produces high- energy high-pressure byproduct gas. The
mechanical energy of the gas pressure is currently dropped through a pressure-
regulating device within the system. The Top Gas Recovery Turbine Project
installs a pressure recovery turbine designed to convert the lost mechanical
energy into marketable electrical energy. The cost to install this project is
$11,200,000. The value of generated electricity is $3,347,000 annually.
SSC will own and contract the turbine’s output to SPD. Features of this loan
proposal include:
• The lender will be granted specific security in the components of the
project that will be isolated from the blanket security interests of BSC
primary lenders and debt instrument holders.
• Zimmermann & Jansen, GMBH has been selected as the general
contractor for this project. This firm has earned a worldwide reputation for
quality engineering with the steel industry and has a proven track record
with the installation of Top Gas Recovery Turbines throughout Europe.
• This system provides a 32.5% electrical load reduction from current blast
furnace operation.
This proposal is for a construction loan of$1 1,200,000 to be made to SSC for the
purpose of financing the cost of design, installation, and related costs of a Top
Gas Recovery Turbine Project.
The following pages contain information about principle participants, project
description, an analysis of the financial benefit, and other supporting technical
and financial information,
John Duffy
SSC, Incorporated
One City Centre
515 North Sixth Street, Suite 1325
St. Louis, MO 63101
Telephone: (314) 241-2201 ext. 224 Fax: (314) 436-1966
SHARED SAVINGS CONTRACTS, INC (SSC)
Shared Savings Contracts, Inc. is proposing to develop and finance the project
and operate the facility in order to sell generated electricity to Bethlehem Steel
Sparrows Point through a “first through the meter” priority purchasing
arrangement.
SSC is an innovative leader in providing energy and productivity savings for its
large industrial manufacturing partners. As a performance based contractor, SSC
is compensated only for achieving bottom-line savings associated with energy
and productivity improvements for its clients. The mission of SSC is to from long-
term partnerships with industrial manufacturers. This approach combines the
valuable resources and expertise of both SSC and its client-partner. The result is
a client who is more competitive and profitable in their respective marketplace.
Bethlehem Steel Sparrows Point spends $200 million per year on energy
consumption and productivity costs are even greater. Initial cost savings
initiatives have been implemented to date and SSC’s existing lender has
absorbed most upfront risks that may be associated with these projects. More
importantly, SSC has generated about $6,830,000 to date in cash receipts from
the Bethlehem Steel Sparrows Point project, thereby demonstrating the financial
strength of this partnership. The financial upside of this project remains and the
startup risk is gone, resulting in substantial value to the lender in the form of risk
mitigation.
Encompassing more than 2,000 acres, the operations at Sparrows Point have
access to the Atlantic Ocean with their location on the Chesapeake Bay near
Baltimore, Maryland. The principal products of these operations are hot-rolled
and cold-rolled sheets, tin mill products, galvanized sheet and Galvalume®
sheet.
Principal facilities include a sintering plant, a large blast furnace, two basic
oxygen furnaces with an annual raw steel production capability of approximately
4 million tons, a two-strand continuous slab caster with a present annual
production capability of approximately 3.6 million tons, a 68-inch hot-strip mill,
two cold-reducing mills (56-inch and 48-inch), continuous and batch annealing
facilities, a galvanizing line, two Galvalume® lines, a 48-inch hot-dip galvanizing
line and tin mill facilities. Sparrows Point obtains coke from various commercial
sources. Sparrows Point continuously casts essentially 100 percent of its total
production volume. Nearly every production unit set records in 1997, while
improving quality and on-time deliveries for customers.
The two-berth ore pier, 1 ,020 feet long by 83 feet wide, and two stacking-
reclaiming machines have an unloading capacity of 1,000 tons per hour. The
reclaiming rate is 4,500 tons per hour.
Sinter Plant
A single-strand machiner has a capacity of4 million tons per year of sinter and
includes blending and screening areas.
Blast Furnace
“L” blast furnace, which holds many of the iron production records in the United
States, averages 9,700 tons per day of molten metal. The furnace received a
$100 million dollar re-line during the summer of 1999, enabling an almost
continuous (94.75%) furnace campaign through 2011. In September of2000,
Sparrows Point commissioned a $60 million dollar pulverized coal injection (PCI)
facility built, owned an operated by a subsidiary of Detroit Edison Energy
Services to provide an alternative, high BTU fuel for the furnace.
The BOF’s two vessels each have a capacity of 290 tons and produce a heat of
steel in about 40 minutes. The shop’s annual capacity is 4 million tons. During
summer of 1999, steelmaking completed $60 million dollars in upgrades to the
BOF. With the re-lining of #2 vessel, the BOF is targeting over 3 Y2 years of
continuous two vessel operation.
Continuous Slab Caster
The facility has two single stand casting machines. Number one caster has
recently been replaced with a 104” wide state-of-the-art line. The caster facility
now has a 4 million ton annual capacity.
The 68-inch hot strip mill is a series of individual mill stands that reduce slabs
into thin strip steel before being coiled. The mill also has offline skin pass and
slitting/trimming units.
The new cold mill will produce cold rolled sheets primarily for the metal
construction and appliance industries. Sparrows Point has long been a leading
supplier to the metal construction industry, beginning with its pioneering
production and patenting of the zinc/aluminum coated Galvalume (TM).
Material in the thin-to-mid range of gauge will be used in prepainted roofing
panels and metal siding, steel studs, exposed lighting fixtures and metal
furniture. Material in the heaviest range is being marketed for access flooring
systems, air conditioning ductwork and large vehicles like buses.
The mill is capable of pickling 1 .7 million tons annually, with annual cold rolled
capacity of about 1 .5 million. About one million tons of annual output will be
coated before shipment to the customer. About 850,000 tons annually will be
coated at Sparrows Point’s Galvalume(TM) or galvanized coating lines installed
in 1993.
The new mill employs about 300 people who were extensively trained during the
past year to operate the highly sophisticated mill.
Tin Mills
Sparrows Point has Behtlehem’s sole production facility for tin mill products, and
it is one of the division’s most stable and valued markets, with shipments of
about 600,000 tons annually. Its products include tinplate, chrome plate, black
plate and tin-coated sheets. The most intensive and difficult to make of the
division’s products, tin and chrome plate required the greatest number of
production steps.
The multi-step process involves a pickling line, cold reduction on the 48-inch
tancem mill, a washing line, continuous or batch annealing, a skin mill, a double
reduction mill, two halogen tin-coating lines, a chrome line, and an automated
packaging line.
ZIMMERMANN & JANSEN, GMBH
Zimmermann & Jansen, GMI3H (Z&J) has over 125 years experience in
manufacturing large gas valves for high temperature applications in the Iron and
Steel, Chemical, Power Generating and Glass industries. The specialty valves
include Hot Blast, Control and Swing Goggle, Angle, Butterfly, 4-Way Ball and
Check Valves. In the integrated steel industry Z&J is the standard by which other
manufacturers are measured.
Expansion Turbine
Generator
Switchgear
Transfonier
Auxiliary Systems (Pumps, Motors, and Starters)
Installation $4,430,000
Revenue
Unit Price $31.00
Total Value $3,347,000
Bethlehem Benefit (9.5%) $ 317,965
SSC Income $3,029,035
Expenses
Debt Service $1,912,209
Maintenance $ 150,000
Engineer $ 150,000
Insurance $ 100,000
Total $2,312,209
A. Current Conditions:
The blast furnace produces a combustible byproduct gas during operation. The
Blast Furnace Gas (BEG) is produced at approximately 3 1 psia and is projected
to have an average flowrate of325,000 SCFM with Pulverized Coal Injection fully
functioning. The BFG is cleaned using a Bishoff Scrubber. The cleaning process
uses 1.5psi of BFG pressure. Pennwood Power Station is designed to utilize the
BFG at 1 .5-psia. Piping losses between the Blast Furnace and Pennwood Power
Station account for another 1.0- psi of pressure drop.
The remaining 27-psia must be dropped since the piping between the Blast
Furnace and Pennwood cannot support the high-pressure gas. Currently the
pressure is dropped across the RS elements of the Bishoff Scrubber. This
pressure drop is a significant energy loss.
The lost energy will be recovered with the installation of a 13.5 MKWH Top Gas
Recovery Turbine. The turbine converts high-pressure BFG into mechanical
energy, which rotates a generator to make electrical power. The low-pressure
outlet of the turbine is supplied to Pennwood and BF Stoves for combustion.
Bethlehem Steel first investigated the installation of a Top Gas Recovery Turbine
in 1982. Due to contractual limitations with the local Power Company and high
capital costs, this project has only reached the Engineering Proposal level.
Recent changes in the electrical contract have created opportunity for new
generation capability at Sparrows Point. Additionally, the turnkey cost of the Top
Gas Recovery Turbine is 60% of the original costs.
B. Project Scope:
The turbine will be installed in a building to be erected southeast of the “L” Blast
Furnace. The installation of the Turbine will not require any additional Blast
Furnace outages. This area has been allocated for such an installation. BFG
main tap connections, after the Bishoff scrubber, were installed during the
1980’s, to facilitate this project. The rated turbine output is sized for the new
Pulverized Coal Injection (PCI) operation. The electrical connections will be
provided through the existing Steel Side Substation.
The operation of the turbine including start-up and shutdown does not impact
Blast Furnace operations. A Programmable Logic Controller signals the transition
of the BFG Main By-pass through these sequences. Additionally, the required
auxiliary services (industrial water, nitrogen, sewer connection, and etc.) are
available and within system limits.
C. Benefit Analysis:
The financial benefit is derived from the value of selling the electrical energy
produced by the turbine connected to a generator. The average value of a
generated megawatt on the PJM Grid in 1 999 sold for $3 1 .00. The following
benefit is based upon that value:
These are collateral benefits that provide significant improvement to “L” Blast
Furnace efficiency and performance. These benefits are not included in the
financial calculations of this project.
Zimmermann & Jansen utilizing a complete turnkey approach will provide turbine
installation. A Build — Operate — Transfer (BOT) method will utilize the following
timeline:
Build — 18 months to complete the turnkey installation
Operate — 8-10 years of SSC controlled operation
Transfer — Options
o Bethlehem Purchase Turbine
o SSC Continue to Operate Turbine
o Third Party Purchase and Operate Turbine
Implementation of this project requires a high level of urgency. The current end of
campaign for the “L” Blast Furnace is scheduled for 2012. The installation time
required for the turbine is 1.5 years. The timing allows only 6 month to begin
construction.