Kazakhmys Power

Market overview

Kazakhmys acquired the Ekibastuz GRES-1 coal fired power plant and the Maikuben West coal mine in May 2008. Under an agreement put in place as part of the acquisition, the assets were managed by AES Corporation, the previous owner of the power plant and coal mine. In the second quarter of 2009, Kazakhmys and AES Corporation ended the management services agreement following which the power plant and coal mine have been under Kazakhmys’ direct management.

In October 2008, Samruk, announced its intention to acquire a stake in the power plant, and completed the acquisition of a 50% stake in Ekibastuz GRES-1 in February 2010. Under the joint venture agreement introduced as part of the transaction, the power plant will be operationally managed by a Kazakhmys appointed team for the next five years, following which a team selected by Samruk will assume management for a five year fixed term. A supervisory board has been created, containing representatives of both owners, to oversee the plant’s management team. The business has been classified as held for sale at the 2009 year end under IFRS, as, following the sale of 50% of Ekibastuz GRES-1 to Samruk, the business will be equity accounted as a joint venture.

Going forward, Ekibastuz GRES-1 is expected to source coal almost exclusively from the Bogatyr mine, which is jointly owned by Samruk and UC RusAl. The strategic value in owning the Maikuben West coal mine has consequently been reduced and Kazakhmys has determined that the mine is now held for sale.

At a glance

Operations:

Location: North Kazakhstan

Divisional operations: Ekibastuz GRES-1 power plant and Maikuben West coal mine

Production overview:

Net dependable capacity: 2,012 MW

Net power generated: 9,737 GWh

Financial overview:

Sales revenues: $238 million

EBITDA (excluding special items): $120 million

Demand

The economic dowturn had a significant impact on electricity demand in Kazakhstan and Russia as industrial output fell. In the first quarter of 2009, with energy intensive industrial users reducing electricity usage, demand was weak and additional supply entered the market as industrial groups with captive power generation used surplus power to supply external customers.

From the second quarter of 2009, demand for electricity improved as industrial production in Kazakhstan and Russia recovered and industrial groups with captive power generation used an increased proportion of energy production internally. Scheduled maintenance at other power plants led to supply outages, enabling Ekibastuz GRES-1 to supply additional volume into the market.

Power stations in the northern grid of Kazakhstan, including Ekibastuz GRES-1, were given greater access to the southern and western grids during 2009 as a consortium led by KEGOC, the operator of the power network in Kazakhstan, made significant improvements to the transmission lines which link Kazakhstan’s three main electricity grids.

The network upgrades included the completion of a 400 MW transmission line linking the northern and western grids in February 2009. A second North to South transmission line was completed in September 2009, increasing the total capacity of the North to South line from 650 MW to 1,350 MW.

GRES-1 share in Kazakhstan power generation

GRES-1 share in Kazakhstan power generation comparing from January 2008 through to December 2009
  • Kazakhstan
  • GRES-1
  • GRES-1 market share
  1. Source: KEGOC

These developments enabled Ekibastuz GRES-1 to increase its market share of the volume of electricity generated in Kazakhstan from approximately 9% at the commencement of the year to 15% at the year end.

Electricity demand is forecast to continue to recover in 2010 as industrial activity recovers in Kazakhstan and Russia.

Tariffs

In April 2009, to encourage investment in power generation plants, the Kazakhstan Government introduced a framework to raise tariff ceilings for domestic electricity sales for the years 2009 to 2015. The ceiling prices will be set by the Ministry of Energy on an annual basis, and are subject to the generator meeting capital investment commitments.

The Ministry of Energy set Ekibastuz GRES-1 a ceiling tariff in April 2009 of 3.60 KZT/kWh. With the introduction of the higher ceiling price and the recovery in electricity demand, Ekibastuz GRES-1 was able to increase electricity tariffs for the domestic market to close to the ceiling tariff by July 2009. The tariff ceiling for 2010 has been set at 4.68 KZT/kWh, a level which is expected to be achieved by Ekibastuz GRES-1 in Kazakhstan during 2010.

Ekibastuz GRES-1: 2009 Kazakhstan electricity tariffs (KZT/kWh)

Ekibastuz GRES-1: 2009 Kazakhstan electricity tariffs (KZT/kilowatt hour) comparing from January 2009 through to December 2010

Ekibastuz GRES-1 exports around 20% of its electricity generation to Russia which is surplus to the demand requirements of the Kazakhstan market. The exports were at lower prices than domestic sales in Kazakhstan reflecting the excess capacity in Russia. Demand in the Russian electricity market recovered over the course of 2009 due to improved economic conditions and as supply was impacted by an accident at Russia’s biggest hydro power plant, Sayano-Shusenskaya, in August 2009. It is expected that export prices to Russia will rise in 2010.

Production summary

2009 2008
Net power generated (GWh) 9,737 10,402
Net power generated attributable to Kazakhmys1 (GWh) 9,737 5,774
Net dependable capacity (MW) 2,012 1,946
Coal extraction (kt) 3,688 3,600
Coal extraction attributable to Kazakhmys1 (kt) 3,688 2,170
  1. 1 2008 comparatives are for the period from acquisition on 29 May 2008.

Net power generated in 2009 was primarily demand driven as the power plant had spare capacity throughout the year. Demand for power in Kazakhstan declined at the end of 2008 and remained subdued in early 2009 but recovered strongly over the second half of the year. Of the 9,737 GWh net power generated in 2009, 61% was in the second half, representing growth of 21% over the same period in 2008. Ekibastuz GRES-1 completed its scheduled annual maintenance work on the units in September 2009, ahead of neighbouring power stations, enabling it to take advantage of the uplift in demand and increase its supply to existing and new customers over the latter months of the year.

The increase of 3% in net dependable capacity from the prior year reflects the overhaul work carried out on Unit 6 in 2008, which returned to operation in October of that year. In 2009, the overhaul of Unit 5 was completed in November.

Coal extraction from Maikuben West was in line with the prior year with shipments to Ekibastuz GRES-1 and to third parties.

In 2010, demand for electricity is expected to be at least at the levels seen in 2009 as the recovery in demand continues. All of the five operating units at the power plant will undergo annual maintenance which is scheduled to take units offline at different times and avoid peak demand periods to minimise the potential impact on sales. Unit 3 is scheduled to undergo an overhaul during 2010, with the completion of the first phase of the overhaul planned prior to the winter season.

Ekibastuz GRES-1: 2009 sales tariffs to Russia (KZT/kWh)

Ekibastuz GRES-1: 2009 sales tariffs to Russia (KZT/kilowatt hour) comparing from January 2009 through to December 2010

Financial summary

$ million (unless otherwise stated) 2009 2008
Sales revenues1 238 156
Average tariff price (KZT/kWh) 3.19 2.42
Domestic sales 3.30 2.59
Export sales 2.78 1.59
Average cost1 (KZT/kWh) 1.54 1.72
EBITDA (excluding special items)1 120 42
Capital expenditure1 61 39
Sustaining 17 4
Expansionary 44 35
  1. 1 2008 comparatives are for the period from acquisition on 29 May 2008.

Revenues

Revenue for 2009 represents Kazakhmys Power’s first full year under Kazakhmys’ ownership during which sales benefited from electricity tariff increases in Kazakhstan and Russia, but were negatively impacted by low sales volumes in the first half of 2009 due to the economic downturn. The revenues, as presented in US dollars, were also negatively impacted by the tenge devaluation in February 2009.

The average realised electricity price for Ekibastuz GRES-1 in Kazakhstan rose from 2.79 KZT/kWh in January 2009 to 3.58 KZT/kWh in December 2009. The strength in demand in Kazakhstan during the second half of the year enabled the power plant to raise prices and grow sales volumes at the same time, assisted by the recovery in industrial production, reduced supply from competitors, and upgrade of the transmission lines giving access to new customers.

The average electricity tariff price achieved in the year, as shown in the table above, includes sales to Russia at rates below those in Kazakhstan. Approximately 20% of sales volumes are exported to Russia, however in 2009, there were no export sales in the first two months due to extended price negotiations.

Kazakhmys Power’s revenues of $238 million included $29 million from the Maikuben West coal mine from sales to residential and industrial users. Third party coal sales volumes decreased by 33% due to the downturn in electricity demand in Russia compared with the prior year. Coal prices for sales to third parties remained largely unchanged from 2008.

EBITDA (excluding special items)

Almost 90% of Kazakhmys Power’s EBITDA is generated by Ekibastuz GRES-1. Due to the challenging marketplace in the first half of the year, Kazakhmys Power’s EBITDA by the end of June 2009 was only $41 million, compared to the second half EBITDA of $79 million, driven by higher sales volumes and prices.

The coal used by Ekibastuz GRES-1, largely sourced from the nearby Bogatyr mine, forms the main operating cost of the power plant. Coal prices at the start of the year were 10% above those in 2008. During the year, Bogatyr raised prices further and Ekibastuz GRES-1 began purchasing varying grades of coal to keep the average cost down. To further control costs, Kazakhmys Power took a number of actions in 2009 including carrying out repair and maintenance work internally and implementing projects to improve the efficiency of the power plant.

The majority of Kazakhmys Power’s operating costs are denominated in tenge and therefore partially mitigated the impact of the tenge devaluation on revenue when reported in US dollars.

Average cost

The cash cost per kWh of electricity decreased by 10% in 2009 due to the measures taken to control costs. Coal costs comprise approximately 49% of all cash costs; the remaining 51% is made up of transmission costs, emission taxes, fuel, water, labour, repair and administrative costs.

Capital expenditure

Sustaining

Sustaining capital expenditure in 2009 related to work at Ekibastuz GRES-1 to maintain and improve the operational efficiency of the existing units. This annual maintenance work was mainly carried out over the summer period with short-term outages. At the Maikuben West coal mine, replacement equipment was purchased in order to fulfil the targeted level of stripping works at the mine and to maintain the mine’s railway network.

Expansionary

The overhaul of Unit 5 to modernise the unit and improve operating efficiency commenced in April 2009 and was successfully completed with the unit recommencing operations in November 2009. The overhaul has increased Unit 5’s gross dependable capacity from 430 MW to its nameplate capacity of 500 MW. A new electrostatic precipitator is also being fitted on Unit 5, with its installation to complete in June 2010, avoiding outages during the peak winter period.

Preliminary work was also conducted on the rehabilitation of Unit 8 during 2009. The rehabilitation programme will involve the replacement of the majority of Unit 8’s components to bring the dormant 500 MW unit into production by 2013. The recommencement of Unit 8 will increase Ekibastuz GRES-1’s total available generation capacity to 3,000 MW by 2013 and enable Ekibastuz GRES-1 to benefit from the forecast growth in sales tariffs and power demand in Kazakhstan.

The two other dormant units are scheduled to be restored following Unit 8. Once the dormant units have been refurbished, the plant will operate at its nameplate capacity of 4,000 MW. The expansion programme is dependent upon the achievement of tariff increases in future years.

The modernisation programme also includes a number of environmental improvements to the power plant, with the installation of electrostatic precipitators on all units to reduce ash emissions to international benchmark standards and improvements to ash disposal systems.

In 2010, capital expenditure will be mainly focused on the rehabilitation of Unit 8. An overhaul of Unit 3 will also be conducted as part of the programme to overhaul each unit at Ekibastuz GRES-1 every five years. The last overhaul on Unit 3 was performed in 2005.