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Headwaters Inc – ‘10-K405’ for 9/30/99

On:  Thursday, 1/13/00   ·   For:  9/30/99   ·   Accession #:  1038838-0-14   ·   File #:  0-27808

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  As Of                Filer                Filing    For·On·As Docs:Size              Issuer               Agent

 1/13/00  Headwaters Inc                    10-K405     9/30/99    7:368K                                   Lindhardt Simone A/FA

Annual Report — [x] Reg. S-K Item 405   —   Form 10-K
Filing Table of Contents

Document/Exhibit                   Description                      Pages   Size 

 1: 10-K405     Form 10-K405 Ended 09/30/99                           62    394K 
 2: EX-10.63    Securities Purchase Agreement With Dh Financial       38    179K 
 3: EX-10.63.1  Security Agreement With Dh Financial                  12     48K 
 4: EX-21.1     Subsidiaries of Covol                                  1      5K 
 5: EX-23       Consent of Independent Accountants                     1      6K 
 6: EX-27.1     Financial Data Schedule                                1      9K 
 7: EX-27.2     Financial Data Schedule                                1     10K 


10-K405   —   Form 10-K405 Ended 09/30/99
Document Table of Contents

Page (sequential) | (alphabetic) Top
 
11st Page   -   Filing Submission
3Item 1. Business
5Engineered Resources
11Utah Synfuel #1
12Proprietary Protection
14Forward Looking Statements
"Item 2. Properties
"Item 3. Legal Proceedings
15NEICO/Earthco Suit
"Item 4. Submission of Matters to A Vote of Security Holders
16Item 5. Market for Registrant's Common Equity and Related Stockholder Matters
19Item 6. Selected Financial Data
20Item 7. Management's Discussion and Analysis of Financial Condition and Results of Operations
28Item 7A. Quantitative and Qualitative Disclosure About Market Risk
"Item 8. Financial Statements and Supplementary Data
"Item 9. Changes in and Disagreements With Accountants on Accounting and Financial Disclosure
"Item 10. Directors and Executive Officers of the Registrant
"Item 11. Executive Compensation
29Item 12. Security Ownership of Certain Beneficial Owners and Management
"Item 13. Certain Relationships and Related Transactions
"Item 14. Exhibits, Financial Statement Schedules, and Reports on Form 8-K
36Signatures
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UNITED STATES SECURITIES AND EXCHANGE COMMISSION WASHINGTON, D.C. 20549 FORM 10-K [X] ANNUAL REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES EXCHANGE ACT OF 1934 For the fiscal year ended September 30, 1999, or [ ] TRANSITION REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES EXCHANGE ACT OF 1934 For the transition period from _____ to _____ Commission file number 0-27808 COVOL TECHNOLOGIES, INC. ------------------------ (Exact name of registrant as specified in its charter) Delaware 87-0547337 -------- ---------- (State or other jurisdiction of (I.R.S. Employer incorporation or organization) Identification No.) 3280 North Frontage Road Lehi, Utah 84043-9534 ---------- ---------- (Address of principal executive offices) (Zip Code) (801) 768-4481 -------------- (Registrant's telephone number, including area code) Securities registered pursuant to Section 12(b) of the Act: None Securities registered pursuant to Section 12(g) of the Act: Common Stock, $.001 par value Indicate by check mark whether the registrant: (1) has filed all reports required to be filed by Section 13 or 15(d) of the Securities Exchange Act of 1934 during the preceding 12 months (or for such shorter period that the registrant was required to file such reports), and (2) has been subject to such filing requirements for the past 90 days. Yes [X] No [ ] Indicate by check mark if disclosure of delinquent filers pursuant to Item 405 of Regulation S-K is not contained herein, and will not be contained, to the best of registrant's knowledge, in definitive proxy or information statements incorporated by reference in Part III of this Form 10-K or any amendment to this Form 10-K. [X] The aggregate market value of the voting stock held by non-affiliates of the registrant as of January 4, 2000 was $10,904,271 based upon the closing price on the Nasdaq National Market(R) reported for such date. This calculation does not reflect a determination that persons whose shares are excluded from the computation are affiliates for any other purpose. The number of shares outstanding of the registrant's common stock as of January 4, 2000 was 17,176,911. --------------------------- DOCUMENTS INCORPORATED BY REFERENCE Portions of the following document are incorporated herein by reference: Portions of the registrant's definitive proxy statement to be issued in connection with registrant's annual stockholders' meeting to be held February 29, 2000. 1
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TABLE OF CONTENTS Page PART I ITEM 1. BUSINESS...................................................... 3 ITEM 2. PROPERTIES.................................................... 15 ITEM 3. LEGAL PROCEEDINGS............................................. 15 ITEM 4. SUBMISSION OF MATTERS TO A VOTE OF SECURITY HOLDERS........... 16 PART II ITEM 5. MARKET FOR REGISTRANT'S COMMON EQUITY AND RELATED STOCKHOLDER MATTERS........................................... 17 ITEM 6. SELECTED FINANCIAL DATA....................................... 20 ITEM 7. MANAGEMENT'S DISCUSSION AND ANALYSIS OF FINANCIAL CONDITION AND RESULTS OF OPERATIONS........................... 21 ITEM 7A. QUANTITATIVE AND QUALITATIVE DISCLOSURE ABOUT MARKET RISK..... 29 ITEM 8. FINANCIAL STATEMENTS AND SUPPLEMENTARY DATA................... 29 ITEM 9. CHANGES IN AND DISAGREEMENTS WITH ACCOUNTANTS ON ACCOUNTING AND FINANCIAL DISCLOSURE............................29 PART III ITEM 10. DIRECTORS AND EXECUTIVE OFFICERS OF THE REGISTRANT............ 29 ITEM 11. EXECUTIVE COMPENSATION........................................ 29 ITEM 12. SECURITY OWNERSHIP OF CERTAIN BENEFICIAL OWNERS AND MANAGEMENT.................................................... 30 ITEM 13. CERTAIN RELATIONSHIPS AND RELATED TRANSACTIONS................ 30 PART IV ITEM 14. EXHIBITS, FINANCIAL STATEMENT SCHEDULES, AND REPORTS ON FORM 8-K................................................... 30 SIGNATURES.............................................................. 37 Forward-Looking Statements Statements in this Form 10-K, including those concerning the Registrant's expectations regarding its business, and certain of the information presented in this report, constitute forward looking statements within the meaning of the Private Securities Litigation Reform Act of 1995. As such, actual results may vary materially from such expectations. For a discussion of the factors that could cause actual results to differ from expectations, please see the caption entitled "Forward Looking Statements" in Item 1 and 7 hereof. There can be no assurance that the Registrant's results of operations will not be adversely affected by such factors. Registrant undertakes no obligation to revise or publicly release the results of any revision to these forward looking statements. Readers are cautioned not to place undue reliance on these forward looking statements, which reflect management's opinion only as of the date hereof. 2
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PART I ITEM 1. BUSINESS The Company Covol Technologies Inc. is a technology development company focused on "Recycling Yesterday's Waste into Tomorrow's Resources."(TM) Company History Covol was originally incorporated in Nevada in 1987 under the name Cynsulo, Inc. but underwent various name changes from 1987 to 1995. In 1991, Covol acquired technology consisting of binding agents used to make briquettes. From 1991 to 1995 Covol focused on the research and development of binding agents principally for iron, coal and coke waste particles. Covol's name was changed to Covol Technologies, Inc. in 1995, at which time Covol was reincorporated in Delaware. In 1995, management of Covol recognized the applicability of its technology to the production of synthetic fuel. Since 1996, the primary focus of Covol has been on developing and commercializing the synthetic fuel technology. Background As a result of efforts by government and business to efficiently use diminishing resources, the recycling industry has developed innovative approaches to recycle, recover and/or enhance the usefulness of wastes and by-products. Covol has developed a family of binder technologies used to form fine materials from wastes and by-products into briquettes to capture their inherent resource value. Cost-effective processes have not been fully implemented generally to capture industrial wastes, despite their potential usefulness and potential value. Storage and disposal of many of these by-products is costly and can be environmentally harmful. Covol's binder technologies are designed to enable the conversion of by-products from the coal and metals industries into valuable fuels and resources. Covol's primary focus over the past three years has been the commercialization of the application of its binder technologies to coal fines. Covol's binder technologies are being used to transform coal fines into a useable fuel. Coal fines are small particles of coal produced as a waste by-product of coal production. A recent study of the coal industry estimated that there are more than 2 billion tons of coal fines residing in waste ponds and landfills in the United States alone. Although coal fines have inherent fuel value, they present recovery and handling challenges that make it difficult to capture that value. Covol's binder technologies molecularly bond the coal fines into a formed fuel through a significant chemical reaction; the resulting product has been classified as a "synthetic fuel" within the meaning of Section 29 of the U.S. Internal Revenue Code. Sales of the fuel therefore qualify for a significant tax credit. The Covol binder technologies can also be used to transform coke dust into formed coke. Coke, which is processed metallurgical coal, is primarily used in the iron making process as a reducing agent and also as an economical fuel source. Coke dust, also known as "coke breeze," is a fine residue by-product resulting from the production, handling and storage of coke and is marketable in its "dust" state because of its high carbon and energy content. In tests, Covol has succeeded in aggregating coke dust into hard briquettes designed to withstand the weight, heat and other environmental factors inside of metal making furnaces, which appear potentially marketable at prices above briquette production costs. The Covol binder technologies can also be used to convert iron rich wastes into usable iron. Mill scale, bag-house dust, furnace sludge, blast furnace dust and other iron rich materials, are all waste by-products created by steel producers. These by-products present environmental problems for the steel industry. Because of their high iron content, they also have high potential value. Approximately 775 million tons of finished steel are consumed 3
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annually in the world with the U.S. producing approximately 100 million tons. The capture of even a fraction of the waste and other by-products of this steel production in the U.S. alone could provide millions of tons of feedstock material for processing. On a test basis, the Covol binder technologies have been demonstrated to be capable of producing briquettes from such steel production wastes. Such briquettes can be further processed in metal reducing furnaces to form high grade pig iron, a common form of feed material used in the steel industry. Additional fuel or resource by-products to which the Covol binder technologies appear applicable after initial testing include: molybdenum, silicon carbide, grinding swarf, lead dross, zinc oxide, titanium dioxide, phosphorous, and charcoal. Briquettes containing these by-products appear potentially marketable to ferrous and non-ferrous metals producers and to other industrial consumers. Except for synthetic fuel production, the Covol binder technologies listed above have not been commercially applied. No assurance can be given that Covol will be able to implement these applications profitably. Covol Binder Technologies Binder Technology. Covol has licensed its technology to other parties to produce and sell the products manufactured with the Covol binder technologies. Covol has contracted with Dow Chemical Company to produce chemical binder materials for the production of synthetic fuel made from coal fines. Substantially all of the equipment and machinery used for producing synthetic fuel is considered standard or "off-the-shelf" and is commercially available both domestically and internationally. Covol has been issued eight U.S. patents and eight foreign patents and has other U.S. and foreign patents pending. The patented technology principally relates to the application of Covol's binder technologies to iron production wastes, coke, coal and other carbon based materials. Covol is in the process of expanding the existing patents and applying for new patents related to waste recovery applications. See "ITEM 1. BUSINESS - Proprietary Protection" for a discussion of Covol's patents, trademarks and other intellectual property. Business Strategy The Covol binder technologies represent the foundation for Covol's business strategy. Covol believes that its success depends upon its ability to engineer industrial wastes and other by-products into value-added fuels and resources. Covol has divided its strategy into two general approaches: engineered fuels and engineered resources. Engineered Fuels. Engineered fuels include fuels recovered or enhanced primarily from carbon based materials. The Covol binder technologies provides a use for fuel-rich wastes and by-products by aggregating them into a solid form for improved handling and processing, and by making such modifications as may be required for a given application of the resulting fuel, for example, reduced moisture, increased hardness or enhanced energy content. Covol's engineered fuels include the production of fuel from briquetted coal fines, coke dust and silicon carbide. For the past three years Covol's business strategy has been focused almost exclusively upon synthetic fuel from coal fines. There are currently 24 synthetic fuel facilities located in 8 states that are utilizing Covol's synthetic fuel technology. Twenty-two of the facilities are owned by unaffiliated third parties and two are currently owned by Covol. Covol is actively pursuing the sale of the two facilities that it owns. All of the synthetic fuel facilities were initially placed into operation before the end of the second calendar quarter of 1998 and Covol and its licensees are currently in the process of increasing production levels and entering into contracts for product sales. Covol is working with its licensees to improve production and optimize quality. Feedstock supply, production and product quality and the marketing of the synthetic fuel all directly affect the amount and timing of royalties to be received by Covol from the synthetic fuel facilities. Accordingly, assisting licensees to optimize the production from these facilities is one of Covol's highest priorities. 4
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Covol has received one-time initial license fees with respect to most of the synthetic fuel facilities. These initial license fees will be recognized as revenue over the life of the license agreements. In the future, most of the revenues related to such facilities are expected to come from royalties that are tied to production and sale of synthetic fuel pursuant to licensing agreements in place. Covol also expects to generate net revenues from the sale of binder materials to the facilities. Another engineered fuel application Covol is pursuing is coke. Coke is processed metallurgical coal which serves as both a fuel and a reducing agent in iron and steel making. The production and handling of coke produces fine particles of coke dust. The aggregation of coke dust into briquettes that are designed to withstand the rigors of handling, heat and weight in metal making furnaces results in a useable fuel. Covol has patented technology and is in the process of patenting additional technology related to coke dust processing. Engineered Resources. Steel mills, nonferrous metal producers and other mineral industries produce wastes and other by-products that may contain valuable unrecovered resources. These wastes often create environmental compliance, storage and disposal problems. The Covol binder technologies provide a way to solve disposal problems, extract the inherent resources, process the materials with current industrial methods, and enhance the materials with qualities that add value and that customize the materials for alternative uses. The resulting products are collectively referred to as "engineered resources." Covol has devoted significant research and development resources to improving and perfecting its technology for these applications, particularly in the processing of iron production wastes. Covol has developed and tested its technologies with fine particulate wastes and other by-products, including: molybdenum, titanium dioxide, grinding swarf, lead dross, zinc oxide, phosphorous, and iron. Covol intends to continue to evaluate these and other engineered resource applications. Strategic Acquisitions. Covol believes that it may have unique opportunities to pursue acquisitions that are synergistic with Covol's financial and environmental objectives and initiatives. The Covol binder technologies may be applied to waste streams that are otherwise of little or no value. Covol intends to pursue possible acquisitions of businesses aligned to the industries in which the Covol business strategy of resource recovery may be applied. Covol intends to broaden its position in the synthetic fuel industry and other resource industries through the acquisition or licensing of technologies that are complementary to the Covol binder technologies. Subsidiaries Covol has organized various special purpose entities to facilitate some of the transactions relating to the 24 synthetic fuel facilities. The entities are listed with Covol's position and interest in the entity as of December 31, 1999 described as follows: o Alabama Synfuel #1 Ltd., a Delaware limited partnership of which Covol serves as general partner and owns 100% o Utah Synfuel #1 Ltd., a Delaware limited partnership of which Covol serves as general partner and owns 100% o Flat Ridge Corporation, a Utah corporation, a wholly-owned subsidiary of Covol o Commonwealth Synfuel, L.L.C., a Utah limited liability company of which Covol is managing member and owns 100% o Carbon Synfuel, L.L.C., a Utah limited liability company of which Covol is the managing member and owns 99% o Pocahontas Synfuel, L.L.C., a Utah limited liability company of which Covol is the managing member and owns 99% 5
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o Mountaineer Fuels, L.L.C., a Utah limited liability company of which Covol is the managing member and owns 99% o Synfuel Investments, Inc., a Utah corporation of which Covol is the sole stockholder; Synfuel Investments owns a 1% ownership interest in each of Carbon Synfuel, Pocahontas Synfuel, and Mountaineer Fuels. The following chart illustrates Covol's corporate structure. Covol's ownership directly or indirectly of each subsidiary is 100%. [Enlarge/Download Table] COVOL TECHNOLOGIES, INC. ------------------------------------ Common- Alabama Utah Flat Ridge wealth Carbon Pocahontas Mountaineer Synfuel Synfuel Synfuel Corp. Synfuel, Synfuel, Synfuel, Fuels, Investments, #1, Ltd. #1, Ltd. L.L.C. L.L.C. L.L.C. L.L.C. Inc. -------- ------- ------ -------- ---------- ------ ----- ---- Tax Credits Section 29 of the U.S. Internal Revenue Code provides a credit against regular federal income tax with respect to sales of qualified fuel to an unrelated party. Where more than one person has an interest in a qualified facility, the Section 29 Credits generated by the facility are allocated pursuant to the proportional interests of such persons in the facility. In order to qualify as a solid synthetic fuel produced from coal for purposes of the Section 29 credit, the fuel produced must differ significantly in chemical composition, as opposed to physical composition, from the raw material used to produce it. Covol has received a Private Letter Ruling, or PLR, from the IRS in which the IRS, based on representations made to it by Covol, ruled that the synthetic fuel technology produces a significant chemical change compared to coal fines and this qualifies the end product as a solid synthetic fuel. Accordingly the IRS has ruled, based on the facts presented to it, that: o Covol, with the use of its patented process, produces a "qualified fuel" within the meaning of Section 29 of the tax code; and o assuming the other requirements of Section 29 are met, the sale of the "qualified fuel" will entitle Covol to claim the Section 29 credit in the taxable year of sale. In its ruling, the IRS noted that no temporary or final regulations pertaining to one or more of the issues addressed in the PLR have been adopted and that the PLR would be modified or revoked by the adoption of temporary or final regulations to the extent the regulations are inconsistent with any conclusions in the PLR. The IRS notes, however, that a PLR is not revoked or modified retroactively, except in rare and unusual circumstances, provided that: o there has been no misstatement or omission of material facts, o the facts at the time of the transaction are not materially different from the facts on which the PLR was based, 6
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o there has been no change in the applicable law, o the PLR was originally issued for a proposed transaction and o the taxpayer directly involved in the PLR acted in good faith in relying on the PLR, and revoking the PLR retroactively would be to the taxpayer's detriment. Covol received its PLR in September 1995. At least seven other PLRs covering fourteen of the synthetic fuel facilities have been obtained by third parties in connection with licenses of Covol's synthetic fuel technology. However, all PLRs are only binding with respect to the specific projects addressed in the PLR and may only be relied on by the party that has obtained the PLR. The Section 29 credit is equal to approximately $6.10 in 1997 dollars for each oil barrel equivalent of the qualifying fuel produced and sold. This equates to approximately $20.00-$28.00 per ton of synthetic fuel briquettes, depending upon the recoverable heat content. The oil barrel equivalent is defined generally as an amount of fuel having a recoverable heat content of 5.8 million Btu's. The Section 29 credit was designed to provide protection for qualifying fuels against market price declines, and it is therefore subject to a phase out after the unregulated oil price reaches specified levels under an annually adjusted formula. In 1997 dollars, the credit would have phased out had the reference price for oil exceeded $47.78 per barrel, but the reference price determined for 1998 was $10.88 and no phase out occurred. There presently is no reference price for 1999. However, the average price of oil in the U.S. was higher in 1999 than 1998. The credit is also subject to reduction insofar as an otherwise qualifying facility benefits from grants or subsidized financing provided by federal, state or local governments, or from tax-exempt bond financing. Section 29 of the tax code contains no provision for carryback or carryforward of Section 29 credits. Once earned, the credits are not subject to subsequent recapture. By virtue of the various limitations and other factors described above, there can be no assurances that any particular amount of Section 29 credit will be allowable and usable. During 1996, certain of the time periods applicable to the Section 29 credit were extended. The Section 29 credit will, under present law, be available for sales of qualified fuels completed before January 1, 2008. The qualified fuels sold must be produced at facilities placed in service by June 30, 1998. The synthetic fuel facilities must have been constructed pursuant to a binding written contract in effect as of December 31, 1996. Synthetic Fuel Manufacturing Facilities The following table represents a summary of the 24 synthetic fuel manufacturing facilities constructed and placed in operation before June 30, 1998 by Covol and its licensees. SYNTHETIC FUEL MANUFACTURING FACILITIES No. of Name of Facility Plants Location Owner/Licensee Utah Synfuel #1 1 Price, Utah Coaltech No. 1 L.P. Carbon Synfuel 1 Price, Utah DTE Kentucky, L.L.C. Mohave Synfuels 1 Laughlin, Mohave Synfuels, Nevada L.L.C. Birmingport 1 Mulga, Birmingham Syn Alabama Fuel, L.L.C. 7
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Brookwood 1 Brookwood, PacifiCorp Syn Alabama Fuel, L.L.C. Pumpkin Center 2 Flat Creek, PacifiCorp Syn #1 & #2 Alabama Fuel, L.L.C. Norton 1 Norton, PC Virginia Virginia Synthetic Fuel #1, L.L.C. Chelyan 1 Chelyan, West PC West Virginia Virginia Synthetic Fuel #1, L.L.C. Muddlety 1 Muddlety, West PC West Virginia Virginia Synthetic Fuel #2, L.L.C. Eckman 1 Eckman, West PC West Virginia Virginia Synthetic Fuel #3, L.L.C. Appalachian 2 Peccus, West Appalachian Synfuel Virginia Synfuel, L.L.C. Mountaineer 1 Tallmansville, Mountaineer Fuels, Fuels West Virginia L.L.C. Pocahontas 1 Northfork, Pocahontas Synfuel West Virginia Synfuel, L.L.C. Ginger Hill 1 Ginger Hill, Ginger Hill Pennsylvania Synfuels, L.L.C. Robena 1 Paisley, Robena, L.L.C. Pennsylvania River Hill 1 Karthaus, DTE River Hill, Pennsylvania L.L.C. Pennsylvania 1 Somerset, Central City Synfuel Project Pennsylvania Synfuel, L.L.C. USA Coal, #1, 4 Pawnee, Illinois A.J.G. Financial #2, #3, & #4 Services, Inc. Pleasant Ridge 1 Alledonia, Ohio Pleasant Ridge --- Synfuels, L.L.C. Total 24 Covol Contracts. Consistent with the requirements for obtaining Section 29 tax credits, in December 1996 Covol entered into fourteen design and construction agreements for the design and construction of new synthetic fuel manufacturing facilities each having capacity of approximately 360,000 tons per year. Depending upon the specific agreement, the contractor was either TIC, CEntry Constructors & Engineers, PICOR or Centerline Engineering Corporation. The PICOR contracts were part of a joint venture with Savage Industries. The construction agreements, among other things, required that the plants be placed in service no later than June 30, 1998. Covol obtained financing and successfully constructed five facilities from its construction agreements. Of these, one was built by TIC for Covol and sold to Birmingham Syn Fuel, L.L.C., a special purpose entity owned by PacifiCorp Financial Services, Inc., two were built for Covol by Centerline, one of which was sold to DTE Kentucky, L.L.C., a special purpose entity owned by DTE Energy Services, Inc., and one of which is held for sale 8
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by Covol; two were built by TIC, one of which was sold to DTE River Hill, L.L.C., a special purpose entity owned by DTE Energy Services, Inc., and one of which is held for sale by Covol. Covol assigned four other construction agreements to licensees and those licensees successfully constructed four facilities as follows: Fluor Corporation. Covol assigned two of its fourteen construction agreements to Appalachian Synfuel L.L.C., a wholly owned subsidiary of Fluor Corporation. The facilities were built at A.T. Massey Coal Company, Inc.'s Marfork Prep Plant Site near Peccus, in Boone County, West Virginia. In conjunction with the assignment of the two contracts, Covol entered into a license agreement with Appalachian for the use of the Covol binder technologies. Under the agreement, Covol was paid an initial license fee. A quarterly license fee is paid based upon the Btu of product produced and sold up to a prescribed amount of production per year. Covol also granted Appalachian the right to pay a lump sum payment for the facilities, in lieu of quarterly license fees over the term of the agreement. Covol provides binder to the facility on a cost plus basis. Pelletco Corporation. Covol assigned two of its construction agreements with Centerline to affiliates of Pelletco Corporation. One contract was assigned to Pleasant Ridge Synfuels, L.L.C. which constructed a facility in Alledonia, Ohio. One contract was assigned to Ginger Hill Synfuels, L.L.C. which constructed a facility at Ginger Hill, Pennsylvania. In connection with these two facilities, Covol entered into technology license and agreements to supply Covol's chemical binder, providing Covol with initial license fees and quarterly license fees based upon the licensees' net cash flow. Covol provides binder to the two facilities on a cost plus basis. Unused Contracts. Covol did not build facilities under five of its fourteen construction agreements, including the two PICOR contracts as part of a joint venture with Savage Industries. The construction agreements provided for penalties if the construction was not pursued by Covol. Covol accrued this liability during the fiscal year ended September 30, 1997 and paid all penalties related to the two PICOR contracts. The remaining liability attributable to the other three contracts was $755,000 as of September 30, 1999. Covol believes that construction under any of the unused contracts is not likely. Additional Licensed Facilities. In addition to the nine facilities constructed under Covol's construction agreements, Covol licensed its technology to eight licensees for use at fifteen facilities constructed by these licensees. These licensees entered into their own construction agreements prior to December 31, 1996, in compliance with Section 29. In total, Covol has licensed or constructed plants using the Covol binder technologies at 24 synthetic fuel facilities that operate at 18 locations in the Rocky Mountain region, Southern Appalachia, Central Appalachia, Northeast Appalachia, Northwest Appalachia, and the Illinois Basin, which are the primary coal supply regions of the United States. For all facilities, the construction agreements were entered into prior to December 31, 1996. In most instances, Covol entered into a construction contract which was either fulfilled by Covol or later assigned to a licensee. In certain instances, the licensees entered into their own construction contracts. A facility generally consists of a conditioner and binder additive and mixing system, briquetting or aggregating equipment, a product dryer, and other supporting systems. However, each facility was individually engineered and constructed, including systems and components specially selected by the respective owners, so that there is variation in features from facility to facility. License and Binder Supply Agreements. All non-Covol entities that have constructed or own facilities using the Covol binder technologies have entered into a technology license and binder supply agreement with Covol. Many license agreements provided for an initial license fee, payable upon reaching project milestones. Covol has received most of the initial license fees related to these facilities which revenue will be recognized by Covol over the life of the license agreements. In addition, pursuant to many of the license agreements, the licensee pays a quarterly earned license fee generally at a prescribed dollar amount multiplied by the recoverable heat denominated in Btu's in the product produced and sold during the calendar quarter. The prescribed dollar amount is subject to adjustment based upon the "inflation adjustment factor" as set forth in Section 29 of the tax code. In some cases, the amount to be paid is subject to adjustment to the extent that licensees incur an operating loss on the production and sale of 9
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synthetic fuel, exclusive of the amount licensees pay as a license fee for the use of the technology. Some license agreements also provide for a goal fee based on time schedules and production amounts. In most cases, the fees paid to Covol under the license agreements are not based on the sales price of the synthetic fuel product. The license agreements generally have a term until the later of January 1, 2008 or the corresponding date after which tax credits may not be claimed or are not otherwise available under Section 29 of the tax code. Covol also agreed, pursuant to the binder supply agreements, to provide binder material to licensees for the manufacture and production of synthetic fuel. The price for the binder sold to the licensees falls into two categories: o a fixed price, or o an amount equal to Covol's cost plus a prescribed mark-up. In some cases, the mark-up may be reduced to the extent the licensee incurs a loss on the production and sale of synthetic fuel, but not below Covol's cost for such binder materials. The binder is currently manufactured by Dow Chemical Corporation for Covol utilizing Covol's patented and proprietary technology. Covol arranges with Dow for shipping of the binder directly to the facilities. Supply of Raw Materials Coal Fines. The synthetic fuel manufacturing facilities use coal fines as the primary feedstock to produce synthetic fuel. Accordingly, a supply of coal fines is essential to the feasibility of a synthetic fuel manufacturing facility. Historically, lower quality coal and mining refuse and fine particles of coal were discarded into refuse piles or impoundments. Today, coal preparation and material handling technologies have reduced the amount of coal that is discarded, but coal fines generated by coal mining and preparation are still problematic for the industry. With some variation, most consumers of coal only purchase coal with an ash content of 12% or less. Discarded coal fines are typically too high in ash content to be used as-is in making marketable synthetic fuel. To make use of fine coal refuse, owners of synthetic fuel plants must either blend the refuse with "clean" coal in appropriate proportions to yield an acceptable ash content, and/or clean the coal refuse itself. Clean coal can be purchased from traditional coal marketers and is available to all synthetic fuel facility owners that have a clean coal/coal refuse blending strategy. Coal fines cleaning is a distinct technology and to implement it successfully requires analysis of the particular coal refuse to determine appropriate plant design and to determine whether feedstock can be economically produced. Capital requirements for coal cleaning or preparation plants adequate to supply a synthetic fuel plant can be in excess of $4 million. Coal cleaning plants require six months or more to design and construct. A feasibility analysis must be performed to determine whether the savings achieved by the plant justify the capital costs of construction together with operational costs, which can vary between approximately $5-10 per ton. The costs of a cleaning plant are compared to the alternative of purchasing clean coal for blending. The decision to construct a coal cleaning plant does not delay delivery of synthetic fuel to market because in all cases clean blending coal is available to purchase as an immediate alternative. The decision to construct a coal cleaning plant is based on how a facility most economically obtains clean feedstock. In facilities owned and operated by licensees, the licensee secures its own supply of coal fines. Licensees that are also coal producers utilize their own feedstock sources. Nonproducer licensees secure deposits of coal fines to supply their facilities. Supply of Binder. Covol purchases its patented and proprietary binder from Dow Chemical Company under a ten year agreement under which Covol pays a prescribed price per pound of binder. Covol arranges with Dow for the delivery of the binder from Dow's manufacturing plants to each of the synthetic fuel facilities owned, operated, or licensed by Covol. 10
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Sale of Facilities Covol has sold four synthetic fuel facilities. The following is a summary of each sale: Utah Synfuel #1. On March 10, 1997, Utah Synfuel #1 Ltd., a Delaware limited partnership in which Covol was at the time a 64% owner and general partner, sold the Utah synthetic fuel facility for $3.5 million, in the form of a nonrecourse promissory note bearing interest at 9.6552% per annum and payable in 44 equal quarterly installments, all in accordance with the Utah Project Purchase Agreement, dated as of March 7, 1997, between Covol, Utah Synfuel #1 and Coaltech No. 1 L.P. The sale of the Utah facility resulted in a loss of approximately $582,000 to Utah Synfuel #1. The promissory note is collateralized by a security interest in the Utah facility, and in the event of a default under the promissory note, Covol's and Utah Synfuel #1's sole right to recovery is limited to the Utah facility without recourse against Coaltech. The loss of $582,000 was not recognized for financial reporting purposes and as described in Note 4 to the Consolidated Financial Statements, all note payments, including interest, reduce the carrying amount of the note receivable. Covol granted Coaltech a put option to require Covol to purchase the Utah facility from Coaltech if: 1. all of the Coaltech limited partners are unable to utilize the federal income tax credits under Section 29 of the tax code, 2. the economic benefits accruing to or experienced by all of the Coaltech limited partners differ significantly from what was initially projected, or 3. there is a permanent force majeure or material damage or destruction of the Utah facility. If the put option is exercised prior to the third anniversary date of the facility sale, the option price will be equal to the fair market value of the limited partnership interests of the optionees on a going concern basis, but in no event will the option price exceed 50% of the capital contributions made by the optionees to fund payments due under the promissory note, the Utah License Agreement and broker fees. If the put option is exercised on or after the third anniversary date, the option price will be $10 and the optionees will not be entitled to any other payments. As part of the sale of the Utah facility, Covol and Utah Synfuel #1 entered into a Supply and Purchase Agreement with Coaltech. Under the agreement, Covol agreed to provide coal fines to the Utah facility for processing into synthetic fuel at an amount equal to Covol's per ton costs, including any wash costs. Utah Synfuel #1 also agreed to purchase from Coaltech the synthetic fuel produced at Coaltech's cost plus one dollar per ton. Coaltech has the right to market its synthetic fuel to a third party, with Utah Synfuel #1 having a right of first refusal to purchase such synthetic fuel. Covol has incurred a loss each quarter in connection with this agreement. The Utah Synfuel #1 facility has experienced several problems, including uncertain coal fines feedstock and product sales commitments. Subsequent to September 30, 1999, Covol received notification from the limited partners of Coaltech that they were effecting a retirement of Covol as the general partner and were terminating Covol as operator of the Utah facility. Covol and Coaltech are in negotiations to resolve the situation, including a likely settlement of the note and termination of the Supply and Purchase Agreement. Birmingham Syn Fuel. Alabama Synfuel #1 Ltd., a Delaware limited partnership in which Covol was at the time a 74% owner and general partner, sold the Birmingham Syn Fuel/Birmingport facility to Birmingham Syn Fuel, L.L.C., a wholly-owned subsidiary of PacifiCorp Financial Services, Inc., on March 6, 1998. The purchase price for the Birmingport facility was $6,500,000 payable in the form of a nonrecourse promissory note collateralized by certain portions of the Birmingport facility. River Hill. Covol and its subsidiaries, Commonwealth Synfuel, L.L.C. and Synfuel Investments, Inc., sold the River Hill facility to DTE River Hill L.L.C., an affiliate of DTE Energy Services, Inc., on August 28, 1999. Covol also entered into a license and binder supply agreement which calls for ongoing royalties and binder sales. The purchase price for the River Hill facility consisted of a cash payment to Covol of $1,250,000, assumption of $5,000,000 of facility debt, completion of capital improvements to the facility and an eight-year royalty arrangement with both Covol and the construction lender, plus contingent payments based upon facility production performance. 11
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Carbon Synfuel. Covol and its subsidiaries, Carbon Synfuel, L.L.C. and Synfuel Investments, Inc., sold the Carbon Synfuel facility to DTE Kentucky, L.L.C., an affiliate of DTE Energy Services, Inc., on December 31, 1999. Covol also entered into a license and binder supply agreement which calls for ongoing royalties and binder sales. In addition to the four facilities discussed above, Covol owns two synthetic fuel manufacturing facilities that Covol has for sale. They are referred to as Pocahontas Synfuel located near Northfork, West Virginia; and Mountaineer Synfuel, near Tallmansville, West Virginia. Covol is negotiating with potential purchasers for the sale of these two facilities. Covol expects the sales to be completed during the second quarter of fiscal year 2000. Proprietary Protection Covol has the following trade names and patents covering certain aspects of Covol's technology: Trade names: Covol Technologies, Inc., Alabama Synfuel #1 Ltd., Utah Synfuel #1 Ltd., Carbon Synfuel, L.L.C., Mountaineer Fuels, L.L.C., Pocahontas Synfuel, L.L.C., Flat Ridge Corporation, Synfuel Investments, Inc., and Engineered Fuel Technologies, Inc. Trademarks and Service Marks: United States Trademark Registration No. 2,038,742 for licensing services identified by "Covol", "Recycling Yesterday's Waste Into Tomorrow's Resources." Patents Covol's eight U.S. and eight foreign patents expire on January 21, 2014. Other United States, Patent Cooperative Treaty, and Foreign Patent Applications are pending. There can be no assurance as to the scope of protection afforded by the patents. In addition, there are other industrial waste recycling technologies in use and others may subsequently be developed, which do not, or will not utilize processes covered by the patents or pending patents. There can be no assurance that any patent issued will not be infringed or challenged by other parties, infringe on patents held by other parties or that Covol will have the resources to enforce any proprietary protection afforded by the patent or defend against an infringement claim. In addition to patent protection, Covol also relies on trade secrets, know-how and confidentiality agreements to protect the Covol binder technologies. However, such methods may not afford complete protection and there can be no assurance that others will not independently develop such know-how or obtain access to Covol's know-how, concepts, ideas, and documentation. Since Covol's proprietary information is important to its business, failure to protect ownership of its proprietary information would likely have a material adverse effect on Covol. Covol's current and expected revenues are dependent upon license agreements by which licensees use the Covol binder technologies to manufacture synthetic fuel and then pay license fees to Covol. Covol expects that revenues will continue to be tied to future licensing agreements in the application of Covol binder technologies to iron rich wastes, coke dust, and other potentially useful wastes and by-products. Covol believes that its patents, trade secrets, know-how and confidential information are the basis upon which Covol is able to obtain licensing agreements. Confidentiality Provisions As part of its business, Covol typically enters into agreements concerning its projects which contain confidentiality provisions. Covol is, on occasion, required to disclose such agreements to the Securities and Exchange Commission as part of its ongoing reporting requirements under the Securities Exchange Act of 1934. In addition, disclosure of such agreements may be required in connection with Covol's SEC registrations or private placement of securities. Some of the agreements may not contain the standard exceptions for the disclosure of 12
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information which is required to be disclosed under law. Consequently, no assurances can be given that Covol has not inadvertently disclosed information regarding its various projects in violation of confidentiality covenants entered into by Covol. Government Regulation Covol's and its licensees' synthetic fuel operations are subject to federal, state and local environmental regulations that impose limitations on the discharge of pollutants into the air and water and establish standards for the treatment, storage and disposal of waste products. In order to establish and operate the synthetic fuel plants, Covol and its licensees obtained various state and local permits. Covol believes that it or its licensees have obtained all required permits to construct and operate synthetic fuel facilities, and that they are in substantial compliance with all relevant laws and regulations governing the synthetic fuel operations. Compliance with permits, regulations, and the approved processes does not create pollution or contamination. Still the possibility exists that regulatory noncompliance or accidental discharges, in spite of safeguards, could create an environmental liability. Acid is the only stored raw material used in the approved process that is classified as hazardous. Therefore, Covol's and its licensees' synthetic fuel operations entail risk of environmental damage and Covol or its licensees may incur liabilities in the future arising from the discharge of pollutants into the environment or from waste disposal practices. Failure by Covol or its licensees to maintain necessary permits to operate synthetic fuel plants and to comply with permit requirements could have a material adverse effect on Covol or its licensees. Other developments, such as the enactment of more stringent environmental laws and regulations, could require Covol or its licensees to incur significant capital expenditures. If Covol or its licensees do not have the financial resources or are otherwise unable to comply with such laws and regulations, such failure could also have a material adverse effect on Covol. Covol's goal is to establish itself as the provider of technologies that will assist others in the processing and reclamation of their wastes and by-products, and Covol seeks for itself and its licensees to avoid creating waste streams or compounding environmental reclamation problems. However, the synthetic fuel manufacturing process using Covol binder technologies typically uses dilute acids. Covol and its licensees must comply with hazardous material handling and storage regulations related to acid solutions and stored concentrates. Covol's and its licensees' synthetic fuel operations are also subject to federal and state safety and health standards. Covol is committed to providing effective management of worker safety and health protection. In addition, Covol has developed a safety policy designed to raise and maintain a high level of safety awareness by both management and employees. Failure to comply with safety and health standards could have a material adverse affect on Covol, for example, a regulatory inspector could close the operation until Covol meets the required standards. Major Customers Approximately 21% of revenues in 1998 and 40% of revenues in 1999 were from a single licensee, 27% of revenues in 1998 and 15% of revenues in 1999 were from a second licensee and 15% of revenues in 1998 and 13% of revenues in 1999 were from a third licensee. No other single customer accounted for over 10% of total revenues in any year presented. Competition Products made using the Covol binder technologies compete with other synthetic products as well as traditional source materials. Competitive factors include price, quality, delivery cost and waste handling costs. Covol may experience competition from other alternative fuel technology companies and their licensees, particularly those companies with technologies to produce coal based solid synthetic fuels. Competition may come in the form of the licensing of the competing technologies to process coal fines or in the marketing of end products qualifying as synthetic fuel. Competition includes, for example, Krystal Bond, KFx Inc. and Startec Inc. Covol will also experience competition from traditional coal and fuel suppliers and natural resource producers in addition to those 13
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companies that specialize in the disposal and recycling of waste products generated by coal, coke, steel and other resource production. Many of these companies have greater financial, management and other resources than Covol. Covol believes that it will be able to compete effectively although there can be no assurance that it will do so successfully. Employees Covol and its subsidiaries currently employ 52 persons full-time. Twenty-seven of such persons are in corporate administration including research, development and marketing, and twenty-five are in synthetic fuel and coal washing operations. None of these employees are covered by a collective bargaining agreement. Forward Looking Statements Statements regarding Covol's expectations as to the financing, development, construction, operation and sale of facilities utilizing the Covol binder technologies, the marketing of products, the receipt of licensing fees, the ability to extend or refinance existing obligations, and other information presented in this Annual Report on Form 10-K that are not purely historical by nature, including those statements regarding Covol's future business plans, the operation of facilities, the estimated capacity of facilities, the availability of coal fines, the marketability of the synthetic fuel and other briquettes and the financial viability of the facilities, constitute forward looking statements within the meaning of the Private Securities Litigation Reform Act of 1995. Although Covol believes that its expectations are based on reasonable assumptions within the bounds of its knowledge of its business and operations, there can be no assurance that actual results will not differ materially from its expectations. In addition to matters affecting Covol's industry or the coal industry or the economy generally, factors which could cause actual results to differ from expectations stated in these forward looking statements include, among others, the following: (1) The commercial success of the Covol binder technologies. (2) Successful sale of Covol owned facilities. (3) Operating issues for licensed and Covol owned facilities including feedstock availability, moisture content, Btu content, correct application of binder formulation, operability of equipment, product durability, resistance to water absorption and overall costs of operations. (4) Marketing issues relating to market acceptance of products manufactured using Covol's technology, including control of moisture content, hardness, special handling requirements and other characteristics of the synthetic fuel product which affect its marketability and its sales price. (5) Securing of necessary sites, including permits and raw materials, for relocation and operation of facilities. (6) Maintenance of placed in service requirements under Section 29 of the tax code by synthetic fuel manufacturing facilities. (7) Ability to obtain needed additional capital on terms acceptable to Covol. (8) Changes in governmental regulations or failure to comply with existing regulations which may result in operational shutdowns of Covol or licensee facilities. (9) The availability of tax credits under Section 29 of the tax code. (10) The commercial feasibility of the Covol binder technologies upon the expiration of Section 29 tax credits. (11) Ability to meet financial commitments under existing contractual arrangements. (12) Ability to meet non-financial commitments under existing contractual arrangements, including requirements to obtain stockholder approval of certain transactions. (13) Ability to commercialize the non-synthetic fuel related Covol binder technologies which have only been tested in the laboratory and not in full-scale operations. (14) Dependence on licensees to successfully implement Covol binder technologies. (15) The market acceptance of products manufactured with Covol binder technologies in the face of competition from traditional products. (16) Ability to produce products with Covol binder technologies with acceptable hardness, moisture level, and other characteristics. (17) Success in the face of competition by others producing synthetic fuel and other recycled products. (18) Sufficiency of intellectual property protections. ITEM 2. PROPERTIES Covol leases an approximately 5,000 square-foot building in Lehi, Utah, which houses its executive offices ("Corporate Headquarters"). In August 1997, Covol entered into a triple-net lease dated August 1, 1997 (the "Headquarters Lease"). The Headquarters Lease provides for a monthly rent of $5,000 during the initial term which expires on July 31, 2000. Thereafter, the Headquarters Lease will automatically extend indefinitely for successive one-year periods at the sole option of Covol, and the monthly rent will increase by 5% per year. In October 1997, Covol purchased an 8,000 square-foot site located in Price, Utah, on which Covol's prototype briquetting plant is located, for $150,000. Included in the purchase was a 1,400 square-foot office and warehouse building which houses equipment. The property is subject to a 10-year $100,000 mortgage held by the seller. The property is currently being leased to a third party for a one-year term. In June 1996, Covol entered into a land lease of approximately 12 acres in Price, Utah with a non-affiliated party at a monthly rental of $600. The lease term commenced on June 20, 1996 and expires on December 31, 2007 but may be extended. In 1996 Covol constructed a 22,000 square-foot building to house the Utah Synfuel #1 facility. In March 1997, this building was subleased by Covol to Coaltech as part of the sale of the Utah Synfuel #1 facility. Covol has constructed an ancillary building, a 1,650 square-foot binder plant. In February 1997, Covol entered into a lease agreement with Earthco for two contiguous parcels located in Wellington, Utah (approximately 6 miles from the Utah Synfuel #1 site). The first parcel covers approximately 30 acres and has a lease term of 15 years. On this parcel, Covol constructed a 3,400 square-foot wash plant at a cost of approximately $8 million. The second parcel covers approximately 357 acres and has a lease term of 5 years. The lease permits Covol to conduct fines recovery operations. The lease provides for total obligations to lease the parcels and acquire the associated fines of approximately $5.5 million, of which $700,000 was paid at the time of lease execution and for payments 4 times each year until May of 2002 for the balance. However, Earthco's ownership rights, and in turn, Covol's leasehold rights are the subject of a lawsuit initiated by NEICO. See "ITEM 3. LEGAL PROCEEDINGS -- NEICO/Earthco Suit" for a discussion of the dispute. In 1997, Covol entered into a 5 year, $850 per month sublease with Combustion Resources, Inc. for approximately 2,400 square feet of building space in Provo, Utah. In 1998, Covol entered into a one year, $1,500 per month lease with Mobile Auto & Storage for approximately 4,000 square feet of building space in Lehi, Utah. This property provides office and laboratory facilities for some of Covol's research and development personnel. In May 1998, Covol entered into a 10 year, $1,000 per year lease with Upshur Property, Inc., for approximately 10 acres of property in Tallmansville, Upshur County, West Virginia. The property is the site of the Mountaineer Synfuel facility. The lease has been terminated and the facility is being sold and relocated. In May 1998, Covol purchased approximately 80 acres of undeveloped property near Sunnyside, Utah for $100,000. In June of 1998 Covol entered into a five year lease with an option to purchase approximately 40 acres of property with office and warehouse improvements. The lease payments are $2,000 per month, escalating to $3,500 per month over time. The leased property is adjacent to the purchased property. Covol plans to conduct some operations on the two properties in the future. None of Covol's subsidiaries have interests in real property. ITEM 3. LEGAL PROCEEDINGS Asbestos Investigation. In January 1996, a manager of Covol entered property owned by Nevada Electric Investment Company, a subsidiary of Nevada Power Corporation, in connection with an offer by Covol to purchase 14
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the property, and with certain other employees of Covol, removed some asbestos over a two-day period. In May of 1996 Covol received a notice of violation and order for compliance from the State of Utah, Division of Air Quality alleging that asbestos was improperly handled, removed, and disposed of. Covol complied with the order and in September of 1996 entered into a settlement agreement with the State of Utah and paid a fine in the amount of $11,000. In late 1997 the U.S. Environmental Protection Agency began its own investigation, referring the matter to the U.S. Attorney's office. In December 1999 the former manager entered into a misdemeanor plea bargain and the U.S. Attorney agreed that criminal matters arising out of the incident are at an end. NEICO/Earthco Suit. On February 21, 1997, Covol entered into a contract on a parcel of real property located near Price, Utah, in which Covol obtained certain possessory and related interests, Covol's primary purpose being to obtain a source of coal fines to serve as feedstock for a nearby synthetic fuel facility. On August 24, 1999, Covol sent a notice of default to Earthco, alleging that Earthco had breached a material provision of the contract because Earthco did not have title to the property. Covol refused to tender its August 21, 1999 payment because of Earthco's breach. In addition, Covol contends that the quantity and/or quality of recoverable coal fines was substantially less than what Covol had understood when entering into the contract, thereby creating grounds to reform the terms of the contract. Earthco subsequently countered with allegations that Covol has breached its obligations under the contract, including failure to make the August 21, 1999 payment. On November 1, 1999, Covol was served with a Complaint in litigation pending in the Seventh Judicial District Court of Carbon County, Utah styled Nevada Electric Investment Company v. Earthco, et al. In the Complaint, and consistent with Covol's position, Nevada Electric Investment Company ("NEICO") alleges that it is the lawful owner of the property near Wellington, Utah described in Covol's lease from Earthco. NEICO seeks a declaratory judgement that Covol is not entitled to possession of the property due to the lack of ownership by Earthco. The Complaint also seeks further relief from Earthco. Covol received Earthco's Answer, Counterclaims and Cross-claim dated December 16, 1999. Earthco's cross-claim against Covol alleged breach of contract and prayed for substantial damages in an amount to be proven at trial but alleged to be in excess of $5 million. Covol filed its Reply and Cross-claim against Earthco on January 7, 2000 denying Earthco's claims and asserting claims of misrepresentation, breach of lease, unjust enrichment, and related claims and for general and consequential damages in an amount to be proven at trial. The disputes among Covol, Earthco and NEICO are at an early stage and resolution is uncertain. Covol intends to defend against claims and prosecute its own claims vigorously. ITEM 4. SUBMISSION OF MATTERS TO A VOTE OF SECURITY HOLDERS None. [Remainder of Page Intentionally Left Blank] 15
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PART II ITEM 5. MARKET FOR REGISTRANT'S COMMON EQUITY AND RELATED STOCKHOLDER MATTERS The shares of common stock of Covol trade on The Nasdaq Stock Market(sm) under the symbol "CVOL". The following table sets forth, for the periods presented, the high and low trading prices of Covol's common stock as reported by Nasdaq from April 1998, to September 1999, and bid quotations as reported by National Quotation Bureau, Inc. from October 1997 through March 1998. The quotations do not reflect adjustments for retail mark-ups, mark-downs or commissions and may not necessarily represent actual transactions. Since Covol has several market makers, the bid prices among the different market makers will generally vary. Accordingly, the bid price may not be representative of actual trades. The following prices may not be considered valid indications of market value due to the limited and sporadic trading in the shares of common stock during certain periods. Low High Fiscal 1998 Quarter ended December 31, 1997 $ 8.88 $13.94 Quarter ended March 31, 1998 10.50 14.06 Quarter ended June 30, 1998 12.25 17.44 Quarter ended September 30, 1998 9.00 17.25 Fiscal 1999 Quarter ended December 31, 1998 $4.25 $9.38 Quarter ended March 31, 1999 4.13 8.13 Quarter ended June 30, 1999 3.25 7.00 Quarter ended September 30, 1999 2.50 6.06 As of January 4, 2000, there were approximately 511 shareholders of record of Covol's common stock. Covol has not paid dividends on its common stock to date and does not intend to pay dividends on its common stock in the foreseeable future. Covol intends to retain earnings, if any, to finance the development and expansion of its business and to pay debt service and dividends on preferred stock. Payment of common stock dividends in the future will depend, among other things, upon Covol's ability to generate earnings, its need for capital and its overall financial condition. Recent Sales of Unregistered Securities The following sets forth all securities issued by Covol within the past fiscal year without registration under the Securities Act of 1933, as amended. No underwriters were involved in any stock issuances nor were any commissions paid in connection therewith. However, Covol did pay finders fees in the form of cash, stock or warrants in connection with various securities issuances. The issuance of qualified options is required to be based on market value. Accordingly, the exercise price is set based on the market price of Covol's common stock, even though the options convert into restricted stock. Covol believes that the following issuances of shares of common stock, notes, debentures and other securities were exempt from the registration requirements of the Securities Act of 1933, as amended, pursuant to the exemption set forth in Section 4(2) thereof. Each security was issued subject to transfer restrictions. Each certificate for each security bears a restricted legend. Each investor made representations to Covol that it was 16
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accredited as that term is defined in Regulation D and that the security was acquired for investment purposes. However, Covol has effective three registration statements filed on form S-3. These registration statements have registered many of the securities described in this section. In 1996, Covol formed two limited partnerships, Alabama Synfuel #1 Ltd. and Utah Synfuel #1 Ltd., to assist with the financing of construction at two synthetic fuel manufacturing facilities. These two facilities have been sold and are now owned by Birmingham Syn Fuel, L.L.C. and Coaltech No. 1 L.P. On September 9, 1998 Covol offered the limited partners in Utah Synfuel #1 and Alabama Synfuel #1 an exchange of Covol's common stock for their limited partnership interests. The exchange ratio was based in part on an independent valuation of the limited partnership's assets and other factors including but not limited to current and future expected cash flow of the partnerships and current market values of Covol's common stock as quoted on NASDAQ. The exchange ratio for Utah Synfuel #1 was 112.828 shares of common stock per each limited partnership unit and 125.97 shares for each Alabama Synfuel #1 limited partnership unit. The limited partnership's units originally sold for $1,000 per unit. As of November 10, 1998, all of the limited partners in Utah Synfuel #1 and all but one of the limited partners in Alabama Synfuel #1 had agreed to exchange their limited partnership interests for shares of Covol's common stock, and accordingly Utah Synfuel #1 became a wholly-owned subsidiary of Covol. In November 1999 the last limited partner in Alabama Synfuel #1 exchanged its limited partnership interest as a part of a licensing agreement so that Alabama Synfuel #1 also became a wholly-owned subsidiary of Covol. During November 1998, Covol completed a financing transaction that consisted of $400,000 of debt and approximately $3,500,000 of equity issued to 28 investors. The debt had a term of twelve months, bears interest at 15% per annum, with an interest only payment due in six months and with the balance of interest and principal due at maturity. The debt is collateralized by certain assets of Covol and is due prior to maturity upon the placement of long-term financing by Covol. The equity transaction consisted of the sale of a unit at a price of $5.00. A unit consisted of one share of restricted common stock of Covol plus a warrant to purchase one additional share of restricted common stock at an exercise price of $7.50. The warrants expire June 30, 2000 if not exercised. The stock and shares issuable pursuant to the related warrants bear "piggyback" registration rights. During January 1999, Covol completed a financing transaction with a major shareholder and lender to Covol, that consisted of the sale of 1,000 shares of a new series of non-voting preferred stock, designated as Series C 7% Convertible Preferred Stock. Covol received approximately $900,000 in net proceeds from the issuance of this preferred stock, which has the following rights and privileges: o Dividends on the preferred stock are cumulative and accrue whether or not they have been declared or whether Covol has any profits. The dividend rate is 7% per year of the liquidation value of $1,000 per share. o The preferred stock is convertible into common shares in incremental stages beginning April 1999 through July 1999, at which time all of the outstanding shares became convertible to common stock. The number of common shares to be received upon conversion is determined by multiplying the number of preferred shares by $1,000 and dividing that number by the conversion price (originally $5.50 per share, subject to market adjustment). Upon conversion, all accrued and unpaid dividends are paid or converted into shares of common stock. o Covol may at its option redeem the outstanding preferred stock beginning July 1999 for a redemption price equal to 125% of the liquidation value plus any accrued and unpaid dividends thereon. Warrants for the purchase of 72,727 shares of common stock were issued in conjunction with this preferred stock. The warrants are exercisable from April 1999 through July 2001 at an exercise price of $6.88 per share. The warrants issued and changes made to other existing warrants were valued at approximately $500,000. The exercise deadline for certain other warrants with an exercise price of $7.00 per share held by the shareholder were extended to June 2000 and certain additional warrants with an exercise price of $30.00 per share were relinquished and canceled. Covol granted registration rights for the restricted common shares issuable upon conversion of the 17
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preferred stock or upon exercise of the common stock warrants. Through January 4, 2000, all of the series C preferred stock had been converted. Approximately 237,000 shares of common stock were issued on conversion of the preferred stock and related accrued but unpaid dividends. On March 17, 1999, Covol completed a financing transaction with a large investment fund. The financing consisted of the issuance of $20,000,000 face value of convertible secured debt, issued at a 50% discount, and the issuance of 60,000 shares of cumulative convertible preferred stock (series D) for $6,000,000, for total gross proceeds of $16,000,000. Warrants for the purchase of common stock were also issued as part of the financing and were valued at approximately $3,000,000. Net cash proceeds were used to retire maturing short-term debt and related accrued interest, for working capital uses and other general corporate purposes. This transaction is described in detail in the Form 8-K filed March 24, 1999 and in the Form 10-Q/A for the quarterly period ended March 31, 1999. Beginning in November 1999 and through January 4, 2000, Covol has issued 1,603,775 shares of common stock on conversion of 15,202 shares of series D preferred stock. In September 1999, Covol entered into a transaction with an affiliate of a major shareholder and lender to Covol, to provide financing of up to $4 million in the form of convertible secured debt. The agreement provides for Covol to make draws as needed. Covol received $850,000 at the time of closing, less a placement fee of 10%, and subsequent to September 30, 1999 received a total of $1,650,000, less a placement fee of 10%. The debt is convertible at $3.00 per share, or market, whichever is less, and is convertible at the rate of 25% every 30 days beginning 30 days from the date of closing, subject to certain restrictions. Covol can redeem all outstanding debt at a rate of 125% of face value by providing 30 days notice. Borrowings are due in March 2001, if not converted earlier, and interest payments are due quarterly beginning December 1999. Covol assigned the royalties to be received from a licensed synthetic fuel facility as collateral for the financing. In November and December 1999, approximately 2,532,000 shares of common stock were issued on conversion of $1,460,000 of the convertible debt. The agreement requires the issuance of warrants to purchase Covol shares equal to 40% of the shares issuable under any borrowings under this financing arrangement. The warrants have a three-year exercise period and an exercise price of $3.60 per share. Warrants for the purchase of a total of approximately 350,000 shares of common stock were issued and were assigned a value, using the Black-Scholes option valuation model, of approximately $477,000. In December 1999, Covol placed $1,500,000 of financing with an investor rather than drawing the entire $4,000,000 of funding as provided under the September financing arrangement. The terms and conditions of this financing are similar to the September financing. As of December 20, 1999, Covol had received a total of $1,500,000, less a placement fee of 10%. The debt is convertible at $.73 per share, the market price at closing, or market price on the conversion date, whichever is less. The debt is convertible after January 21, 2000. The agreement requires the issuance of warrants to purchase Covol shares equal to 40% of the shares issuable under the debt agreement. Warrants for the purchase of approximately 935,000 shares were issued. The warrants have a three-year exercise period and an exercise price of $.88 per share, and were assigned a value, using the Black-Scholes option valuation model, of approximately $269,000. 18
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ITEM 6. SELECTED FINANCIAL DATA The following selected financial data are derived from the consolidated financial statements of Covol. This information should be read in conjunction with the consolidated financial statements, related notes and other financial information included herein. In 1996, Covol sold its construction subsidiaries. All construction - related operations were reflected as discontinued operations in the 1995 and 1996 financial statements. The note receivable received by Covol as consideration for the sale is "marked to market" each quarter based on the market value of Covol's stock held as collateral, and the resulting adjustments are reflected in Covol's statement of operations. The selected financial data as of and for the years ended September 30, 1995 and 1996 and as of September 30, 1997 are derived from audited financial statements not included herein. The selected financial data for the year ended September 30, 1997, and as of and for the years ended September 30, 1998 and 1999 were derived from the financial statements of Covol which have been audited by PricewaterhouseCoopers LLP included elsewhere herein. [Enlarge/Download Table] Year Ended September 30, --------------------------------------------------------------------- (thousands of dollars, except per-share data) 1995 1996 1997 1998 1999 ----------------------------------------------- -------------- -------------- ------------- -------------- ------------ OPERATING DATA: Total revenues $ 129 $ 295 $ 147 $ 3,074 $ 6,719 Loss from continuing operations (4,524) (12,955) (10,498) (11,308) (28,393) Net loss (5,654) (13,836) (10,498) (11,308) (28,393) Basic and diluted net loss per common share: Loss per share from continuing operations (1.00) (1.86) (1.32) (1.17) (2.39) Net loss per share (1.25) (1.99) (1.32) (1.17) (2.39) Purchase of property, plant and equipment and facilities held for sale 694 5,055 7,194 36,963 861 September 30, -------------- -------------- ---------------------------------------- (thousands of dollars) 1995 1996 1997 1998 1999 ------------------------------------------------ -------------- -------------- -------------- ----------- ------------ BALANCE SHEET DATA: Working capital (deficit) $(480) $(3,482) $(3,471) $ 7,497 $(2,037) Net property, plant and equipment 1,330 7,125 13,619 15,809 14,182 Total assets 2,660 8,072 26,590 68,061 58,095 Long-term obligations 177 364 5,362 23,256 30,138 Total stockholders' equity (deficit) 1,183 (233) 6,426 14,746 (1,028) 19
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ITEM 7. MANAGEMENT'S DISCUSSION AND ANALYSIS OF FINANCIAL CONDITION AND RESULTS OF OPERATIONS The following discussion and analysis should be read in conjunction with the information set forth under the caption entitled "ITEM 6. SELECTED FINANCIAL DATA" and the consolidated financial statements and notes thereto for Covol included elsewhere herein. Year Ended September 30, 1999 Compared to Year Ended September 30, 1998 The information set forth below compares Covol's operating results for 1999 with its operating results for 1998. Revenues. Total revenues for the year ended September 30, 1999 ("1999") increased by $3,645,000 to $6,719,000 as compared to $3,074,000 for the year ended September 30, 1998 ("1998"). During 1999, Covol recognized license fees totaling $3,526,000 while $860,000 of license fees were recognized during 1998. The license fees in 1999 consisted of the straight-line amortization of one-time non-refundable initial license fees of $875,000 and recurring earned license fees or royalty payments of $2,651,000. License fees in 1998 consisted of the straight-line amortization of one-time non-refundable initial license fees of $654,000 and recurring license fees or royalty payments of $206,000. Initial license fees, which are not expected to increase in future periods, are normally received when construction of the related synthetic fuel facility begins, when construction is completed, or when certain construction milestones or other conditions are met, but are recognized on a straight-line basis over the period covered by Covol's license agreements with licensees. Recurring earned license fees or royalty payments, which are expected to increase in future periods, are due quarterly based upon synthetic fuel produced and sold as reported to Covol by its licensees. Synthetic fuel sales were $767,000 in 1999 compared to $32,000 in 1998 and represent the sale of product from Covol-owned facilities. This revenue is expected to decrease in the future as Covol sells the remaining Covol-owned facilities. One facility was sold in September 1999, another facility was sold in December 1999 and Covol expects to sell its two remaining owned facilities in early 2000. Covol sold six binder mixing plants to licensees during 1998 for $1,088,000, generating a gross profit of $200,000. There were no such sales of binder mixing plants during 1999 nor are any expected in the future. Covol provides binder material to its licensees either at a fixed price or at Covol's cost plus a contracted markup. Covol purchases the binder materials under a long-term contract with a large chemical company. Total binder sales during 1999 were $2,140,000 with a corresponding direct cost to Covol of $1,695,000. Total binder sales during 1998 were $994,000 with a corresponding direct cost to Covol of $642,000. Covol expects a significant increase during 2000 of production of synthetic fuel by its licensees as licensees move toward full production levels with a corresponding increase in earned license fees or royalty payments and sales of binder products. However, Covol cannot assure increases in license fees, royalty payments and binder sales as the primary factor is Covol's licensees ability to successfully obtain adequate feedstock coal fines, process fines into synthetic fuel, and develop markets for synthetic fuel now and in the future. Covol believes that its licensees have made significant progress in these areas during 1999 but continued success cannot be assured. Synthetic fuel is a relatively new product and competes with standard coal products. Industrial coal users must be satisfied that the synthetic fuel is a suitable substitute for standard coal products. Moisture content, hardness, special handling requirements and other characteristics of the synthetic fuel product may affect its marketability and its sales price. Many industrial coal users are also limited in the amount of synthetic fuel product they can purchase because they have committed to purchase a substantial portion of their coal requirements through long-term coal contracts already in place. Reliance on spot markets and the overall downward trend in coal prices have generally produced lower sales prices as compared to long-term coal supply contracts common in the utility industry. Market acceptance of the synthetic fuel product appears to have improved during 1999 even though Covol's owned facilities and its licensees have only been able to secure long-term contracts for the sale of a small portion of their production. The suitability of synthetic fuel as a coal substitute, particularly the quality characteristics of synthetic fuel, and the traditional long-term supply contract practices of fuel buying in the utility industry, have made the identification of purchasers of synthetic fuel difficult. Covol has tried to solve this problem by identifying buyers for its owned facilities that are either consumers of coal or who have access to long-term coal 20
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contracts. Synthetic fuel is a coal substitute and the market and price are as broad and varied as the coal market itself. The US coal market exceeds one billion tons annually, and the prices range from approximately $12 to $35 per ton in the areas where facilities using the Covol technology are located. Prices are dependent on many factors, including Btu content, ash and sulfur content, moisture, location, etc. Covol believes that initial market resistance for synthetic fuel has decreased and believes long-term contracts can now be secured allowing Covol and its licensees to market the synthetic they produce at prices similar to coal. Section 29 of the Internal Revenue Code provides a tax credit for the production and sale of qualified synthetic fuel. Covol and Covol's licensees have received numerous private letter rulings from the IRS in which the IRS agrees that synthetic fuel manufactured using Covol's technology qualifies for the Section 29 tax credits. Covol is aware of at least eight private letter rulings issued by the IRS that cover Covol's technology. Based upon the language of Section 29 and private letter rulings issued by the IRS to Covol and Covol's licensees, Covol believes the synthetic fuel facilities were built and completed by June 30, 1998 and are therefore eligible for Section 29 tax credits. See ITEM 1. BUSINESS - Tax Credits for an explanation of qualifications for Section 29 tax credits. The synthetic fuel facilities that qualify for tax credits under Section 29 of the tax code receive economic benefits from the tax credits in addition to the benefits from operations. It is possible that synthetic fuel facilities built after June 30, 1998 that are not eligible for tax credits could not be operated profitably. Section 29 expires on December 31, 2007 after which tax credits will not be available to the synthetic fuel facilities. In order to remain competitive and commercially viable after 2007, Covol and its licensees must manage their costs of production and feedstock, and must also develop the market for synthetic fuel with prices comparable to coal. Covol has developed and patented technologies related to the briquetting of wastes and by-products from the coal, coke and steel industries and has also tested in the laboratory the briquetting of other materials. However, to date, Covol has only commercialized the coal-based synthetic fuel application. The other applications have not been commercialized or proven out in full-scale operations. The level of success Covol has in commercializing these other applications will directly impact Covol's future success and its ability to expand operations beyond the coal applications. Our accounting and valuation procedures assume all of the Covol owned facilities qualify for section 29 tax credits so that synthetic fuel production will continue to be the highest and best use of our equipment and facilities. If the facilities lost their qualification under Section 29, the equipment and facilities' carrying value would likely be higher than the fair value based on the alternative highest and best use, which could result in an impairment charge at that time. Operating Costs and Expenses. Operating costs and expenses increased by $16,444,000 or 130% to $29,132,000 during 1999 from $12,688,000 during 1998. Cost of coal briquetting operations increased $7,391,000 from $5,565,000 during 1998 to $12,956,000 during 1999. During 1999, Covol incurred significantly higher operating expenses in connection with the continued refinement and implementation of the briquetting process in connection with the 24 facilities placed in service during 1998, and in particular the operating costs of the four facilities owned by Covol which are being held for sale. These expenses primarily related to labor and operating expenses at the four Covol synthetic fuel facilities and the wash plant located in Utah, losses related to the writedown of inventory purchased from Coaltech, and costs incurred in providing assistance to Covol's licensees in resolving ramp-up issues at their synthetic fuel facilities. Covol expects to continue incurring operating losses into 2000 until all of these facilities are sold. Covol expects to realize a gain when the facilities are sold and would expect the cost of coal briquetting operations to be reduced to a level significantly less than the 1998 level. Until October 1999, Covol operated one of the synthetic fuel facilities for Coaltech, a partnership for which Covol was the general partner. Under the operating agreement, Covol is contractually obligated to purchase all of the synthetic fuel produced at cost plus $1 per ton. Production of synthetic fuel from this facility during 1999 and 1998 was not significant and accordingly, the cost per ton was significantly in excess of the current market value. These costs and the corresponding write-down of this inventory to its market value are included in the cost of coal briquetting operations. The write-down was approximately $1,815,000 during 1999 and $1,400,000 during 1998. Covol operated the Coaltech Utah facility at a loss because of the need to gain operating experience (it was the first synthetic fuel facility Covol built and operated), test alternative production methods, maintain operational status for Section 29 qualification, maintain the relationship with AJ Gallagher, an owner of the Utah facility who is 21
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a major licensee and partner of Covol, and other related business reasons. Subsequent to September 30, 1999, Covol received notification from the limited partners of Coaltech that they were effecting a retirement of Covol as the general partner and were terminating Covol as operator of the Utah facility. Covol and Coaltech are in negotiations to resolve the situation, including a likely settlement of the note and termination of the supply and purchase agreement. Settlement payments are expected to be consistent with amounts reflected in the accompanying consolidated financial statements. Proceeds from this settlement will be used to repay the $4,313,000 note payable due January 2000 to one of the limited partners. It is also expected that the limited partners will continue to purchase binder materials from Covol and use Covol's technology in the production of synthetic fuel when operations of the Utah facility are resumed. Asset Write-offs and Other Non-recurring Charges. In May 1995, Covol entered into an agreement with Geneva Steel Company to build and operate a synthetic fuel briquetting facility. The facility never reached commercial operating levels, but was held for other uses, including potential relocation to another site for use in the production of synthetic fuel or in other applications. In early 1999, Geneva filed a voluntary petition for relief under Chapter 11 of the United States Bankruptcy Code due to a lack of sufficient liquidity. Primarily as a result of this event, Covol moved a substantial portion of the equipment comprising the facility from the Geneva site to another location where it is being used in a different application of Covol's technology. Certain assets at the Geneva site, primarily consisting of leasehold improvements on the property where the facility was located, were abandoned. The carrying value of these assets, totaling approximately $556,000, was written off during 1999. During 1997, Covol entered into an agreement to purchase coal fines for feedstock for a synthetic fuel facility in Utah. Beginning in 1997 and continuing through May 1999, Covol made payments totaling approximately $3,917,000, of which $240,000 was transferred to cost of coal briquetting operations. The net amount paid was recorded as advances on inventories. Quarterly payments of approximately $396,000 are required under the agreement. The agreement provides for total payments of $5,500,000 between February 1997 and May 2000 for the removal of 2 million tons of coal fines (at a price of $2.75 per ton) from the property. The agreement also provides for removal of an additional 500,000 tons at $2.75 per ton. No payment is required for removal of any coal fines in excess of 2.5 million tons. Covol entered into the contract based on its understanding that the other party to the agreement (the "Seller") was the owner of the property and that there were in excess of 2 million tons of recoverable coal fines on the property. Subsequently, Covol learned that a third party disputes that the Seller is the owner of the property, and that there may be substantially less than 2 million tons of recoverable fines on the property. Consequently, in August 1999, Covol notified the Seller that unless the Seller could procure and provide evidence that it could warrant title to the property and would adjust contract payments to reflect the actual recoverable fines at the property, Covol may elect to terminate the contract and seek appropriate damages. On this basis, Covol has refused to make further quarterly payments to the Seller under the contract. The Seller responded by denying Covol's claims and alleging issues of property reclamation and bonding and failed contract payment. Covol denies these allegations. Covol no longer has purchasing responsibilities for the facility as the owner has notified Covol of its intention to relocate the facility. The dispute is in an early stage of litigation and resolution is uncertain. See "ITEM 3. LEGAL PROCEEDINGS". Based on the uncertainty of recovering the net advances paid through litigation, Covol wrote off the entire $3,677,000 of advances on inventories in the fourth quarter of 1999. In addition to the above charges, in the fourth quarter of 1999 Covol wrote off a $660,000 note receivable and recorded a liability for approximately $469,000 related to a settlement agreement with a company that had provided Covol with advise with respect to the use of certain synthetic fuel technology, certain financing obtained, and the sale of certain synthetic fuel manufacturing facilities. These write-offs and the settlement provision total approximately $5,362,000, which amount is recorded as asset write-offs and other non-recurring charges in the consolidated statement of operations. Selling, general and administrative expenses increased $291,000 or 7% to $4,727,000 during 1999 from $4,436,000 for 1998. The largest components of selling, general and administrative expenses for both 1999 and 1998 were payroll, professional services and travel expenses. Payroll costs increased approximately $450,000, due primarily to increased headcount and salary costs, professional services increased approximately $20,000 and travel decreased approximately $50,000 from 1998 to 1999. Also, there was approximately $250,000 of commissions incurred in connection with the placement of synthetic fuel license agreements in 1998 while there were no such commissions in 1999. Changes in the other categories from year to year were not material. Compensation expense from stock options, stock warrants, and issuance of common stock increased 22
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$1,614,000 to $2,553,000 for 1999 from $939,000 for 1998. This expense relates to options granted in prior periods that vest over several years and the compensation value that is being recognized as an expense over the vesting period. During 1999, Covol terminated several employees to whom compensatory stock options were granted in prior years. These stock options were not forfeited upon termination, resulting in the write off of the unamortized deferred compensation related to these individuals. Loss on sale of facility. In 1998, Covol sold a synthetic fuel facility located in Alabama on which a loss of $218,000 was recognized. In 1999, Covol sold a facility located in Pennsylvania on which a loss of approximately $1,839,000 was recognized. The sales price on the 1999 transaction consisted of a cash payment to Covol of $1,250,000, assumption of $5,000,000 of facility debt, completion of capital improvements to the facility and an eight-year royalty arrangement with both Covol and the construction lender. Covol can receive additional cash payments in the form of both accelerated and increased royalties upon obtaining firm synthetic fuel "off-take" agreements in excess of 100,000 tons per year and operating the facility at rated capacity for a ten-day period. Covol must achieve these performance milestones by June 30, 2000. The maximum amount under these provisions of approximately $9,700,000 is achieved if "off-take" agreements to sell 360,000 tons per year are put in place for the synthetic fuel production of the facility in addition to the ten-day operations period. Further, Covol can receive an additional $4,000,000 payment if the facility operates at 115% of capacity for a three-month period in any consecutive three months prior to December 31, 2001. Covol will recognize revenue and a corresponding gain under the royalty arrangement upon receipt of the royalty payments and for achievement of performance milestones. Covol also sold a synthetic fuel facility in December 1999, and entered into agreements to sell two other facilities in January 2000, as more fully described in Note 17 to the consolidated financial statements. Other Income and Expense. During 1999, Covol had net other expenses of $5,980,000 compared to $1,694,000 for 1998. This increase of $4,286,000 relates primarily to an increase in interest expense of $3,508,000, a change between periods of $1,228,000 in the mark-to-market adjustment of the carrying value of the related party note receivable collateralized by common stock, and a decrease in minority interest in losses of consolidated subsidiaries of $401,000, partially offset by an increase in interest income of $1,006,000. Interest expense in 1998 of $2,745,000 consisted primarily of amortization of the discount incurred upon the issuance of convertible debt and warrants at a discount. Interest expense of $6,253,000 in 1999 consisted of interest accrued on notes payable used to finance the construction of synthetic fuel facilities held for sale and for operating needs and $2,075,000 of amortization of debt discount and debt issue costs. Interest expense has increased significantly as a result of the debt issued during March 1999. Interest expense will decrease as a result of any future repayments of debt related to the sale of facilities held for sale. During 1996, Covol sold certain construction companies and received as consideration a $5,000,000 note receivable ("Note"). The Note is "marked to market" each quarter based upon the market value of Covol's common stock held as collateral and is reflected in the consolidated balance sheet at the underlying value of this collateral, $400,000 at September 30, 1999. This adjustment resulted in a write-down of $1,209,000 during 1999, compared to a write-up of $19,000 during 1998 for a net change of $1,228,000. A $515,000 payment on this Note during 1999 was included in interest income for 1999, while no interest income on the Note was recognized in 1998. Another reason for the increase in interest income in 1999 over 1998 relates to a full year's interest being recognized on the $6,500,000 note receivable from the sale of the Alabama facility in March 1998. During September 1998, Covol offered the limited partners of Utah Synfuel #1 and Alabama Synfuel #1 common stock of Covol in exchange for their limited partnership interests. These exchanges, most of which were accounted for in September 1998, were substantially completed by November 1998, at which time Utah Synfuel #1 became a wholly-owned subsidiary of Covol and Alabama Synfuel #1 became a 98%-owned subsidiary of Covol. As a result of these exchanges, minority interest in the losses of consolidated subsidiaries decreased from approximately $392,000 in 1998 to approximately $0 in 1999. Net loss. For 1999, the net loss of $28,393,000 represents a change of $17,085,000 from the net loss of $11,308,000 in 1998. This is primarily due to the increase in cost of briquetting operations, the asset write-offs and other non-recurring charges, and the increase in interest expense. Covol did not recognize any income tax benefit in 23
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1999 or 1998 since the realization of its deferred tax asset of approximately $21,800,000, consisting primarily of net operating loss carryforwards, is dependent on generation of future taxable income. Year Ended September 30, 1998 Compared to Year Ended September 30, 1997 The information set forth below compares Covol's operating results for 1998 with its operating results for 1997. Revenues. Total revenues for the year ended September 30, 1998 increased by $2,927,000 to $3,074,000 as compared to $147,000 for 1997. During 1998 Covol recognized license fees totaling $860,000 while $105,000 of license fees were recognized during 1997. These fees consisted of the straight-line amortization of one-time non-refundable initial license fees of $654,000, and recurring license fees or royalty payments of $206,000. The fees in 1997 related solely to amortization of the Coaltech non-refundable initial license fee. Initial license fees are normally received when construction of the related synthetic fuel facility begins, when construction is completed, or when certain construction milestones or other conditions are met, but are recognized on a straight-line basis over the period covered by Covol's license agreements with licensees. Recurring license fees or royalty payments are due quarterly based upon synthetic fuel produced and sold as reported to Covol by its licensees. Covol sold six binder mixing plants to licensees during 1998 for $1,088,000, generating a gross profit of $200,000. Covol provides binder material to its licensees either at a fixed price or at Covol's cost plus a contracted markup. Covol purchases the binder materials under a long-term contract with a large chemical company. Total binder sales during 1998 were $994,000 with a corresponding direct cost to Covol of $642,000. Operating Costs and Expenses. Operating costs and expenses increased by $2,372,000 or 23% to $12,688,000 during 1998 from $10,316,000 during 1997. Cost of coal briquetting operations increased $305,000 from $5,260,000 during 1997 to $5,565,000 during 1998. During 1997, Covol recorded an expense for $1,477,000 relating to construction penalties for failure to proceed under several contracts Covol had entered into. There was no similar expense in 1998. However, during 1998 Covol incurred significantly higher operating expenses in connection with the continued refinement and implementation of the briquetting process, and the commercialization of this process in connection with the 24 facilities placed in service during 1998, including the four facilities held for sale. These expenses related in part to the construction and operation of four synthetic fuel facilities built by Covol that were held for sale, costs incurred in providing assistance to Covol's licensees during the ramp-up of their synthetic fuel facilities, and increased personnel costs. These increases during 1998 effectively offset the 1997 construction penalty expenses. Covol operated one of the synthetic fuel facilities for Coaltech, a partnership for which Covol is the general partner. Under this operating agreement, Covol is contractually obligated to purchase all of the synthetic fuel produced at cost plus $1 per ton. Production of synthetic fuel from this facility during 1998 was not significant and accordingly, the cost per ton is significantly in excess of the current market value. These costs and the corresponding write-down of this inventory to its market value are included in the cost of coal briquetting operations. The write-down was approximately $1,400,000 during 1998 and $1,548,000 during 1997. Selling, general and administrative expenses increased $1,438,000 or 48% to $4,436,000 during 1998 from $2,998,000 for 1997. Approximately $500,000 of this increase related to a substantial increase in travel and related costs as Covol's employees spent a significantly greater amount of time at Covol facilities and licensee-owned facilities. The balance of the increase in expenses relates to approximately $250,000 of commissions incurred in connection with the placement of synthetic fuel license agreements, $175,000 in increased professional fees and a $500,000 increase in payroll and related costs, resulting from additional employees hired. Compensation expense on stock options, stock warrants, or issuance of common stock decreased $1,119,000 or 54% to $939,000 for 1998 from $2,058,000 for 1997. This decrease is attributable to a change in policy to only grant stock options at strike prices that are not "in-the-money," for the purpose of providing an incentive to the recipient of the options to create shareholder value. The majority of the 1998 expense relates to options granted in prior years that vest over several years and the compensation value that is being recognized as an expense over the vesting period. In 1998, Covol sold the facility owned by Alabama Synfuel #1 Ltd. for $6,500,000, in exchange for a note receivable due not later than February 2003. A loss of $218,000 was incurred from the sale of this facility. Covol 24
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believes the note receivable, which is classified as a facility-dependent note receivable in the consolidated balance sheet, is collectible from the debtor, or in the event of the debtor's failure to satisfy the obligation, by the debtor's parent, Covol that will ultimately utilize the tax credits generated from the synthetic fuel facility. In 1997, Utah Synfuel #1 transferred its facility to Coaltech for $3,500,000, evidenced by a promissory note payable in 44 quarterly installments of $130,000 starting March 31, 1997. The actual cost to construct the Utah Synfuel #1 facility was $4,082,000. In accordance with generally accepted accounting principles and after discussion with the staff of the Securities and Exchange Commission, this transaction has not been reflected as a sale for accounting purposes. The original cost of the facility, less cash payments received from Coaltech, is reflected in the consolidated balance sheet as a facility transferred under note receivable arrangement. During 1996, Covol sold certain construction companies and received as consideration a $5,000,000 note receivable ("Note") with interest at 6% payable over five years. It was determined that the Note should be discounted to an appropriate market rate and accordingly, the Note was discounted at 10.25% resulting in a discount of $1,281,000. The Note is collateralized by stock and stock options of Covol and is reflected in the consolidated balance sheet at the underlying value of the collateral. Accordingly, the Note is "marked to market" each quarter based upon the market value of Covol's common stock. This adjustment resulted in income of $19,000 being recognized during 1998, compared to an expense of $60,000 recognized during 1997. The Note is guaranteed by the buyer of the construction companies and there has been no event of default or past due payment on the Note. Covol does not accrue interest on this Note and as of September 30, 1998 the Note had a carrying value of $1,609,000 in Covol's consolidated balance sheet. Other Income and Expense. During 1998, Covol had net other expenses of $1,694,000 compared to $329,000 for 1997. This increase of $1,365,000 relates primarily to an increase of $618,000 in net interest expense and a decrease of $853,000 in minority interest in the net losses of consolidated subsidiaries (Utah Synfuel #1 and Alabama Synfuel #1). During September 1998, Covol offered the limited partners of Utah Synfuel #1 and Alabama Synfuel #1 an exchange of their limited partnership interests for common stock of Covol. These exchanges, most of which were accounted for in September 1998, were substantially completed in November 1998, at which time Utah Synfuel #1 became a wholly-owned subsidiary of Covol and Alabama Synfuel #1 became a 98%-owned subsidiary of Covol. Net Loss. For 1998, the loss increased by $810,000 from $10,498,000 for 1997 to $11,308,000. The increase is primarily due to increased operating costs and other expenses as discussed previously. Covol did not recognize any income tax benefit in 1998 or 1997 since the realization of its deferred tax assets, consisting primarily of net operating loss carryforwards, depends on generation of future taxable income. Liquidity and Capital Resources Liquidity. During 1998, Covol and its licensees completed the construction of and began operations at 24 synthetic fuel facilities. Covol owned four facilities which it held for sale during 1999. One facility was sold in August 1999 and another was sold in December 1999. Covol currently owns two facilities which are being offered for sale and anticipates the sale of these facilities in early 2000. Proceeds from the sale of these facilities will be used to retire debt that was incurred principally in connection with the construction and operation of the facilities and for working capital needs. Total operating expenses associated with the four owned facilities cost approximately $500,000 per month during the quarter ended September 30, 1999. These operating expenses fluctuate depending on the level of activity at the owned facilities. Net cash used in operating activities for the year ended September 30, 1999 ("1999") was $17,516,000 compared to $5,366,000 of cash used during the year ended September 30, 1998 ("1998"). Most of this change in cash flow from operations is attributable to the 1999 net loss of $28,393,000 as compared to $11,308,000 in 1998. Covol has been able to fund its operating activities, including the continued refinement and commercialization of its patented binder technologies, through the incurrence of debt and the issuance of convertible preferred stock, common stock and common stock warrants. During 1999, proceeds from the issuance of notes payable totaled approximately $11,193,000, proceeds from the issuance of preferred stock totaled $6,367,000 and proceeds from the issuance of common stock totaled $3,775,000. 25
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Capital Resources. During 1999, Covol's investing activities were not significant. Investing activities in 1998 were significant and consisted primarily of the purchase of property, plant and equipment and the four facilities held for resale, with most of the funds for these activities coming from the issuance of notes payable ($35,454,000) and from working capital. Covol believes that funds required for investing activities will continue to be significantly lower during 2000 as compared to 1998 because the construction of synthetic fuel facilities that qualified for federal income tax credits under Section 29 of the IRC was completed during 1998. In order to receive tax credits under IRC Section 29, the synthetic fuel sold must be produced at a facility placed in service by June 30, 1998 and Covol has no current plans to construct additional synthetic fuel facilities. There are 24 synthetic fuel plants that currently utilize Covol's patented technology and from which Covol intends to earn license fees and / or profits from the sale of binder. These facilities do not presently operate at levels needed to generate significant revenues to Covol. Improved operations at the plants depend on the ability of the plant owners to produce synthetic fuel that meets market specifications in order for the plant owners to market the synthetic fuel. Covol is assisting the plant owners in their efforts to overcome production and marketing problems. Covol anticipates that recurring license fees or royalties from the production and sale of synthetic fuel will continue to increase during 2000 and beyond. As production levels increase, sales of the binder materials by Covol to its licensees are expected to increase proportionately. Funds received by Covol from these activities are expected to be sufficient to cover Covol's operating costs and expenses at some point during 2000. In order for operating activities to produce significant positive cash flow, Covol and its licensees must successfully address certain operating issues and marketing difficulties. These problems have delayed Covol's expected growth in license fees, and have resulted in lower than expected cash flows and higher than expected capital requirements. Operating issues which must be addressed include, but are not limited to, feedstock availability, moisture content, Btu content, correct application of binder formulation, operability of equipment, product durability, resistance to water absorption and overall costs of operations, which in many cases to date have resulted in unit costs in excess of synthetic fuel sale prices. Marketing difficulties which must be addressed relate to market acceptance of products manufactured using Covol's technology. Industrial coal users must be satisfied that the synthetic fuel is a suitable substitute for standard coal products. Moisture content, hardness, special handling requirements and other characteristics of the synthetic fuel product may affect its marketability and its sales price. Many industrial coal users are also limited in the amount of synthetic fuel product they can purchase from Covol and its licensees because they have committed to purchase a substantial portion of their coal requirements through long-term coal contracts already in place. Reliance on spot markets and the overall downward trend in coal prices have generally produced lower sales prices as compared to long-term coal supply contracts common in the utility industry. Market acceptance of the synthetic fuel product appears to have improved during 1999 even though Covol's owned facilities and its licensees have only been able to secure long-term contracts for the sale of a small portion of their production. The suitability of synthetic fuel as a coal substitute, particularly the quality characteristics of synthetic fuel, and the traditional long-term supply contract practices of fuel buying in the utility industry, have made the identification of purchasers of synthetic fuel difficult. Covol believes that initial market resistance for synthetic fuel has decreased and believes long-term contracts can now be secured allowing Covol and its licensees to market the synthetic fuel they produce at prices similar to coal. Covol incurred a net loss for the year ended September 30, 1999 of $28,393,000 and used $17,516,000 of cash in its operating activities for the year. As discussed in Note 6 to the consolidated financial statements, Covol has $20,626,000 of long-term debt due during the year ending September 30, 2000. In addition, Covol's convertible note payable with a face amount of $20,000,000 and related redeemable convertible preferred stock with an aggregate liquidation preference of approximately $5,600,000 at December 31, 1999 contain certain provisions including an increase in the interest rate, immediate convertibility, required escrow payments and possible immediate payment of outstanding amounts in the event of a default by Covol. Such an event could include a failure of Covol's shareholders to approve the issuance of the convertible debt and convertible preferred stock by March 31, 2000 or failure of Covol to achieve the targeted earnings levels. Covol believes that shareholder approval will be obtained and that Covol will achieve the targeted earnings levels during fiscal 2000. 26
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Covol has funded its operations during the year ended September 30, 1999 primarily through the issuance of debt and equity securities, and the sale of a synthetic fuel facility. During November 1998, Covol issued common stock and common stock warrants for total net proceeds of approximately $3,729,000. During January 1999, Covol issued convertible preferred stock and warrants for total net proceeds of approximately $899,000. During March 1999, Covol issued convertible secured debt, convertible redeemable preferred stock and common stock warrants for total net proceeds of approximately $14,581,000. From September through December 1999, Covol issued convertible secured debt and warrants for total net proceeds of approximately $3,500,000 and is currently in discussions with creditors to whom debt is owed in January 2000. As discussed in Note 17 to the consolidated financial statements, in August 1999 and December 1999, Covol sold two synthetic fuel facilities for cash proceeds in excess of amounts required to fully retire the related debt collateralized by the facilities. Also, on January 13, 2000, Covol excuted definitive agreements for the sale of one synthetic fuel facility and executed a letter of intent for the sale of the only remaining facility held for sale. Covol believes that there are several alternatives available that will provide the working capital necessary to meet operational requirement and debt payments as they become due, including proceeds from the sale of its remaining facilities held for sale, funds from operations, and only if no other alternatives exist, additional financing. Covol believes it will be able to extend the repayment terms of its debt and that excess proceeds from the sale of facilities will be sufficient to fund Covol's operations until its operating activities begin producing positive cash flow. In connection with the financing Covol obtained in March 1999, Covol has agreed to certain covenants contained in the recently completed financing documents. One covenant requires Covol to meet certain earnings targets for the quarter ending December 31, 1999 and for subsequent quarters. Consolidated earnings before interest, taxes, depreciation and amortization (EBITDA) and certain other adjustments, of $5,000,000 is required for the quarter ending December 31, 1999. The EBITDA target increases in subsequent quarters. As of the date of this report, Covol expects it will be able to comply with this provision during fiscal 2000. Covol's current operations are at levels below this requirement; however, the sale of the Covol-owned facility in December 1999 resulted in a gain in excess of $5,000,000. Additionally, operating expenses have decreased as a result of the sale of the facilities in August 1999 and December 1999. Operation of the synthetic fuel facilities at or near capacity should result in EBITDA at levels in excess of this requirement. Non-compliance with this provision would result in an increase in the debt coupon rate by one percentage point immediately and each 90 days thereafter until cured. Also, the debt would become immediately convertible at a price not less than $6.67 or more than $10.00 which calculation is based upon the current market price of Covol's stock. Upon the second event of non-compliance with this provision, Covol will be required to deposit approximately $3,000,000 into an escrow account. Failure to make payments into the escrow account results in royalty payments from the related collateral being made directly to the debt holders. There are other provisions and covenants in these loan documents that may restrict or prohibit certain activities. Forward Looking Statements Statements in this Item 7 regarding Covol's expectations as to the receipt of licensing and royalty fees, revenues, the receipt of operation and maintenance fees, the receipt of fees for sale of binder materials, reduction in operating expenses, ability to extend or refinance debt, and other information presented herein that are not purely historical by nature, constitute forward looking statements within the meaning of the Private Securities Litigation Reform Act of 1995. Although Covol believes that its expectations are based on reasonable assumptions within the bounds of its knowledge of its business and operations, there can be no assurance that actual results will not differ materially from its expectations. In addition to matters affecting Covol's industry or the coal industry or the economy generally, factors which could cause actual results to differ from expectations set forth in the above-identified forward looking statements include in part, the following: 27
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o the ability of Covol and its licensees to resolve the operational and marketing issues described above; o the ability of licensees to produce and sell synthetic fuel at or near the rated capacity of the synthetic fuel facilities and willingness and ability of licensees to make timely payments for binder materials purchased and royalty amounts due; o ability to obtain needed additional capital on terms acceptable to Covol; o changes in governmental regulation or failure to comply with existing regulation which may result in operational shutdowns of its facilities; and o the availability of tax credits under Section 29 of the tax code and qualification of facilities currently in service. See "ITEM 1. BUSINESS--Forward Looking Statements" for a description of additional factors which could cause actual results to differ from expectations. Impact of Inflation During 1999, cost increases to Covol were not materially impacted by inflation. Other Items Covol has reviewed all recently issued, but not yet adopted, accounting standards in order to determine their effects, if any, on the results of operations or financial position of Covol. Based on that review, Covol believes that none of these pronouncements will have any significant effects on current or future financial position or results of operations. ITEM 7A. QUANTITATIVE AND QUALITATIVE DISCLOSURE ABOUT MARKET RISK None. ITEM 8. FINANCIAL STATEMENTS AND SUPPLEMENTARY DATA The financial statements and supplementary financial data required by this Item 8 are set forth in Item 14 of this Form 10-K. All information which has been omitted is either inapplicable or not required. ITEM 9. CHANGES IN AND DISAGREEMENTS WITH ACCOUNTANTS ON ACCOUNTING AND FINANCIAL DISCLOSURE There are no changes in or disagreements with accountants on accounting or financial statement disclosure. PART III ITEM 10. DIRECTORS AND EXECUTIVE OFFICERS OF THE REGISTRANT The information to be set forth under the captions "Executive Officers," "Section 16(a) Beneficial Ownership Reporting Compliance" and "Proposal No. 1: Election of Director" in Covol's Proxy Statement to be dated on or about January 17, 2000, for the Annual Meeting of Stockholders to be held on or about February 29, 2000 (the "Proxy Statement"), are incorporated herein by reference. ITEM 11. EXECUTIVE COMPENSATION The information to be set forth under the caption "Executive Compensation and Related Information" in the Proxy Statement is incorporated herein by reference; provided, however, that Covol specifically excludes from such incorporation by reference any information set forth under the captions "Compensation Committee Report on Executive Compensation" and "Stockholder Return Performance Graph" in the Proxy Statement. 28
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ITEM 12. SECURITY OWNERSHIP OF CERTAIN BENEFICIAL OWNERS AND MANAGEMENT Security ownership of certain beneficial owners and management to be set forth under the caption "Security Ownership of Directors, Nominees and Principal Stockholders" in the Proxy Statement is incorporated herein by reference. ITEM 13. CERTAIN RELATIONSHIPS AND RELATED TRANSACTIONS The information to be set forth under the caption "Transactions with Related Parties" in the Proxy Statement is incorporated herein by reference. PART IV ITEM 14. EXHIBITS, FINANCIAL STATEMENT SCHEDULES, AND REPORTS ON FORM 8-K (a) 1. Financial Statements Consolidated Financial Statements of Covol Technologies, Inc. Report of Independent Accountants........................................ F-1 Consolidated Balance Sheets as of September 30, 1998 and 1999............ F-2 Consolidated Statements of Operations for the years ended September 30, 1997, 1998 and 1999........... F-4 Consolidated Statements of Changes in Stockholders' Equity (Deficit) for the years ended September 30, 1997, 1998 and 1999........... F-5 Consolidated Statements of Cash Flows for the years ended September 30, 1997, 1998 and 1999........... F-8 Notes to Consolidated Financial Statements............................... F-10 2. Financial Statement Schedules All financial statement schedules for which provision is made in the applicable accounting regulations of the Securities and Exchange Commission are not required under the related instructions or are inapplicable, and therefore have been omitted. 3. Listing of Exhibits Certain other instruments which would otherwise be required to be listed below have not been so listed because such instruments do not authorize securities in an amount which exceeds 10% of the total assets of Covol and its subsidiaries on a consolidated basis and Covol agrees to furnish a copy of any such instrument to the Commission upon request. There is included a restated financial data schedule for the years ended September 30, 1997 and 1998. [Enlarge/Download Table] Exhibit No. Description Location 2.1 Agreement and Plan of Reorganization, dated July 1, 1993 between Covol and the (1) Stockholders of R1001 29
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Exhibit No. Description Location 2.2 Agreement and Plan of Merger dated August 14, 1995 between Covol and Covol (1) Technologies, Inc., a Delaware corporation 2.3 Stock Purchase Agreement, dated July 1, 1993, among Covol, Lloyd C. McEwan, Michael (1) McEwan, Dale F. Minnig and Ted C. Strong regarding the purchase of Industrial Management & Engineering, Inc. and Central Industrial Construction, Inc. 2.4 Stock Sale Transaction Documentation, effective as of September 30, 1994, between Covol (1) and Farrell F. Larson regarding Larson Limestone Company, Inc. 2.5 Stock Purchase Agreement dated February 1, 1996 by and among Covol, Michael McEwan (1) and Gerald Larson regarding the sale of State, Inc., Industrial Engineering & Management, Inc., Central Industrial Construction, Inc., and Larson Limestone Company, Inc. 2.5.1 Amendment to Share Purchase Agreement regarding the sale of the Construction Companies (1) 2.5.2 Amendment No. 2 to Share Purchase Agreement regarding the sale of the Construction (2) Companies 3.1 Certificate of Incorporation of Covol (1) 3.1.1 Certificate of Amendment of the Certificate of Incorporation of Covol dated January 22, (1) 1996 3.1.2 Certificate of Amendment of the Certificate of Incorporation dated June 25, 1997 (6) 3.1.3 Certificate of Designation, Number, Voting Powers, Preferences and Rights of Covol's (7) Series A 6% Convertible Preferred Stock (Originally designated as Exhibit No. 3.1.2) 3.1.4 Certificate of Designation, Number, Voting Powers, Preferences and Rights of Covol's (8) Series B Convertible Preferred Stock (Originally designated as Exhibit No. 3.1.3) 3.1.5 Certificate of Designation, Number, Voting Powers, Preferences and Rights of Covol's (14) Series C 7% Convertible Preferred Stock 3.1.6 Certificate of Designations, Number, Voting Powers, Preferences and Rights of the Series (15) of the Preferred Stock of Covol Technologies, Inc. to be Designated Series D 7% Cumulative Convertible Preferred Stock 3.2 By-Laws of Covol (1) 3.2.1 Certificate of Amendment to Bylaws of Covol dated January 31, 1996 (1) 3.2.2 Certificate of Amendment to the Bylaws dated May 20, 1997 (Originally designated as (6) Exhibit No. 3.2.1) 3.2.3 Certificate of Amendment to the Bylaws dated June 25, 1997 (Originally designated as (6) Exhibit No. 3.2.2) 4.1 Promissory Note between Covol and Mountaineer Synfuel, L.L.C. dated May 5, 1998 (filed (12) as Exhibit 10.52.2 hereto) 4.2 Promissory Note dated December 8, 1998 of Covol to Mountaineer Synfuel, L.L.C. (filed as (13) Exhibit 10.52.4 hereto) 4.3 Security Agreement dated December 8, 1998 between Mountaineer Synfuel, L.L.C. and (13) Covol (filed as Exhibit 10.52.5 hereto) 4.4 Convertible Secured Note executed by Covol in favor of OZ Master Fund, Ltd., dated as of (15) March 17, 1999 (filed as Exhibit 10.58.1 hereto) 30
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Exhibit No. Description Location 9.1 Special Powers of Attorney Coupled With an Interest dated February 1, 1996 between Covol, (1) Gerald Larson and Michael McEwan 10.4 Master Equipment Lease Agreement, dated May 4, 1995, between Keycorp Leasing Ltd. and (1) Covol 10.5 1995 Stock Option Plan (1) 10.5.1 First Amendment to the 1995 Stock Option Plan (1) 10.8 Lease Agreement, dated May 31, 1994, between Covol and Byrleen Hanson regarding (1) Carbon County, Utah 10.11.2 License Agreement dated September 10, 1996, between Covol and CoBon Energy, LLC (3) 10.13 Promissory Note dated February 15, 1996 in favor of Covol from Michael McEwan and (1) Gerald Larson 10.16.1 Stock Option Agreement dated June 1, 1996 with Brent M. Cook (3) 10.28 Debenture Agreement and Security Agreement, dated December 20, 1996, between AJG (3) Financial Services, Inc. and Covol 10.30 Lease Agreement, dated December 12, 1996, between Covol and UPC, Inc. regarding Price (3) City, Utah property 10.33 Utah Project Purchase Agreement, dated as of March 7, 1997, by and among Covol, US #1, a (4) Delaware limited partnership, and Coaltech No. 1, L.P., a Delaware limited partnership ("Coaltech") 10.34 License and Binder Purchase Agreement, dated as of March 7, 1997, by and among Covol, (4) US #1 and Coaltech 10.35 Operation and Maintenance Agreement, dated as of March 7, 1997, by and between Covol (4) and Coaltech 10.36 Purchase and Supply Agreement, dated as of March 7, 1997, by and among Covol, US #1 (4) and Coaltech 10.37 Abandonment Option Agreement, dated as of March 7, 1997, by and among Covol and the (4) limited partners of Coaltech 10.38 Convertible Loan and Security Agreement, dated as of March 20, 1997, by and between (5) Covol and PacifiCorp Financial Services, Inc. ("PacifiCorp") 10.38.1 Amendment to Convertible Loan and Security Agreement, dated December 12, 1997 by and (9) between Covol and PacifiCorp 10.39 Alabama Project Purchase Agreement ("Alabama Agreement") dated as of March 20, 1997, (5) by and among Covol, AS #1 and Birmingham Syn Fuel, L.L.C. 10.39.1 Letter Amendment, dated June 27, 1997, to Alabama Agreement. (9) 10.39.2 ** Letter Amendment, dated July 7, 1997, to Alabama Agreement. (9) 10.39.3 Letter Amendment, dated August 28, 1997, to Alabama Agreement. (9) 10.39.4 Letter Amendment, dated December 12, 1997, to Alabama Agreement. (9) 31
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Exhibit No. Description Location 10.39.5 ** Amended and Restated License Agreement, and Binder Purchase dated December 12, 1997, (9) by and among Covol, AS #1 and Birmingham Syn Fuel. 10.39.6** Letter Amendment dated February 20, 1998, to the Alabama (10) Project Purchase Agreement dated as of March 20, 1997, by and among Covol, AS #1, and Birmingham Syn Fuel. 10.39.7 Call Option Agreement date February 20, 1998, between Birmingham Syn Fuel and Covol. (10) 10.39.8** Letter Amendment dated February 20, 1998, to the Amended and Restated License and (10) Binder Purchase Agreement dated as of December 12, 1997, by and among Covol. AS #1 and Birmingham Syn Fuel. 10.39.9** Non-negotiable Promissory Note dated February 20, 1998, in favor of AS #1, executed by (10) Birmingham Syn Fuel as debtor. 10.39.10 Security Agreement dated February 20, 1998, by and among Covol, AS #1 and Birmingham (10) Syn Fuel. 10.40 Conditional Option Agreement, dated as of March 20, 1997, by and among Birmingham Syn (5) Fuel I, Inc., Birmingham Syn Fuel II, Inc., PacifiCorp, AS #1 and Covol 10.42** Amended and Restated Agreement Concerning Additional Facilities, dated December 12, (9) 1997, by and between PacifiCorp., Birmingham Syn Fuel, LLC and Covol 10.43 Lease Agreement between Industrial Management Engineering, Inc. and Covol (9) 10.45** License and Binder Purchase Agreement, dated December 14, 1997, between Appalachian (9) Synfuel, LLC and Covol 10.47** License Agreement, dated as of August 5, 1997, by and between Pelletco Corporation and (9) Covol 10.48** Preparation Plant and Find Ponds Lease (Wellington, Utah), dated February 21, 1997, (9) between Earthco and Covol 10.49** Agreement Concerning Additional Facilities, dated December 27, 1996, between AJG (9) Financial Services, Inc. and Covol 10.50.1** Form of Amended and Restated License and Binder Purchase Agreement dated (11) February 3, 1998, between PC Virginia Synthetic Fuel #1, PC West Virginia synthetic Fuel #1, PC West Virginia synthetic Fuel #2, PC West Virginia Synthetic Fuel #3 and Covol. 10.51 Employment Agreement, dated March 20, 1997 with Max E. Sorenson (9) 10.52.1 Asset Purchase Agreement between Mountaineer Synfuel, L.L.C. as Purchase and Covol as (12) Seller dated May 5, 1998 10.52.2 Promissory Note between Covol and Mountaineer Synfuel, L.L.C. dated May 5, 1998 (12) 10.52.3 Deed of Ground Lease between Upshur Property, Inc. and Covol dated May 5, 1998 (12) 10.52.4 Promissory Note dated December 8, 1998 of Covol Technologies, Inc. to Mountaineer (13) Synfuel, L.L.C. 10.52.5 Security Agreement dated December 8, 1998 between Mountaineer Synfuel, L.L.C. and (13) Covol Technologies, Inc. 10.52.6 Leasehold Credit Line Deed of Trust and Security Agreement dated December 8, 1998 by (13) Covol Technologies, Inc. for Mountaineer Synfuel, L.L.C. as Beneficiary. 32
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Exhibit No. Description Location 10.52.7 Amendment No. 1 to Deed of Ground Lease dated December 8, 1998 between Upshur (13) Property, Inc. and Covol Technologies, Inc. 10.53.1 Debenture Agreement and Security Agreement dated as of January 9, 1998, between Covol (13) and AJG Financial Services, Inc. 10.53.2 Debenture dated as of January 9, 1998 between Covol and AJG Financial Services, Inc. (13) 10.53.3 Warrant A dated as of January 9, 1998, issued by Covol in favor of AJG Financial (13) Services, Inc. 10.53.4 Warrant B dated as of January 9, 1998, issued by Covol in favor of AJG Financial (13) Services, Inc. 10.53.5 Registration Rights Agreement dated as of January 9, 1998, between Covol and AJG (13) Financial Services, Inc. 10.54 Employment Agreement effective May 1, 1998 with Steven G. Stewart (13) 10.55 Employment Agreement effective August 1, 1997 with Dee J. Priano (13) 10.56 Employment Agreement effective April 21, 1998 with Brent M. Cook (14) 10.57 Employment Agreement effective January 1, 1999 with Steven R. Brown (14) 10.58 Securities Purchase Agreement between Covol Technologies, Inc. and OZ Master Fund, Ltd. (15) dated as of March 17, 1999 10.58.1 Convertible Secured Note executed by Covol in favor of OZ Master Fund, Ltd. dated as of (15) March 17, 1999 10.58.2 Registration Rights Agreement between Covol Technologies, Inc. and OZ Master Fund, Ltd. (15) dated as of March 17, 1999 10.58.3 Security Agreement between Covol Technologies, Inc. and OZ Master Fund, Ltd. dated as of (15) March 17, 1999 10.58.4 Series A Warrant in favor of OZ Master Fund, Ltd. dated March 17, 1999 (15) 10.58.5 Series B Warrant in favor of OZ Master Fund, Ltd. dated March 17, 1999 (15) 10.58.6 Series C Warrant in favor of OZ Master Fund, Ltd. dated March 17, 1999 (15) 10.58.7 Series D Warrant in favor of OZ Master Fund, Ltd. dated March 17, 1999 (15) 10.58.8 Series E Warrant in favor of Leeds Group dated March 17, 1999 (15) 10.58.9 Series E Warrant in favor of Howard L. Schwartz dated March 17, 1999 (15) 10.58.10 Series E Warrant in favor of Jack A. Schwebel dated March 17, 1999 (15) 10.58.11 Series E Warrant in favor of Brent M. Lockwood dated March 17, 1999 (15) 10.59 Secured Draw Down Promissory Note dated June 12, 1998 executed by Covol in favor of (16) Trans Pacific Stores, Ltd. 10.59.1 Loan and Security Agreement dated June 12, 1998 executed by Covol in favor of Trans (16) Pacific Stores, Ltd. 10.59.2 Letter Amendment dated May 6, 1999 between Covol and Trans Pacific Stores, Ltd. (16) 33
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Exhibit No. Description Location 10.60 Employment Agreement effective April 20, 1999 with Kirk A. Benson (17) 10.61 Purchase Agreement dated as of August 27, 1999 relating to the sale of the River Hill (18) Project*** 10.61.1 License and Binder Purchase Agreement dated as of August 27, 1999 relating to the River (18) Hill Project*** 10.61.2 Modification Agreement dated as of August 27, 1999 by and between the Purchaser of the (18) River Hill Project, Fun Enterprises Pty Limited and Covol Technologies, Inc.*** 10.62 Securities Purchase Agreement dated September 17, 1999 between Aspen Capital Resources, (19) L.L.C. and Covol 10.62.1 Security Agreement dated September 17, 1999 between Aspen Capital Resources, L.L.C. and (19) Covol 10.63 Securities Purchase Agreement dated December 7, 1999 between DH Financial, L.C. and * Covol 10.63.1 Security Agreement dated December 6, 1999 between DH Financial, L.C. and Covol * 16.1 Letter to Securities and Exchange Commission, dated March 24, 1995, from Jones, Jensen & (1) Orton & Company, certified public accountants 21.1 List of Subsidiaries of Covol * 23.1 Consent of PricewaterhouseCoopers LLP * 27.1 Financial Data Schedule for the fiscal year ended September 30, 1999 * 27.2 Restated Financial Data Schedule for the fiscal years ended September 30, 1997 and 1998 *
----------------------- * Filed herewith. ** Confidential treatment has been granted to certain portions of this exhibit, which portions have been deleted and filed separately with the Securities and Exchange Commission. *** This exhibit contains confidential material which has been omitted pursuant to a Confidential Treatment Request. The omitted information has been filed separately with the Securities and Exchange Commission. Unless another exhibit number is indicated as the exhibit number for the exhibit as "originally filed," the exhibit number in the filing in which any exhibit was originally filed and to which reference is made hereby is the same as the exhibit number assigned herein to the exhibit. (1) Incorporated by reference to the indicated exhibit filed with Covol's Registration Statement on Form 10, filed February 26, 1996. (2) Incorporated by reference to the indicated exhibit filed with Covol's Registration Statement on Form 10/A, Amendment No. 2, dated April 24, 1996. (3) Incorporated by reference to the indicated exhibit filed with Covol's Annual Report on Form 10-K for the fiscal year ended September 30, 1996. (4) Incorporated by reference to the indicated exhibit filed with Covol's Current Report on Form 8-K, dated March 10, 1997. (5) Incorporated by reference to the indicated exhibit filed with Covol's Quarterly Report on Form 10-Q, for the quarterly period ended March 31, 1997. 34
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(6) Incorporated by reference to the indicated exhibit filed with Covol's Quarterly Report on Form 10-Q, for the quarterly period ended June 30, 1997. (7) Incorporated by reference to the indicated exhibit filed with Covol's Current Report on Form 8-K, dated August 19, 1997. (8) Incorporated by reference to the indicated exhibit filed with Covol's Current Report on Form 8-K, for event dated September 18, 1997, filed October 28, 1997. (9) Incorporated by reference to the indicated exhibit filed with Covol's Annual Report on Form 10-K for the fiscal year ended September 30, 1997. (10) Incorporated by reference to the indicated exhibit filed with Covol's Current Report on Form 8-K, for event dated March 3, 1998, filed March 23, 1998. (11) Incorporated by reference to the indicated exhibit filed with Covol's Quarterly Report on Form 10-Q, for the quarterly period ended March 31, 1998. (12) Incorporated by reference to the indicated exhibit filed with Covol's Quarterly Report on Form 10-Q for the quarter ended June 30, 1998. (13) Incorporated by reference to the indicated exhibit filed with Covol's Annual Report on Form 10-K, for the fiscal year ended September 30, 1998. (14) Incorporated by reference to the indicated exhibit filed with Covol's Quarterly Report on Form 10-Q, for the quarterly period ended December 31, 1998. (15) Incorporated by reference to the indicated exhibit filed with Covol's Current Report on Form 8-K, for the event dated March 17, 1999, filed March 24, 1999. (16) Incorporated by reference to the indicated exhibit filed with Covol's Quarterly Report on Form 10-Q, for the quarterly period ended March 31, 1999. (17) Incorporated by reference to the indicated exhibit filed with Covol's Quarterly Report on Form 10-Q for the quarter ended June 30, 1999. (18) Incorporated by reference to the indicated exhibit filed with Covol's Current Report on Form 8-K/A, for event dated August 27, 1999, filed September 28, 1999. (19) Incorporated by reference to the indicated exhibit filed with Covol's Registration Statement on Form S-3/A (SEC file no. 333-67371), filed October 13, 1999. Reports on Form 8-K The following reports on Form 8-K were filed during the quarter ended September 30, 1999: o July 7, 1999 Announcement of Proposed Transactions o September 13, 1999, as amended on September 28, 1999, Announcement of Sale of River Hill Facility Exhibits The response to this portion of Item 14 is submitted as a separate section of this report. See Item 14 (a) (3) above. Financial Statement Schedules The response to this portion of Item 14 is submitted as a separate section of this report. See Item 14 (a) (2) above. 35
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SIGNATURES Pursuant to the requirements of Section 13 or 15(d) of the Securities Exchange Act of 1934, the registrant has duly caused this report to be signed on its behalf by the undersigned, thereunto duly authorized. COVOL TECHNOLOGIES, INC. By:/s/ Kirk A. Benson -------------------------------- Kirk A. Benson Chief Executive Officer and Principal Executive Officer By:/s/ Steven G. Stewart -------------------------------- Steven G. Stewart, Principal Financial Officer Date: January 13, 2000 Pursuant to the requirements of the Securities Exchange Act of 1934, this report has been signed below by the following persons on behalf of the registrant and in the capacities and on the dates indicated. SIGNATURE TITLE DATE /s/ Kirk A. Benson Chief Executive Officer January 13, 2000 ----------------- (Principal Executive Officer) and Kirk A. Benson Director /s/ Steven G. Stewart Chief Financial Officer January 13, 2000 ----------------- (Principal Financial and Steven G. Stewart Accounting Officer) /s/ Brent M. Cook President and Director January 13, 2000 ----------------- Brent M. Cook /s/ DeLance W. Squire Director January 13, 2000 --------------------- DeLance W. Squire /s/ James A. Herickhoff Director January 13, 2000 ----------------------- James A. Herickhoff /s/ Raymond J. Weller Director January 13, 2000 --------------------- Raymond J. Weller /s/ John P. Hill, Jr. Director January 13, 2000 --------------------- John P. Hill, Jr. 36
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Report of Independent Accountants To the Board of Directors Covol Technologies, Inc. and Subsidiaries In our opinion, the accompanying consolidated balance sheets and the related consolidated statements of operations, stockholders' equity (deficit), and cash flows present fairly in all material respects, the consolidated financial position of Covol Technologies, Inc. and Subsidiaries ("Covol") as of September 30, 1998 and 1999, and the consolidated results of their operations and their cash flows for the years ended September 30, 1997, 1998 and 1999, in conformity with generally accepted accounting principles. These financial statements are the responsibility of Covol's management; our responsibility is to express an opinion on these financial statements based on our audits. We conducted our audits of these statements in accordance with generally accepted auditing standards, which require that we plan and perform the audit to obtain reasonable assurance about whether the financial statements are free of material misstatement. An audit includes examining, on a test basis, evidence supporting the amounts and disclosures in the financial statements, assessing the accounting principles used and significant estimates made by management, and evaluating the overall financial statement presentation. We believe that our audits provide a reasonable basis for the opinion expressed above. /s/ PricewaterhouseCoopers LLP Salt Lake City, Utah January 13, 2000 F-1
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[Enlarge/Download Table] COVOL TECHNOLOGIES, INC. AND SUBSIDIARIES CONSOLIDATED BALANCE SHEETS As of September 30, (thousands of dollars) 1998 1999 ----------------------------------------------------------------------------------- -------------- ---------------- ASSETS Current assets: Cash and cash equivalents $ 727 $ 461 Receivables 3,200 3,155 Due from related party 1,012 2,722 Inventories 1,645 573 Advances on inventories 2,522 -- Facilities held for sale 27,582 20,139 Prepaid expenses and other current assets 361 19 -------------- ---------------- Total current assets 37,049 27,069 -------------- ---------------- Property, plant and equipment, net of accumulated depreciation 15,809 14,182 -------------- ---------------- Other assets: Restricted cash and investments 748 843 Facility-dependent notes and accrued interest receivable 7,646 7,879 Facility transferred under note receivable arrangement 3,166 2,641 Intangible assets, net of accumulated amortization 3,118 3,647 Deposits and other assets 525 1,834 -------------- ---------------- Total other assets 15,203 16,844 -------------- ---------------- Total assets $68,061 $58,095 ============== ================ (continued) The accompanying notes are an integral part of the consolidated financial statements F-2
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[Enlarge/Download Table] COVOL TECHNOLOGIES, INC. AND SUBSIDIARIES CONSOLIDATED BALANCE SHEETS, continued As of September 30, (thousands of dollars and shares) 1998 1999 ------------------------------------------------------------------------------------ -------------- ---------------- LIABILITIES AND STOCKHOLDERS' EQUITY (DEFICIT) Current liabilities: Accounts payable $ 3,036 $ 1,179 Due to related party 1,609 2,706 Accrued interest payable, current 653 1,452 Accrued liabilities 2,205 2,905 Notes payable, current 22,049 20,626 -------------- ---------------- Total current liabilities 29,552 28,868 -------------- ---------------- Long-term liabilities: Notes payable, non-current 13,930 17,887 Accrued interest payable, non-current 566 210 Notes and accrued interest payable - related parties 147 -- Deferred revenues from advance license fees 8,377 7,501 Deferred compensation 236 208 -------------- ---------------- Total long-term liabilities 23,256 25,806 -------------- ---------------- Total liabilities 52,808 54,674 -------------- ---------------- Minority interest in consolidated subsidiaries 507 117 Commitments and contingencies Redeemable convertible preferred stock, $0.001 par value, issued and outstanding 0 shares at September 30, 1998 and 60 shares at September 30, 1999 (aggregate liquidation preference of $7,607 at September 30, 1999) -- 4,332 Stockholders' equity (deficit): Convertible preferred stock, $0.001 par value; authorized 10,000 shares, issued and outstanding 316 shares at September 30, 1998 and 17 shares at September 30, 1999 (aggregate liquidation preference of $3,705 at September 30, 1999) 1 1 Common stock, $0.001 par value; authorized 25,000 shares, issued and outstanding 11,272 shares at September 30, 1998 and 12,766 shares at September 30, 1999 11 13 Capital in excess of par value 69,284 78,457 Accumulated deficit (43,002) (71,713) Notes and interest receivable -- related parties, from issuance of, or collateralized by, common stock, net of allowance (7,773) (6,564) Deferred compensation from stock options (3,775) (1,222) -------------- ---------------- Total stockholders' equity (deficit) 14,746 (1,028) -------------- ---------------- Total liabilities and stockholders' equity (deficit) $68,061 $58,095 ============== ================ The accompanying notes are an integral part of the consolidated financial statements F-3
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[Enlarge/Download Table] COVOL TECHNOLOGIES, INC. AND SUBSIDIARIES CONSOLIDATED STATEMENTS OF OPERATIONS Year ended September 30, (thousands of dollars, except per-share data) 1997 1998 1999 --------------------------------------------------------------------- ----------------- ------------------ ------------------ Revenues: License fees $ 105 $ 860 $ 3,526 Synthetic fuel sales 42 32 767 Binder sales --- 994 2,140 Binder plant sales --- 1,088 --- Other --- 100 286 ----------------- ------------------ ------------------ Total revenues 147 3,074 6,719 ----------------- ------------------ ------------------ Operating costs and expenses: Cost of coal briquetting operations 5,260 5,565 12,956 Cost of binder --- 642 1,695 Cost of binder plants --- 888 --- Asset write-offs and other non-recurring charges --- --- 5,362 Selling, general and administrative 2,998 4,436 4,727 Compensation expense from stock options, stock warrants and issuance of common stock 2,058 939 2,553 Loss on sale of facility --- 218 1,839 ----------------- ------------------ ------------------ Total operating costs and expenses 10,316 12,688 29,132 ----------------- ------------------ ------------------ Operating loss (10,169) (9,614) (22,413) ----------------- ------------------ ------------------ Other income (expense): Interest income 98 580 1,586 Interest expense (1,645) (2,745) (6,253) Minority interest in net (income) losses of consolidated subsidiaries 1,245 392 (9) Write-up (write-down) of notes receivable - related parties, collateralized by common stock (60) 19 (1,209) Other, net 33 60 (95) ----------------- ------------------ ------------------ Total other income (expense) (329) (1,694) (5,980) ----------------- ------------------ ------------------ Net loss $(10,498) $(11,308) $(28,393) ================= ================== ================== Basic and diluted loss per common share $(1.32) $(1.17) $(2.39) ================= ================== ================== The accompanying notes are an integral part of the consolidated financial statements F-4
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[Enlarge/Download Table] COVOL TECHNOLOGIES, INC. AND SUBSIDIARIES CONSOLIDATED STATEMENT OF CHANGES IN STOCKHOLDERS' EQUITY (DEFICIT) Notes and interest receivable -related parties, from issuance of, Deferred Convertible Preferred or compen- (thousand Stock Common Stock Capital in collateralized sation of dollars ------------------------------------------------------ excess of par Accumulated by, common from stock and shares) Shares Amount Shares Amount valule deficit stock options ----------------------------------------------------------------------------------------------------------------------------------- Balances at September 30, 1996 -- $-- 7,714 $8 $33,715 $(21,196) $(7,580) $(5,180) Common stock issued for cash, including exercise of stock options and warrants 603 1 2,773 Deferred compensation related to the issuance of stock options at below market value to officers, directors and employees 1,178 (1,178) Common stock issued for services 98 -- 789 Inducement related to conversion of notes payable into common stock 323 Common stock issued to repay note payable - related parties 21 -- 136 Common stock issued on conversion of note payable 141 -- 1,125 Common stock issued under a subscription agreement for cash received in October 1997 50 -- 350 Common stock issued for cash, including exercise of stock options 400 -- 2,798 Common stock issued for distribution rights 30 -- 266 Common stock issued under subscription agreements for cash received in October 1997 32 -- 227 Amortization of deferred compensation from stock options 1,675 Interest expense related to issuance of convertible debt at a discount 1,429 Payment on notes receivable - related parties 109 Write-down of notes receivable - related parties 60 The accompanying notes are an integral part of the consolidated financial statements F-5
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[Enlarge/Download Table] COVOL TECHNOLOGIES, INC. AND SUBSIDIARIES CONSOLIDATED STATEMENT OF CHANGES IN STOCKHOLDERS' EQUITY (DEFICIT), continued Notes and interest receivable -related parties, from issuance of, Deferred Convertible Preferred or compen- (thousand Stock Common Stock Capital in collateralized sation of dollars ------------------------------------------------------ excess of par Accumulated by, common from stock and shares) Shares Amount Shares Amount valule deficit stock options ----------------------------------------------------------------------------------------------------------------------------------- Preferred stock issued for cash, net of offering costs 303 1 5,094 Net loss for the year ended September 30, 1997 (10,498) ----------------------------------------------------------------------------------------------------------- Balances at September 30, 1997 303 1 9,089 9 50,203 (31,694) (7,411) (4,683) ----------------------------------------------------------------------------------------------------------- Common stock issued to purchase minority interests in subsidiaries 540 1 5,383 Common stock issued for cash, including exercise of stock options 533 -- 3,257 Preferred stock issued for cash, net of offering costs 13 -- 90 Common stock issued on conversion of notes payable and accrued interest to common stock 1,107 1 8,178 Interest expense related to issuance of convertible debt at a discount 2,046 Payment received on notes receivable -- related parties 329 Amortization of deferred compensation from stock options 908 Write-up of notes receivable - related parties (19) Compensation expense related to issuance of stock options for services 3 -- 127 Reclassification of notes receivable - related parties (672) Net loss for the year ended September 30, 1998 (11,308) ----------------------------------------------------------------------------------------------------------- Balances at September 30, 1998 316 1 11,272 11 69,284 (43,002) (7,773) (3,775) ----------------------------------------------------------------------------------------------------------- Common stock issued to purchase minority interests in subsidiaries 70 -- 519 Common stock and warrants to purchase common stock issued for cash, including exercise of stock options 776 1 3,774 The accompanying notes are an integral part of the consolidated financial statements F-6
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[Enlarge/Download Table] COVOL TECHNOLOGIES, INC. AND SUBSIDIARIES CONSOLIDATED STATEMENT OF CHANGES IN STOCKHOLDERS' EQUITY (DEFICIT), continued Notes and interest receivable -related parties, from issuance of, Deferred Convertible Preferred or compen- (thousand Stock Common Stock Capital in collateralized sation of dollars ------------------------------------------------------ excess of par Accumulated by, common from stock and shares) Shares Amount Shares Amount valule deficit stock options ----------------------------------------------------------------------------------------------------------------------------------- Value of common stock warrants issued under terms of existing debt agreement and in connection with extension of note payable due date -- -- 453 Common stock issued for rights to technology 60 -- 375 Common stock issued on conversion of preferred stock and in payment of dividends (300) -- 602 1 194 (195) Return of previously issued common stock by a director (14) -- -- Value of common stock options and warrants issued in connection with debt financing -- -- 323 Preferred stock and warrants to purchase common stock issued for cash, net of offering costs 1 -- 899 Value of common stock warrants issued in connection with redeemable convertible preferred stock and convertible debt 2,435 Value of extended and repriced warrants issued in connection with satisfaction of notes payable -- -- 201 Preferred stock cash dividends (123) Write-down of notes receivable - related parties 1,209 Amortization of deferred compensation from stock options 2,553 Net loss for the year ended September 30, 1999 (28,393) ----------------------------------------------------------------------------------------------------------- Balances at September 30, 1999 17 $1 12,766 $13 $78,457 $(71,713) $(6,564) $(1,222) =========================================================================================================== The accompanying notes are an integral part of the consolidated financial statements F-7
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[Enlarge/Download Table] COVOL TECHNOLOGIES, INC. AND SUBSIDIARIES CONSOLIDATED STATEMENTS OF CASH FLOWS Year ended September 30, (thousands of dollars) 1997 1998 1999 -------------------------------------------------------------------------------------------------------------------------------- Cash flows from operating activities: Net loss $(10,498) $(11,308) $(28,393) Adjustments to reconcile net loss to net cash used in operating activities: Depreciation and amortization 193 523 2,570 Recognition of deferred revenue from advance license fees (105) (654) (876) Asset write-offs and other non-recurring charges --- --- 5,362 Amortization of deferred compensation from stock options 1,675 1,035 2,553 Loss on sale of facility and loss on disposition of equipment --- 218 1,979 Minority interest in net income (losses) of consolidated subsidiaries (1,245) (392) 9 Write-down (write-up) of notes receivable - related parties 60 (19) 1,209 Interest expense related to amortization of debt discount and debt issuance costs --- --- 2,075 Interest expense related to issuance of convertible debt at a discount 1,429 2,046 --- Common stock issued for services 1,055 --- --- Inducement expense related to conversion of notes payable into common stock 323 --- --- Increase (decrease) from changes in operating assets and liabilities, net of effects from investing and financing activities: Receivables (444) (3,690) (1,944) Inventories and other current assets (1,155) (1,570) 107 Accrued interest receivable - non-current --- (486) (893) Accounts payable and other current liabilities 2,576 935 (637) Accrued interest payable, non-current 204 362 (356) Deferred revenues from advance license fees 1,650 7,486 --- Other, net (142) 148 (281) -------------------------------------- Net cash used in operating activities (4,424) (5,366) (17,516) -------------------------------------- Cash flows from investing activities: Purchase of property, plant and equipment and facilities held for sale (7,194) (36,963) (861) Proceeds from sale of facilities held for sale and equipment --- --- 1,433 Purchase of rights to technology --- --- (127) Proceeds from facility transferred under note receivable arrangement 235 647 525 Increase in deposits collateralizing letters of credit and restricted cash --- (748) (95) Investment in licensee facility --- (340) --- Issuance of note receivable --- (660) --- -------------------------------------- Net cash provided by (used in) investing activities (6,959) (38,064) 875 -------------------------------------- Cash flows from financing activities: Proceeds from issuance of notes payable and warrants 6,070 35,454 11,193 Payment on notes payable (1,109) (330) (4,690) Proceeds from issuance of notes payable -- related parties 595 --- --- Payment on notes payable -- related parties (756) --- (147) Proceeds from issuance of preferred stock and warrants, net 5,095 90 6,367 Proceeds from issuance of common stock and warrants, net 5,573 3,257 3,775 Preferred stock dividends --- --- (123) Proceeds from receivable -- stock subscriptions --- 577 --- Proceeds from notes receivable -- related parties, collateralized by common 109 329 --- stock Proceeds from issuance of minority interests in subsidiaries 302 --- --- Cash distribution to minority interest limited partners (206) --- --- -------------------------------------- Net cash provided by financing activities 15,673 39,377 16,375 -------------------------------------- Net increase (decrease) in cash and cash equivalents 4,290 (4,053) (266) Cash and cash equivalents, beginning of year 490 4,780 727 -------------------------------------- Cash and cash equivalents, end of year $4,780 $ 727 $ 461 ====================================== (continued) The accompanying notes are an integral part of the consolidated financial statements F-8
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[Enlarge/Download Table] COVOL TECHNOLOGIES, INC. AND SUBSIDIARIES CONSOLIDATED STATEMENTS OF CASH FLOWS, continued Year ended September 30, (thousands of dollars) 1997 1998 1999 ------------------------------------------------------------------------------------------------------------------------------- Supplemental schedule of non-cash investing and financing activities: Common stock issued to purchase minority interests in subsidiaries $ --- $5,384 $ 519 Common stock issued on conversion of preferred stock and in payment of --- --- 2,761 dividends Common stock issued on conversion of notes payable and related accrued interest 8,179 --- Common stock issued for rights to technology --- --- 375 Notes payable issued for rights to technology --- --- 426 Notes payable issued for equipment 1,607 --- 424 Property, plant and equipment acquired through reduction of current assets --- --- 413 Reduction of note payable upon sale of facility held for sale --- --- 5,800 Facility dependent note receivable issued for sale of facility --- 6,500 --- Facility transferred under note receivable arrangement 4,082 --- --- Note payable issued for inventory 1,595 --- --- Accounts payable for facilities held for sale 1,968 588 --- Common stock issued for notes receivable 577 --- --- Common stock issued to repay notes payable and accrued interest -- related party 1,261 --- --- Distribution to minority limited partners offset against note receivable 66 --- --- Supplemental disclosure of cash flow information - cash paid for interest, net of amounts capitalized $208 $49 $3,646 The accompanying notes are an integral part of the consolidated financial statements F-9
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COVOL TECHNOLOGIES, INC. AND SUBSIDIARIES NOTES TO CONSOLIDATED FINANCIAL STATEMENTS ----------- 1. Summary of Significant Accounting Policies Business Organization and Nature of Operations Covol Technologies, Inc. was originally incorporated in Nevada in 1987 and was reincorporated in Delaware in August 1995. In June 1996, Utah Synfuel #1 Ltd. ("Utah Synfuel #1") and Alabama Synfuel #1 Ltd. ("Alabama Synfuel #1"), each a Delaware limited partnership (collectively the "Partnerships"), were formed. Covol Technologies, Inc. is both the general partner and a limited partner in the Partnerships (see Note 13). Covol Technologies, Inc. and Subsidiaries' ("Covol") primary business is to commercialize its binder technologies which are used to recycle waste by-products from the coal, steel and other industries into marketable fuel and resources. Through June 1998, Covol's focus was on the construction of facilities and the licensing of its binder technologies to entities that constructed facilities that convert coal fines into synthetic fuel briquettes. At September 30, 1999, Covol and its licensees were operating 28 facilities in ten states at various levels of production, including four facilities which are using a technology that Covol acquired during 1999. During 1999, Covol has been actively pursuing the sale of its four owned facilities. One of the facilities was sold in August 1999 and another was sold in December 1999 (see Notes 15 and 17). Covol expects to sell the remaining two facilities in early 2000 (see Note 17). Covol has no current plans to construct additional synthetic fuel facilities. There are 24 synthetic fuel plants that currently utilize Covol's patented technology and from which Covol intends to earn license fees and / or profits from the sale of binder. These facilities do not presently operate at levels needed to generate significant revenues to Covol. Improved operations at the plants depend on the ability of the plant owners to produce synthetic fuel that meets market specifications in order for the plant owners to market the synthetic fuel. Covol is assisting the plant owners in their efforts to overcome production and marketing problems. Covol anticipates that recurring license fees or royalties from the production and sale of synthetic fuel will continue to increase during 2000 and beyond. As production levels increase, sales of the binder materials by Covol to its licensees are expected to increase proportionately. Funds received by Covol from these activities are expected to be sufficient to cover Covol's operating costs and expenses at some point during 2000. In order for operating activities to produce significant positive cash flow, Covol and its licensees must successfully address certain operating issues and marketing difficulties. These difficulties have delayed Covol's expected growth in license fees, and have resulted in lower than expected cash flows and higher than expected capital requirements. Operating issues which must be addressed include, but are not limited to, feedstock availability, moisture content, Btu content, correct application of binder formulation, operability of equipment, product durability, resistance to water absorption and overall costs of operations, which in many cases to date have resulted in unit costs in excess of synthetic fuel sale prices. Marketing difficulties which must be addressed relate to market acceptance of products manufactured using Covol's technology. Industrial coal users must be satisfied that the synthetic fuel is a suitable substitute for standard coal products. Moisture content, hardness, special handling requirements and other characteristics of the synthetic fuel product may affect its marketability and its sales price. Many industrial coal users are also limited in the amount of synthetic fuel product they can purchase from Covol and its licensees because they have committed to purchase a substantial portion of their coal requirements through long-term coal contracts already in place. Reliance on spot markets and the overall downward trend in coal prices have generally produced lower sales prices as compared to long-term coal supply contracts common in the utility industry. Market acceptance of the synthetic fuel product appears to have improved during 1999 even though Covol's owned facilities and its licensees have only been able to secure long-term contracts for the sale of a small portion of their production. The suitability of synthetic fuel as a coal substitute, particularly the quality characteristics of synthetic fuel, and the traditional long-term supply contract practices of fuel buying in the utility industry, have made the identification of purchasers of synthetic fuel difficult. Covol believes that initial market resistance for synthetic fuel has decreased and believes long-term contracts can now be secured allowing Covol and its licensees to market the synthetic fuel they produce at prices similar to coal. Principles of Consolidation The consolidated financial statements for all years presented include the accounts of Covol and its two subsidiaries, Utah Synfuel #1 and Alabama Synfuel #1. All significant intercompany transactions and accounts are eliminated in consolidation. During 1997, Covol became a 1% general partner of Coaltech No. 1 L.P. ("Coaltech"), a Delaware limited partnership, for $10. Based upon Covol's lack of effective control over Coaltech and the limited partners' financial responsibility for its operations, Covol's investment in Coaltech is accounted for using the equity method of accounting with proportional elimination of intercompany revenues and expenses. See Notes 16 and 17. F-10
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COVOL TECHNOLOGIES, INC. AND SUBSIDIARIES NOTES TO CONSOLIDATED FINANCIAL STATEMENTS, continued ----------- Revenue and Cost Recognition Revenues from the licensing of Covol's technology are recognized in the period when earned. Non-refundable advance license fees are received when certain synthetic fuel facility construction milestones are met or when the facilities are certified operational for their intended use. These non-refundable advance license fees are deferred and recognized on a straight-line basis over the period covered by the related license agreement. Recurring license fees or royalty payments are recognized in the period synthetic fuel is produced and sold by licensees. Revenues from the sale of coal briquettes are recognized as product is shipped. Collateral is not required for receivables and allowances are provided for uncollectible accounts when appropriate. Segment Reporting In 1999, Covol adopted Statement of Financial Accounting Standards No. 131, "Disclosures about Segments of an Enterprise and Related Information" ("SFAS 131"). SFAS 131 superseded SFAS No. 14, replacing the "industry segment" approach with the "management" approach. The management approach designates the internal organization that is used by management for making operating decisions and assessing performance as the source of reportable segments. The adoption of SFAS No. 131 did not affect Covol's results of operations or financial position. Based on Covol's method of internal reporting, Covol operates and reports as a single industry segment, which is the commercialization of its binder technologies. Approximately $653,000 of revenues in 1998 and $2,673,000 of revenues in 1999 were from a single licensee, $839,000 of revenues in 1998 and $1,032,000 of revenues in 1999 were from a second licensee and $463,000 of revenues in 1998 and $849,000 of revenues in 1999 were from a third licensee. No other single customer accounted for over 10% of total revenues in any year presented. Cash and Cash Equivalents Covol considers all highly liquid debt instruments with an original maturity of three months or less to be cash equivalents. Cash and cash equivalents are deposited with financial institutions located in Utah and at times may exceed insured depository limits. Due From/To Related Party Due from related party consists of amounts receivable from Coaltech primarily for operating expenses. Due to related party represents amounts due to Coaltech for the purchase of synthetic fuel briquettes (see Notes 16 and 17). Inventories Inventories are stated at the lower of cost or market with cost determined using an average cost method, and consist primarily of coal fines and synthetic fuel available for sale. Covol has a lease arrangement that provides for the purchase and removal of coal fines which are used as feedstock for a synthetic fuel facility. Payments made under the lease arrangement prior to removal of the coal fines are recorded as advances on inventories (see Note 14). Facilities Held for Sale At September 30, 1999, facilities held for sale consisted of three synthetic fuel facilities and were stated at the lower of cost or estimated net realizable value. One of the facilities was sold in December 1999 (see Note 17). The facilities were constructed to be sold at or above their cost to licensees of Covol's technology. Covol is actively pursuing the sale of the remaining two facilities and anticipates completing the sales in early 2000 (see Note 17). Covol recognizes a gain or loss on facilities held for sale when the sale is consummated. The gain or loss represents the difference between the carrying value and the sales price and is reflected as a component of operating costs and expenses. Property, Plant and Equipment Property, plant and equipment is recorded at cost, including interest on funds borrowed during the construction period, and is depreciated using the straight-line method over its estimated useful life. Maintenance, repairs and minor replacements are charged to expense as incurred. Upon the sale or retirement of property, plant and equipment, any gain or loss on disposition is reflected in the statement of operations, and the related asset cost and accumulated depreciation are removed from the respective accounts. F-11
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COVOL TECHNOLOGIES, INC. AND SUBSIDIARIES NOTES TO CONSOLIDATED FINANCIAL STATEMENTS, continued ----------- Restricted Cash and Investments Restricted investments consist primarily of highly liquid interest bearing deposits held as collateral for certain Covol obligations and cash restricted by agreement for payments to one of Covol's major vendors. Intangible Assets Intangible assets consist of (i) the excess of the value of the consideration paid for the purchase of certain limited partners' interests in subsidiaries over the fair values of the related assets, which fair values approximated their carrying cost (see Note 13); and (ii) rights to technology, consisting of a coal-based synthetic fuel technology and related licensing and patent rights. These intangible assets are being amortized on the straight-line method over approximately ten- and nine-year periods, respectively. Valuation of Long-Lived Assets Covol periodically evaluates the carrying value of long-lived assets, including intangible assets, when events and circumstances warrant such a review. The carrying value of a long-lived asset is considered impaired when the anticipated cumulative undiscounted cash flow from that asset is less than its carrying value. In that event, a loss is recognized based on the amount by which the carrying value exceeds the fair market value of the long-lived asset. Two impairment-related losses have been recognized in Covol's consolidated financial statements for 1999, as more fully described in Note 14. Common Stock, Options and Warrants Common stock issued for services is accounted for using the fair value of the shares of common stock, determined at the time the shares are issued. The measurement date used to value non-employee option grants is the option grant date. Such options, as well as warrants issued in connection with debt and equity financings, including repricings and extensions of option and warrant expiration dates, are valued using the Black-Scholes model. If modifications to existing options or warrants relating to debt securities occur, the incremental value of the modified options or warrants is capitalized and amortized to interest expense over the remaining life of the related debt. Loss per Share Calculation In 1998, Covol adopted Statement of Financial Accounting Standards No. 128, "Earnings per Share" ("SFAS 128"). SFAS 128 replaced the calculation of primary and fully diluted earnings per share with basic and diluted earnings per share. Unlike primary earnings per share, basic earnings per share excludes any dilutive effects of options, warrants and convertible securities. Diluted earnings per share is similar to the previous fully diluted earnings per share. Loss per share amounts for all periods presented conform to SFAS 128 requirements and no restatements were necessary (see Note 11). For all periods presented, options, warrants and convertible securities (as disclosed in Notes 5, 6, 7 and 10) were not included in the calculation of loss per share because the effect would have been antidilutive. Use of Estimates The preparation of financial statements in conformity with generally accepted accounting principles requires management to make estimates and assumptions that affect the reported amounts of assets and liabilities, and the disclosure of contingent assets and liabilities at the date of the financial statements, and the reported amounts of revenues and expenses during the reporting period. Actual results could differ from those estimates. Reclassifications Certain prior year amounts have been reclassified to conform with the current year's presentation. The reclassifications had no effect on net loss, total assets or total liabilities. F-12
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COVOL TECHNOLOGIES, INC. AND SUBSIDIARIES NOTES TO CONSOLIDATED FINANCIAL STATEMENTS, continued ----------- 2. Current Financial Condition Covol incurred a net loss for the year ended September 30, 1999 of $28,393,000 and used $17,516,000 of cash in its operating activities for the year. As discussed in Note 6, Covol has $20,626,000 of long-term debt due during the year ending September 30, 2000. In addition, Covol's convertible note payable with a face amount of $20,000,000 and related redeemable convertible preferred stock with an aggregate liquidation preference of approximately $5,600,000 at December 31, 1999 contain certain provisions including an increase in the interest rate, immediate convertibility, required escrow payments and possible immediate payment of outstanding amounts in the event of a default by Covol. Such an event could include a failure of Covol's shareholders to approve the issuance of the convertible debt and convertible preferred stock by March 31, 2000 or failure of Covol to achieve the targeted earnings levels. Covol believes that shareholder approval will be obtianed and that Covol will achieve the targeted earnings levels during fiscal 2000. Covol has funded its operations during the year ended September 30, 1999 primarily through the issuance of debt and equity securities and the sale of a synthetic fuel facility. During November 1998, Covol issued common stock and common stock warrants for total net proceeds of approximately $3,729,000. During January 1999, Covol issued convertible preferred stock and warrants for total net proceeds of approximately $899,000. During March 1999, Covol issued convertible secured debt, convertible redeemable preferred stock and common stock warrants for total net proceeds of approximately $14,581,000. From September through December 1999, Covol issued convertible secured debt and warrants for total net proceeds of approximately $3,500,000 and is currently in discussions with creditors to whom debt is owed in January 2000. As discussed in Note 17, in August 1999 and December 1999, Covol sold two synthetic fuel facilities for cash proceeds in excess of amounts required to fully retire the related debt collateralized by the facilities. Also, on January 13, 2000, Covol executed definitive agreements for the sale of one synthetic fuel facility and executed a letter of intent for the sale of the only remaining facility held for sale (see Note 17). Covol believes that there are several alternatives available that will provide the working capital necessary to meet operational requirements and debt payments as they become due, including proceeds from the sale of its remaining facilities held for sale, funds from operations, and only if no other alternatives exist, additional financing. Covol believes it will be able to extend the repayment terms of its debt and that excess proceeds from the sale of facilities will be sufficient to fund Covol's operations until its operating activities begin producing positive cash flow. 3. Property, Plant and Equipment Property, plant and equipment consists of the following at September 30: [Enlarge/Download Table] (thousands of dollars) Range of estimated useful 1998 1999 lives --------------------------------------- ------------------------------- -------------- -------------- Land $ 153 $ 204 Buildings and improvements 10 - 15 years 12,060 12,235 Machinery and equipment 5 - 10 years 4,666 4,757 -------------- -------------- 16,879 17,196 Less accumulated depreciation (1,070) (3,014) ============== ============== Net property, plant and equipment $15,809 $14,182 ============== ============== Depreciation expense was $193,000 in 1997, $474,000 in 1998, and $1,988,000 in 1999. F-13
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COVOL TECHNOLOGIES, INC. AND SUBSIDIARIES NOTES TO CONSOLIDATED FINANCIAL STATEMENTS, continued ----------- 4. Notes Receivable Notes receivable, all of which were recorded initially at their fair value, consist of the following at September 30: [Enlarge/Download Table] (thousands of dollars) 1998 1999 ---------------------------------------------------------------------------------------------- -------------- -------------- Facility-dependent Notes and Accrued Interest Receivable, Non-current Note receivable from a corporation, bearing interest at 12%, principal and interest due not later than February 2003, collateralized by a synthetic fuel facility in Alabama sold by Covol in 1998. This note receivable is recorded at an amount which does not exceed its fair value. $6,500 $6,500 Accrued interest receivable from the above corporation 486 1,379 Unsecured note receivable from a corporation, bearing interest at 10%, receivable in quarterly principal installments. This note was written off in September 1999 (see Note 14). 660 --- -------------- -------------- $7,646 $7,879 ============== ============== Facility Transferred under Note Receivable Arrangement Facility transferred under note receivable arrangement with Coaltech, bearing interest at 9.7%, principal and interest payments of $130 due quarterly through December 2007, collateralized by a synthetic fuel facility in Utah. All note payments, including principal and interest reduce the carrying amount of this asset (see Note 17). $3,166 $2,641 ============== ============== 5. Financing Transactions During and subsequent to the year ended September 30, 1999, Covol completed several financing transactions, including the following: o Issuance of approximately 746,000 shares of common stock and warrants to purchase approximately 746,000 shares of common stock pursuant to a private offering in November 1998, for net proceeds of approximately $3,729,000. The warrants have an exercise price of $7.50 per share and expire in June 2000. o Issuance of 1,000 shares of series C preferred stock and warrants to purchase approximately 73,000 shares of common stock in January 1999, for net proceeds of approximately $899,000 (see Note 7). The warrants have an exercise price of $6.88 per share, expire July 2001and were assigned a value of approximately $500,000. o Issuance of 60,000 shares of series D redeemable convertible preferred stock, convertible secured debt and warrants to purchase approximately 1,284,000 shares of common stock in March 1999, for total net proceeds of approximately $14,581,000 (see Notes 6 and 7). The warrants have exercise prices ranging from $5.00 to $10.00 per share and expiration dates ranging from March 2002 to March 2004. The warrants, some of which were issued in connection with the convertible preferred stock, some in connection with the convertible debt, and some in connection with both the preferred stock and debt, were valued at approximately $3,000,000. The value of the warrants issued in connection with both the preferred stock and debt was allocated on a pro-rata basis, based on the equity and debt portions of the total financing. The restricted common stock issuable pursuant to the conversion of the convertible securities and exercise of approximately 971,000 warrant shares have been provided demand and piggyback registration rights. The remaining warrants have been provided piggyback registration rights. o Issuance of convertible secured debt and warrants to purchase approximately 113,000 shares of common stock in September 1999, for total net proceeds of $740,000 (see Note 6). The warrants have an exercise price of $3.60 per share, expire in September 2002 and were assigned a value of approximately $184,000. o Issuance of convertible secured debt and warrants to purchase approximately 1,172,000 shares of common stock in October and December 1999, in two unrelated transactions, for total net proceeds of approximately $2,815,000. The warrants have exercise prices ranging from $.88 to $3.60 per share, have expiration dates ranging from September 2002 to December 2002 and were assigned a value of approximately $562,000. F-14
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COVOL TECHNOLOGIES, INC. AND SUBSIDIARIES NOTES TO CONSOLIDATED FINANCIAL STATEMENTS, continued ----------- During November and December 1999, approximately $1,460,000 of the convertible debt issued in the September and October transactions described above was converted into approximately 2,532,000 shares of common stock. In January 2000, Covol gave a redemption notice to the holder of approximately $1,040,000 of the convertible debt issued in October 1999. [Enlarge/Download Table] 6. Long-term Liabilities Notes Payable Notes payable consist of the following at September 30: (thousands of dollars) 1998 1999 ------------------------------------------------------------------------------------------------- ------------- ------------- Note payable to a corporation bearing interest at prime (8.25% at September 30, 1999) plus 2%, collateralized by plant and equipment, repaid subsequent to September 30, 1999 (see Note 17). $ 2,900 $ 2,900 Note payable to the same corporation referred to in the preceding paragraph, bearing interest at 6%, collateralized by a coal wash plant in Utah, principal and interest due January 2000 (see Note 17). 4,263 4,313 Notes payable to the same corporation referred to in the preceding two paragraphs, bearing interest at 6%. 50% of accrued interest is due February 2000 with remaining accrued interest and principal due February 2001. Collateralized by a synthetic fuel facility in West Virginia, held for sale, and license fees payable to Covol from the production and sale of synthetic fuel from four synthetic fuel facilities owned by the same corporation. 6,680 6,500 Note payable to a limited liability company, bearing interest at 10% payable monthly, with principal due June 2000. Collateralized by a synthetic fuel facility in West Virginia, held for sale, and license fees payable to Covol from the production and sale of synthetic fuel from six synthetic fuel facilities. 8,242 9,191 Convertible secured note payable to an investment company issued at a discount, bearing a stated interest rate of 2.5% on the $20,000 face amount. The note is due March 2004, but is expected to be redeemed or converted into common stock by the note holder prior to maturity if not redeemed earlier by Covol. Interest is payable semiannually on January 1 and July 1. The note is collateralized by license fees payable to Covol from the production and sale of synthetic fuel from four synthetic fuel facilities located in Virginia and West Virginia. -- 10,265 Convertible secured note payable to a Covol shareholder issued at a discount, bearing a stated interest rate of 8% on the $850 face amount. The note is due March 2001, but may be converted into common stock by the note holder prior to maturity if not redeemed earlier by Covol. Interest is payable quarterly beginning December 1999. The note is collateralized by license fees payable to Covol from the production and sale of synthetic fuel from a synthetic fuel facility. --- 622 Note payable to a corporation, bearing interest at 14% payable monthly. $1,000 of principal was paid in January 2000 and $3,000 of principal is due April 2000. Collateralized by a promissory note receivable and by certain future license fees receivable by Covol. A member of Covol's Board of Directors is affiliated with this corporation. 4,000 4,000 Note payable to the same corporation referred to in the preceding paragraph, bearing interest at 14%, paid in March 1999. 4,000 --- Note payable to a corporation, bearing interest at 15%, paid in August 1999 (see Note 15). 5,800 --- Other 94 722 ------------- ------------- 35,979 38,513 Less: current portion (22,049) (20,626) ============= ============= Total non-current $13,930 $17,887 ============= ============= F-15
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COVOL TECHNOLOGIES, INC. AND SUBSIDIARIES NOTES TO CONSOLIDATED FINANCIAL STATEMENTS, continued ----------- Convertible Secured Note Payable The $20,000,000 convertible secured note payable listed above is redeemable by Covol at any time prior to September 17, 2001 for an amount equal to the face amount of the debt. The debt is redeemable by Covol from September 18, 2001 and prior to March 17, 2002 for an amount equal to 109.85% of the face amount of the debt. The debt is convertible into common stock of Covol at the option of the noteholder at a discount to the market price at the time of conversion as described below. The debt is convertible by the holder after March 17, 2002, except upon the occurrence of an event of default. If converted, the number of shares into which the debt can be converted would be calculated based on a price per share of common stock equal to 33% of the then market price at the time of conversion, but not less than $6.67 per share nor more than $10.00 per share. Covol's present intent is to redeem the debt prior to March 17, 2002, assuming sufficient cash from operations is available. A deferred asset was recorded for the portion of financing costs allocated to the debt. This asset is being amortized over 36 months, the most likely period of time over which the debt is expected to remain outstanding. Amortization is computed using the effective interest method. Paid-in capital was credited for the relative value of the warrants directly related to the issuance of debt and the warrants allocated to the issuance of debt, as compared to the total combined fair values of the warrants and debt. A liability was recorded for $21,970,000, 109.85% of the face value of the debt, and debt discount of approximately $13,300,000 was recorded to yield a level interest rate on the net amount of debt outstanding between the issue date and 36 months from the issue date. Each period, interest expense is recorded consisting of the total of i) interest expense based on the stated interest rate and the face value of the debt; ii) amortization of debt discount; and iii) amortization of debt issue costs. Covol will be in default of the provisions of the debt agreement if certain events occur. These events include, in addition to events commonly considered defaults, failure of the shareholders to approve the issuance of the convertible debt by March 31, 2000 (see Note 16), incurring one or more judgments in excess of $5,000,000, which judgments are not discharged, stayed or otherwise satisfied within 30 days of the judgments, and the failure to meet certain earnings targets. The earnings targets apply initially to the quarter ending December 31, 1999, and then to subsequent quarterly periods. Consolidated earnings of $5,000,000, as defined in the applicable agreement, are required for the quarter ending December 31, 1999. In subsequent quarters, earnings targets increase incrementally up to $6,500,000 for the quarter ending December 31, 2001 and subsequent quarters. There are provisions for the carryover of earnings which exceed the targets to subsequent quarters, if necessary, subject to certain limitations. The debt is collateralized by license fees payable to Covol from the production and sale of synthetic fuel from four synthetic fuel facilities located in Virginia and West Virginia. In the event of default, the interest rate on the debt increases immediately by 1% and increases automatically by 1% at the end of each succeeding 90-day period, to the extent permitted by law, until the event is cured. Depending on the nature of the event of default, in most instances, either i) the note and accrued interest become immediately convertible into common stock and the conversion price is subject to adjustment, based on the market price of Covol's common stock and other factors, as provided for in the loan agreement; or ii) all unpaid principal and interest become immediately due and payable. So long as any of this debt or any of Covol's series D preferred stock is outstanding, the holders have the right, as a group, to elect one director to Covol's Board of Directors. Payments of dividends and certain other transactions require approval of the holders. Collateral, Interest Rates and Debt Maturities Substantially all of Covol's property, plant and equipment, facilities held for sale and license fees payable to Covol from the production and sale of synthetic fuel from owned and licensed synthetic fuel facilities are collateral for notes payable. The weighted average interest rate on notes payable was 8.5% at September 30, 1998 and 7.9% at September 30, 1999. Future maturities of notes payable as of September 30, 1999 are as follows: Year ending September 30, (thousands of dollars) --------------------------- --------------------- 2000 $20,626 2001 7,587 2002 129 2003 63 2004 22,000 Thereafter 41 --------------------- Subtotal 50,446 Unamortized discount (11,933) ===================== Net carrying value $38,513 ===================== F-16
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COVOL TECHNOLOGIES, INC. AND SUBSIDIARIES NOTES TO CONSOLIDATED FINANCIAL STATEMENTS, continued ----------- Notes Payable - Related Parties Notes payable - related parties represents unsecured amounts due to two officers of Covol bearing interest at prime plus 2%. Principal and accrued interest were paid in April 1999. Deferred Compensation In 1993, Covol assumed a liability to pay a stockholder of Covol $40,000 per year for seven years beginning February 1999. The present value of the unpaid portion of this liability, discounted at approximately 5%, is reflected as deferred compensation in the consolidated balance sheet. Interest Costs During 1997, Covol incurred total interest costs of approximately $2,023,000 (including approximately $1,429,000 of non-cash interest expense resulting from issuance of convertible debt at a discount), of which approximately $378,000 was capitalized. During 1998, Covol incurred total interest costs of approximately $4,135,000 (including approximately $2,046,000 of non-cash interest expense resulting from issuance of convertible debt at a discount), of which approximately $1,390,000 was capitalized. During 1999, Covol incurred total interest costs of approximately $6,253,000 (including approximately $2,075,000 of non-cash interest expense resulting from amortization of debt discount and debt issuance costs), none of which was capitalized. 7. Preferred Stock Preferred Series A - Non-Voting As of September 30, 1999, there were 3,000 shares of Series A preferred stock issued and outstanding. The Series A preferred shares are non-voting and have the following rights and privileges. The holders of the shares are entitled to cumulative dividends at the rate of 6% per year of the liquidation value of $1,000 per share. These dividends accumulate whether or not they have been declared or whether Covol has any profits. Additional shares of Series A preferred stock may be issued in lieu of cash to pay accumulated dividends on these shares. Upon the liquidation of Covol, the holders of the Series A preferred shares are entitled to receive $1,000 per share, together with all accumulated and unpaid dividends, if any. Each share of Series A preferred stock includes a warrant to purchase 28.571 shares of common stock or a total of 85,713 shares, at a price of $8.00 per share. These warrants had an original expiration date in August 1999, but were subsequently extended to December 2000. The holders of the shares are entitled to convert their shares to common shares at any time. The number of common shares to be received upon conversion is determined by multiplying the number of preferred shares by $1,000 and dividing by the conversion price of $7.00 per share. Covol has the right to require any holder of the Series A preferred shares to convert their shares into common stock. No dividends have been declared through September 30, 1999. Dividends in arrears at September 30, 1999 totaled approximately $381,000, or $126.90 per share. Preferred Series B - Non-Voting As of September 30, 1999, there were 14,310 shares of Series B preferred stock issued and outstanding. There were 312,882 shares outstanding at September 30, 1998 of which 298,572 shares, along with related accumulated but undeclared dividends, were converted into approximately 323,000 shares of common stock during 1999. The Series B preferred shares are non-voting and have the following rights and privileges. The holders of the shares are entitled to cumulative dividends at the rate of approximately 7% per year of the liquidation value of $7 per share. These dividends accumulate whether or not they have been declared or whether Covol has any profits. Additional shares of Series B preferred stock may be issued in lieu of cash to pay accumulated dividends on these shares. Upon the liquidation of Covol, the holders of the Series B preferred shares are entitled to receive $7 per share, together with all accumulated and unpaid dividends, if any. Each unit (comprising 3 shares) of Series B preferred stock includes a warrant to purchase one share of common stock at a price of $8.00 per share. These warrants expired in September 1999. The holders of the shares are entitled to convert their shares to the same number of shares of common stock at any time, subject to adjustment for dilution. Accumulated dividends may be converted by Covol into common stock at the conversion price of $7.00 per share. No dividends have been declared through September 30, 1999. Dividends in arrears at September 30, 1999 totaled approximately $14,000, or $1.01 per share. Based upon the conversion price per share at the date of issuance, a non-cash dividend of approximately $165,000 was imputed upon issuance. F-17
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COVOL TECHNOLOGIES, INC. AND SUBSIDIARIES NOTES TO CONSOLIDATED FINANCIAL STATEMENTS, continued ----------- Preferred Series C - Non-Voting As of September 30, 1999, there were 200 shares of Series C preferred stock issued and outstanding. There were no shares outstanding at September 30, 1998. 1,000 shares were issued in January 1999, of which 800 shares, along with related accumulated but undeclared dividends, were converted into approximately 279,000 shares of common stock during 1999. In November 1999, the remaining 200 shares, along with related accumulated but undeclared dividends, were converted into approximately 189,000 shares of common stock. Warrants for the purchase of approximately 73,000 shares of common stock were issued in connection with the issuance of the preferred stock. The warrants are exercisable until July 2001 at an exercise price of $6.88 per share. The exercise deadline for certain other warrants with an exercise price of $7.00 per share held by this stockholder was extended to June 2000 and certain additional warrants with an exercise price of $30.00 per share were relinquished and canceled. The new and extended warrants were valued at approximately $500,000. Covol granted registration rights for the restricted common shares issuable upon conversion of the preferred stock or upon exercise of the common stock warrants. Based upon the conversion price per share at the date of issuance, a non-cash dividend of approximately $236,000 was imputed upon issuance. Preferred Series D - Voting As of September 30, 1999, there were 60,000 shares of Series D preferred stock issued and outstanding, all of which were issued in March 1999. There were no shares outstanding at September 30, 1998. This series of preferred stock is senior, with respect to dividend rights, payments upon liquidation, or redemption, to all other capital stock of Covol, including the other series of preferred stock which are outstanding or which may be issued in the future. Holders of the preferred stock have voting rights as to all matters voted on by the holders of common stock and are entitled to one vote for each share of common stock issuable upon conversion of the preferred stock. In addition, holders of the preferred stock and the $20,000,000 convertible secured note payable described in Notes 5 and 6 vote as a group for one director. The holders of the shares are entitled to cumulative dividends at the rate of 7% per year of the liquidation value of $100 per share. These dividends accrue whether or not they have been declared or whether Covol has any profits and are payable quarterly. Additional shares of Series D preferred stock may be issued in lieu of cash to pay accrued dividends on these shares. No dividends have been declared through September 30, 1999, but dividends are payable quarterly and approximately $123,000 was paid in July 1999. Dividends in arrears at September 30, 1999 totaled approximately $107,000, or $1.79 per share, which amount was paid in October 1999. Based upon the conversion price per share at the date of issuance, a non-cash dividend of approximately $667,000 was imputed upon issuance. Upon the liquidation of Covol, the holders of the Series D preferred shares are entitled to receive $125 per share, together with all accrued and unpaid dividends, if any. The preferred stock is redeemable at Covol's option through March 17, 2002 at 125% of its liquidation value, subject to adjustment for changes in the value of Covol's common stock. The preferred stock is redeemable at the option of the preferred stockholder only upon occurrence of a change in control or an event of default. The number of shares of common stock into which the preferred stock is convertible is determined by multiplying the number of preferred shares by $100 and dividing by the lesser of $5.25 or 90% of the market value of Covol's common stock on the date of conversion. On March 17, 2002, all outstanding preferred stock automatically converts to common stock. During November and December 1999, 15,202 preferred shares were converted into approximately 1,604,000 shares of common stock. 8. Notes and Interest Receivable -- Related Parties, Collateralized by Common Stock Notes and interest receivable -- related parties, collateralized by common stock, consist of the following at September 30: [Enlarge/Download Table] (thousands of dollars and shares) 1998 1999 ---------------------------------------------------------------------------------------------- ------------- -------------- Note receivable from a stockholder, $5,000 face amount, bearing interest at 6%, renegotiated in November 1997, principal and interest of $515 due in annual installments beginning January 1999 through January 2004, with remaining balances due January 2005, collateralized by 150 shares of Covol's common stock held by Covol, options expiring in January 2006 to acquire 25 shares of Covol's common stock committed by the stockholder to be provided to Covol, and a personal guarantee of the stockholder. The carrying value is equal to the fair value of the 150 shares and options to acquire 25 shares and is net of unamortized discount after renegotiation of $1,281 based upon an imputed rate of 10.25%, and an allowance for impairment of $2,129 in 1997, $2,110 in 1998, and $3,319 in 1999. Interest income of $515 was recognized in 1999. No interest income was recognized during 1997 or 1998. $1,609 $400 F-18
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COVOL TECHNOLOGIES, INC. AND SUBSIDIARIES NOTES TO CONSOLIDATED FINANCIAL STATEMENTS, continued ----------- Notes and interest receivable from 16 current and former officers and employees, issued upon exercise of options to purchase 450 shares of common stock at $5.31 to $8.38 per share, bearing interest at 5.7%, principal and interest due in December 2000, collateralized by 900 shares of Covol's common stock. No interest income was recognized during 1998 or 1999. 5,492 5,492 Notes receivable from seven officers of Covol, bearing interest at prime (8.25% at September 30, 1999) plus 2%, principal and interest due August 2000, originally collateralized by partnership interests which were subsequently exchanged for 79 shares of Covol's common stock (see Note 13). No interest income was recognized during 1997, 1998 or 1999. 672 672 ============= ============== $7,773 $6,564 ============= ==============
9. Fair Value of Financial Instruments SFAS No. 107 requires that the fair market value of certain financial instruments be disclosed in the financial statements. Covol has the following financial instruments that are subject to the provisions of SFAS No. 107: * Cash and cash equivalents * Receivables * Notes receivable, including facility transferred under note receivable arrangement * Notes payable * Notes receivable - related parties, from issuance of, or collateralized by, common stock A substantial portion of Covol's financial instruments are of a short-term nature. Accordingly, while the fair values of some of the individual financial instruments vary somewhat from their carrying values, the aggregate carrying values as reflected in the consolidated financial statements for 1998 and 1999 approximated fair value, with the exception of the notes payable in 1999 for which the aggregate market value approximated $42,300,000 at September 30, 1999. 10. Stock Options and Warrants Stock Options At September 30, 1999, Covol had one stock option plan (the "Option Plan") under which 2,400,000 shares of common stock are reserved for ultimate issuance. A committee of Covol's Board of Directors, or in its absence the Board (the "Committee"), administers and interprets the Option Plan. This Committee is authorized to grant options and other awards both under the terms of the Option Plan and outside the Option Plan to eligible employees, officers, directors, and consultants of Covol. The Option Plan provides for the granting of both incentive stock options and non-statutory stock options. Terms of options granted under the Option Plan, including vesting requirements, are determined by the Committee. Options granted under the Option Plan vest over periods ranging up to ten years, expire ten years from the date of grant and are not transferable other than by will or by the laws of descent and distribution. Incentive stock option grants must meet the requirements of the Internal Revenue Code. Covol has elected to continue to apply Accounting Principles Board Opinion No. 25, "Accounting for Stock Issued to Employees" ("APB 25"), and related interpretations in accounting for its Option Plan. The alternative fair value method of accounting prescribed by SFAS No. 123, "Accounting for Stock-Based Compensation" ("SFAS 123"), requires the use of option valuation models that were not developed for use in valuing employee stock options, as discussed below. Accordingly, under APB 25, no compensation expense has been recognized for stock option grants to employees, officers and directors when the exercise price of stock options equals or exceeds the market price of Covol's common stock on the date of grant. When options are issued with terms considered compensatory, the related compensation expense is amortized to expense over the specified vesting period on a straight-line basis. Deferred compensation related to options that vest over time was approximately $1,178,000 for options issued in 1997 and $0 for options issued in both 1998 and 1999. The amortized compensation expense related to compensatory options was approximately $1,572,000, $908,000 and $2,553,000 for 1997, 1998 and 1999, respectively. Compensation expense related to options that vested immediately was approximately $103,000, $127,000 and $0 for 1997, 1998 and 1999, respectively. F-19
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COVOL TECHNOLOGIES, INC. AND SUBSIDIARIES NOTES TO CONSOLIDATED FINANCIAL STATEMENTS, continued ----------- If Covol had elected to account for options granted based on their fair value, as prescribed by SFAS 123, net loss and net loss per share would have been increased to the pro forma amounts shown in the table below. [Enlarge/Download Table] (thousands of dollars, except per-share data) 1997 1998 1999 --------------------------------------------------------------------------- ---------------- --------------- --------------- Net loss attributed to common stockholders -- reported $(10,687) $(11,645) $(29,704) -- pro forma (11,302) (14,567) (32,969) Basic and diluted net loss per share -- reported (1.32) (1.17) (2.39) -- pro forma (1.40) (1.46) (2.65) The fair value of each stock option grant was determined using the Black-Scholes option pricing model and the following assumptions: expected stock price volatility of .50 to .70, risk-free interest rate of 4.4% to 7.8%, weighted average expected option lives of 5 - 10 years and no dividends. The Black-Scholes option valuation model was developed for use in estimating the fair value of traded options which have no vesting restrictions and are fully transferable. In addition, option valuation models require the input of highly subjective assumptions including expected stock price volatility. Because Covol's stock options have characteristics significantly different from those of traded options, and because changes in the subjective input assumptions can materially affect the fair value, in management's opinion, the existing models do not necessarily provide a reliable single measure of the fair value of stock options. The following table is a summary of activity for all of Covol's stock options, including options not granted under the Option Plan, for the years ended September 30: [Enlarge/Download Table] 1997 1998 1999 --------------------------- ------------------------- -------------------------- Weighted Weighted Weighted Average Average Average Exercise Exercise Exercise (thousands of shares) Shares Price Shares Price Shares Price ------------------------------------------- ------------- ------------- ------------ ------------ ------------ ------------- Outstanding at beginning of year 1,367 $1.62 1,614 $ 2.85 2,370 $6.29 Granted 445 6.08 850 12.34 667 5.40 Exercised (73) 1.84 (94) 1.93 (30) 1.50 Canceled (125) 1.50 --- --- (36) 2.34 ============= ============= ============ ============ ============ ============= Outstanding at end of the year 1,614 $2.85 2,370 $ 6.29 2,971 $6.18 ============= ============= ============ ============ ============ ============= Exercisable at end of year 712 $2.04 1,038 $5.23 1,801 $5.23 ============= ============= ============ ============ ============ ============= Weighted average fair value of options granted during the year below market $9.53 $10.21 n/a Weighted average fair value of options granted during the year at market $5.57 $9.91 $2.93 Weighted average fair value of options granted during the year above market n/a n/a $2.92 F-20
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COVOL TECHNOLOGIES, INC. AND SUBSIDIARIES NOTES TO CONSOLIDATED FINANCIAL STATEMENTS, continued ----------- The following table summarizes information about all stock options outstanding at September 30, 1999: [Enlarge/Download Table] (thousands of shares) Options Outstanding Options Exercisable ------------------------ ------------------------------------------------------------- ------------------------------------ Weighted Number Average Weighted Number Weighted Outstanding at Remaining Average Exercisable at Average Range of Exercise September 30, Contractual Life Exercise September 30, Exercise Prices 1999 in Years Price 1999 Price ------------------------ ---------------------- ------------------- ------------------ ------------------ ----------------- $1.50 to $2.50 1,159 6.5 $ 1.58 982 $ 1.60 $4.13 to $9.00 1,060 8.6 6.44 524 7.66 $11.00 to $13.56 752 8.6 12.93 295 13.00 ---------------------- ------------------ 2,971 1,801 ====================== ================== Stock Warrants As of September 30, 1999, there were warrants outstanding for the purchase of approximately 3,126,000 shares of common stock at prices ranging from $3.50 to $20.00 per share and with expiration dates from November 1999 to March 2004. All of these warrants were issued in connection with private placements of common and preferred stock or notes payable during the years 1997 through 1999 (see Note 5). In October 1998, Covol issued warrants for the purchase of 100,000 shares of common stock pursuant to the terms of the outstanding $4,000,000 note payable to a corporation described in Note 6. Also, certain other warrants for the purchase of common stock have been repriced and / or the exercise period has been extended in order to meet the terms of various agreements Covol has entered into. 11. Basic and Diluted Loss per Share [Enlarge/Download Table] (thousands of dollars and shares, except per-share data) 1997 1998 1999 --------------------------------------------------------------------------- ---------------- --------------- --------------- Numerator: Net loss $(10,498) $(11,308) $(28,393) Preferred stock dividends (undeclared) (24) (337) (466) Imputed preferred stock dividends (165) --- (845) ================ =============== =============== Net loss attributable to common stockholders $(10,687) $(11,645) $(29,704) ================ =============== =============== Denominator - weighted-average shares outstanding 8,080 9,969 12,418 ================ =============== =============== Basic and diluted loss per common share $(1.32) $(1.17) $(2.39) Imputed preferred stock dividends are calculated based upon the amount by which the price of Covol's common stock exceeds the conversion price at the date convertible preferred shares are issued. 12. Income Taxes Covol accounts for income taxes using the asset and liability approach in accordance with Statement of Financial Accounting Standards (SFAS) No. 109, "Accounting for Income Taxes." Covol files a consolidated tax return with its 100% owned subsidiaries. The majority-owned limited partnerships file a separate tax return, as required. As of September 30, 1999, Covol has net operating loss carryforwards of approximately $43,750,000 which can be used to offset future taxable income. The net operating loss carryforwards expire from 2005 to 2019. Covol also has approximately $190,000 in research and development tax credit carryforwards which can be used to offset future tax liabilities. The tax credit carryforwards expire from 2007 to 2013. The utilization of these carryforwards against future taxable income may become subject to an annual limitation due to changes in ownership of Covol's common stock. F-21
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COVOL TECHNOLOGIES, INC. AND SUBSIDIARIES NOTES TO CONSOLIDATED FINANCIAL STATEMENTS, continued ----------- The provision for income taxes for the years ended September 30, 1997, 1998 and 1999 differs from the statutory federal income tax rate due to the following: [Enlarge/Download Table] (thousands of dollars) 1997 1998 1999 --------------------------------------------------------------------------- --------------- --------------- -------------- Tax benefit at statutory rates $3,738 $1,355 $ 9,653 Change in valuation allowance (3,840) (1,377) (10,573) State income taxes, net of federal tax effect 101 39 936 Other, including redetermination of prior years' tax estimates 1 (17) (16) --------------- --------------- -------------- Federal income tax provision $ 0 $ 0 $ 0 =============== =============== ============== The components of the net deferred tax asset as of September 30, 1998 and 1999 are as follows: [Enlarge/Download Table] (thousands of dollars) 1998 1999 ------------------------------------------------------------------------------------------- -------------- --------------- Deferred tax assets (liabilities): Net operating loss carryforwards $7,995 $ 16,319 Research and development tax credit carryforwards 189 189 Compensation expense related to common stock options 2,084 2,989 License fee revenue recognition 315 400 Write-down of notes receivable 304 1,156 Estimated liabilities 356 282 Depreciation (88) 378 Other 40 55 -------------- --------------- Total deferred tax assets 11,195 21,768 Valuation allowance (11,195) (21,768) -------------- --------------- Net deferred tax asset $ 0 $ 0 ============== =============== The valuation allowance increased by $10,573,000 during 1999, representing the additional amount of deferred tax assets at September 30, 1999 not considered recoverable through the reversal of taxable temporary differences or the generation of future taxable income. The valuation allowance increased by $1,377,000 during 1998 and by $3,840,000 during 1997. SFAS No. 109 requires that a valuation allowance be provided if it is more likely than not that some portion or all of a deferred tax asset will not be realized. Covol's ability to realize the benefit of its deferred tax assets will depend on the generation of future taxable income through its continuing operations or through the sale of assets. Because Covol has not generated significant revenues to date, Covol believes that a valuation allowance of $21,768,000 should be provided as of September 30, 1999. This estimate may change in the near term depending on the level of earned license fees received in 2000 and on the consummation of selling the assets held for sale. 13. Purchase of Limited Partners' Interests in Subsidiaries In September 1998, Covol formally offered the limited partners in its two consolidated subsidiaries, Utah Synfuel #1 and Alabama Synfuel #1, an exchange of Covol's common stock for their limited partnership interests. The exchange ratio was based in part on an independent valuation of the limited partnerships' assets and other factors including but not limited to current and future expected cash flows of the partnerships and the market value of Covol's common stock at the date of the offer, $9.00 per share. As of September 30, 1998, substantially all of the limited partners had elected to exchange their limited partnership interests for shares of Covol's common stock. During October and November 1998, all but one of the other limited partners exchanged their interests and Utah Synfuel #1 became a wholly-owned subsidiary of Covol and Alabama Synfuel #1 became a 98%-owned subsidiary of Covol. Covol recorded this exchange using the market values of Covol's common stock on the dates the limited partners tendered acceptance of Covol's offer. These market values ranged from $6.75 to $11.13 per share. Approximately 610,000 shares of common stock were issued in these transactions. Subsequent to September 30, 1999, Covol reached an agreement settling several outstanding issues with the remaining limited partner of Alabama Synfuel #1 following which Alabama Synfuel #1 became a wholly-owned subsidiary of Covol. The carrying value of the intangible asset recorded in the exchange transactions, net of accumulated amortization, was approximately $2,786,000 at September 30, 1999. F-22
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COVOL TECHNOLOGIES, INC. AND SUBSIDIARIES NOTES TO CONSOLIDATED FINANCIAL STATEMENTS, continued ----------- 14. Asset Write-offs and Other Non-recurring Charges In May 1995, Covol entered into an agreement with Geneva Steel Company to build and operate a synthetic fuel briquetting facility. The facility never reached commercial operating levels, but was held for other uses, including potential relocation to another site for use in the production of synthetic fuel or in other applications. In early 1999, Geneva filed a voluntary petition for relief under Chapter 11 of the United States Bankruptcy Code due to a lack of sufficient liquidity. Primarily as a result of this event, Covol moved a substantial portion of the equipment comprising the facility from the Geneva site to another location where it is being used in a different application of Covol's technology. Certain assets at the Geneva site, primarily consisting of leasehold improvements on the property where the facility was located, were abandoned. The carrying value of these assets, totaling approximately $556,000, was written off during 1999. During 1997, Covol entered into an agreement to purchase coal fines for feedstock for two synthetic fuel facilities in Utah. Beginning in 1997 and continuing through May 1999, Covol made payments totaling approximately $3,917,000, of which $240,000 was transferred to cost of coal briquetting operations. The net amount paid was recorded as advances on inventories. Quarterly payments of approximately $396,000 are required under the agreement. The agreement provides for total payments of $5,500,000 between February 1997 and May 2000 for the removal of 2 million tons of coal fines (at a price of $2.75 per ton) from the property. The agreement also provides for removal of an additional 500,000 tons at $2.75 per ton. No payment is required for removal of any coal fines in excess of 2.5 million tons. Covol entered into the contract based on its understanding that the other party to the agreement (the "Seller") was the owner of the property and that there were in excess of 2 million tons of recoverable coal fines on the property. Subsequently, Covol learned that a third party disputes that the Seller is the owner of the property, and that there may be substantially less than 2 million tons of recoverable fines on the property. Consequently, in August 1999, Covol notified the Seller that unless the Seller could procure and provide evidence that it could warrant title to the property and would adjust contract payments to reflect the actual recoverable fines at the property, Covol may elect to terminate the contract and seek appropriate damages. On this basis, Covol has refused to make further quarterly payments to the Seller under the contract. The Seller responded by denying Covol's claims and alleging issues of property reclamation and bonding and failed contract payment. Covol denies these allegations. The dispute is in an early stage of litigation and resolution is uncertain. Based on the uncertainty of recovering the net advances paid through litigation, Covol wrote off the entire $3,677,000 of advances on inventories in the fourth quarter of 1999. In addition to the above charges, in the fourth quarter of fiscal year 1999 Covol wrote off a $660,000 note receivable and recorded a liability for approximately $469,000 related to a settlement agreement with a company that had provided Covol with advise with respect to the use of certain synthetic fuel technology, certain financing obtained and the sale of certain synthetic fuel manufacturing facilities. These write-offs and the settlement provision total approximately $5,362,000, which amount is recorded as asset write-offs and other non-recurring charges in the consolidated statement of operations. 15.Sale of Facilities In 1998, Covol sold a synthetic fuel facility located in Alabama on which a loss of $218,000 was recognized. The sales price was $6,500,000 payable in the form of a nonrecourse promissory note collateralized by certain portions of the facility. In 1999, Covol sold a facility located in Pennsylvania on which a loss of approximately $1,839,000 was recognized. The sales price consisted of a cash payment to Covol of $1,250,000, assumption of $5,000,000 of facility debt, completion of capital improvements to the facility and an eight-year royalty arrangement with both Covol and the construction lender. Covol remains contingently liable for $800,000 of the facility debt which liability has been recorded in accrued liabilities in the consolidated balance sheet at September 30, 1999. Covol entered into an agreement in which it operates the facility on behalf of the buyer. Covol also entered into its standard supply agreements. Covol can receive additional cash payments in the form of both accelerated and increased royalties upon obtaining firm synthetic fuel "off-take" agreements in excess of 100,000 tons per year and operating the facility at rated capacity for a ten-day period. Covol must achieve these performance milestones by June 30, 2000. The maximum amount under these provisions of approximately F-23
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COVOL TECHNOLOGIES, INC. AND SUBSIDIARIES NOTES TO CONSOLIDATED FINANCIAL STATEMENTS, continued ----------- $9,700,000 is achieved if "off-take" agreements to sell 360,000 tons per year are put in place for the synthetic fuel production of the facility in addition to the ten-day operations period. Further, Covol can receive an additional $4,000,000 payment if the facility operates at 115% of capacity for a three-month period in any consecutive three months prior to December 31, 2001. Covol will recognize revenue and a corresponding gain under the royalty arrangement upon receipt of the royalty payments and for achievement of performance milestones. Covol also sold a synthetic fuel facility in December 1999, as more fully described in Note 17. 16. Commitments and Contingencies Commitments and contingencies as of September 30, 1999 not disclosed elsewhere, are as follows: Leases Rental expense was approximately $318,000, $480,000, and $1,309,000 for 1997, 1998 and 1999, respectively. Covol has noncancellable operating leases for equipment and for real estate. At September 30, 1999, minimum rental payments due under these leases, are as follows: Year ending September 30: (thousands of dollars) ----------------------------- ----------------------- 2000 $401 2001 222 2002 89 2003 41 2004 8 ======================= $761 ======================= Letters of Credit Covol has entered into arrangements with a bank that provide for the issuance of letters of credit totaling up to $698,000. These arrangements are collateralized by certificates of deposit totaling approximately $588,000 in 1998 and $460,000 in 1999 that are included in restricted investments in the accompanying consolidated balance sheet. As of September 30, 1999, there was approximately $536,000 of liabilities covered by these arrangements. Legal or Contractual Matters Included in accrued liabilities at September 30, 1998 and 1999 is $755,000 related to canceled construction contracts that contain a "failure to proceed" liability clause. In March 1997, Covol transferred the Utah Synfuel #1 facility to Coaltech. In connection with this transaction, Utah Synfuel #1 licensed Coaltech to use Covol's binder technologies for a non-refundable advance license fee of $1,400,000, which is being recognized as income over the contractual term of the license agreement of 2007, and a recurring license fee that is payable quarterly and that is based upon synthetic fuel produced and sold at the Utah facility by Coaltech. Covol contracted with Coaltech to operate the facility for which Covol receives a quarterly fee, which is also based upon synthetic fuel produced and sold. The limited partners of Coaltech have an option wherein they can require Covol to repurchase this facility under certain conditions. This put option can be exercised if 1) none of the limited partners are able to utilize the federal income tax credits under Section 29 of the tax code, 2) the economic benefits accruing to or experienced by all of the Coaltech limited partners differ significantly from what was initially projected, or 3) there is a permanent force majeure or material damage or destruction of the Utah facility. If the put option is exercised prior to March 2000, the option price will be equal to the fair market value of the limited partnership interests of the optionees on a going concern basis, but in no event will the option price exceed 50% of the capital contributions paid to Covol by Coaltech. If the put option is exercised after March 2000, the option price will be $10. In accordance with generally accepted accounting principles and after discussions with the staff of the Securities and Exchange Commission, this transaction has not been reflected as a sale for accounting purposes. The original cost of the facility less cash payments received from Coaltech, is reflected in the consolidated balance sheet as a facility transferred under note receivable arrangement. Additionally, Covol entered into a supply and purchase agreement with Coaltech wherein Covol agreed to provide to Coaltech coal fines for processing into synthetic fuel at a price equal to Covol's cost. Covol agreed to purchase from Coaltech the synthetic fuel produced, at Coaltech's cost plus one dollar per ton. As a result of this commitment to purchase Coaltech's production, Covol has experienced losses related to the write-down of the synthetic fuel purchased to the lower of cost or market. This write-down to date has approximated 90% of the amount Covol has paid for the synthetic fuel. Based upon expected manufacturing costs and current coal prices, Covol expects to incur a loss under this supply and purchase agreement which will reduce the earned license fees received. Covol believes that over the life of this arrangement, total earned license fees will exceed total losses incurred under the supply and purchase agreement. Also, Covol believes Coaltech cannot require Covol to purchase product for which Covol does not have third party sales, limiting such losses. F-24
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COVOL TECHNOLOGIES, INC. AND SUBSIDIARIES NOTES TO CONSOLIDATED FINANCIAL STATEMENTS, continued ----------- However, Covol and Coaltech are in negotiations to modify the recurring license fee, terminate the operating contract, settle the note receivable, and terminate the supply and purchase agreement (see Note 17). In June 1996, Covol formed Alabama Synfuel #1, Ltd. to construct a synthetic fuel facility. In connection with the construction of this facility, Covol entered into a supply agreement for coal fines to be used at the facility, under which Covol was obligated to purchase a minimum of 20,000 tons of coal fines per month through December 2001. Covol assigned this agreement to the purchaser of the facility and accordingly, has no ongoing obligation. Covol has been paid for the coal fines purchased but has a dispute with the provider of the coal fines for a portion of the coal fines Covol paid for. The resolution of this dispute is not expected to have a material impact on Covol. In January 1996, a manager of Covol entered property owned by Nevada Electric Investment Company, a subsidiary of Nevada Power Corporation, in connection with an offer by Covol to purchase the property, and with certain other employees of Covol, removed some asbestos over a two-day period. In May 1996, Covol received a notice of violation and order for compliance from the State of Utah, Division of Air Quality alleging that asbestos was improperly handled, removed, and disposed of. Covol complied with the order and in September 1996 entered into a settlement agreement with the State of Utah and paid a fine in the amount of $11,000. In late 1997, the U.S. Environmental Protection Agency began its own investigation, referring the matter to the U.S. Attorney's office which proceeded with a grand jury inquiry. The former manager has entered into a misdemeanor plea bargain and the U. S. Attorney has agreed that the plea resolves all criminal matters arising out of the incident. In September 1996, Covol entered into an agreement with Coalco Corporation whereby Coalco was to advise Covol with respect to the financing and sale of certain synthetic fuel manufacturing facilities. A dispute arose between Covol and Coalco about services rendered or to be rendered by Coalco and the amount and timing for payment for such services. A settlement was reached in November 1999 whereby Covol agreed to pay Coalco $1,500,000 plus a royalty based on the synthetic fuel sold from five licensee-owned facilities. Of the $1,500,000 to be paid, $479,000 was accrued as of September 30, 1999 and paid in November 1999. An additional $279,000 was paid in December 1999 and $470,000 is due and payable in January 2000 as a result of the sale of a synthetic fuel facility in December 1999 (see Note 17). The remaining balance will be paid upon the receipt of cash proceeds from any future sales of synthetic fuel facilities held for sale. Pelletco, an affiliate of Coalco, is a licensee of Covol. In March 1999, Covol entered into a financing transaction involving the issuance of convertible preferred stock and a convertible F-25
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COVOL TECHNOLOGIES, INC. AND SUBSIDIARIES NOTES TO CONSOLIDATED FINANCIAL STATEMENTS, continued ----------- secured note (see Notes 6 and 7). The transaction requires, among other things, (1) stockholder approval of the transaction, (2) registration of common stock into which the securities issued may be converted, and (3) achievement of earnings targets beginning in the first quarter of Covol's fiscal year 2000. Covol is preparing for a stockholder meeting to seek approval of the financing transaction. Covol filed the required registration statement on Form S-3 covering the March 1999 financing transaction and such registration statement has been declared effective. Failure to comply with this or other terms and conditions of these financing agreements could result in an increase in the interest rate, immediate convertibility, required escrow payments and possible immediate payment of outstanding amounts. Covol is negotiating for the sale of two synthetic fuel manufacturing facilities held for sale. Current negotiations contemplate the relocation of those facilities by the purchasers. Covol will likely incur costs in terminating the relationships with the current facility site owners and feedstock providers. In the case of the Pocahontas Synfuel facility, Covol may incur up to $2.5 million to terminate the relationship with the site owner and feedstock supplier. In the case of the Mountaineer Fuels facility, Covol may incur up to $3.25 million to terminate the lease and feedstock supply agreement. In February 1997, Covol entered into a contract on a parcel of real property located near Price, Utah, in which Covol obtained certain possessory and related interests, Covol's primary purpose being to obtain a source of coal fines to serve as feedstock for a nearby synthetic fuel facility. In August 1999, Covol sent a notice of default to Earthco, alleging that Earthco had breached a material provision of the contract because Earthco did not have title to the property. Covol has refused to tender its August 1999 payment because of Earthco's breach. In addition, Covol contends that the quantity and/or quality of recoverable coal fines was substantially less than what Covol had understood when entering into the contract, thereby creating grounds to reform the terms of the contract. Earthco subsequently countered with allegations that Covol has breached its obligations under the contract, including failure to make the August 1999 payment. In November 1999, Covol was served with a Complaint in litigation pending in the Seventh Judicial District Court of Carbon County, Utah titled Nevada Electric Investment Company v. Earthco, et al. In the Complaint, and consistent with Covol's position, Nevada Electric Investment Company ("NEICO") alleges that it is the lawful owner of the property near Wellington, Utah described in Covol's lease from Earthco. NEICO seeks a declaratory judgement that Covol is not entitled to possession of the property due to the lack of ownership by Earthco. The Complaint also seeks further relief from Earthco. Covol received Earthco's Answer, Counterclaims and Cross-claim in December 1999. Earthco's cross-claim against Covol alleged breach of contract and requested substantial damages in an amount to be proven at trial but alleged to be in excess of $5 million. Covol filed its Reply and Cross-claim against Earthco in January 2000 denying Earthco's claims and asserting claims of misrepresentation, breach of lease, unjust enrichment, and related claims and for general and consequential damages in an amount to be proven at trial. The disputes among Covol, Earthco and NEICO are at an early stage and resolution is uncertain. Covol intends to defend against claims and prosecute its own claims vigorously. Covol is also involved in several legal proceedings that have arisen out of the normal course of business. Covol believes that many of these claims are without merit and in all cases intends to vigorously defend its position. Management does not believe that the outcome of these activities will have a significant effect upon the operations or the financial position of Covol. Employment Contracts Covol has entered into employment agreements with the Chief Executive Officer, President, Chief Financial Officer and certain vice presidents. The agreements, which are renewable by Covol, generally have a term of approximately three years and provide for annual salaries and benefits ranging from approximately $87,000 to $191,000 annually per officer, currently totaling approximately $1,100,000 for all officers combined. All agreements provide for termination benefits under specific conditions. 17. Events Subsequent to September 30, 1999 Events subsequent to September 30, 1999, not disclosed elsewhere, include the following. Coaltech Developments On October 29, 1999, Covol received notification from the limited partners of Coaltech that they were effecting a retirement of Covol as the general partner of the partnership and were terminating Covol as operator of the Utah facility. The limited partners also assert that as a consequence of the retirement of Covol as general partner, Covol is deemed to have forfeited its 1% interest in the Partnership. The notification demands that Covol indemnify the limited partners for all of their losses, damages, payments, costs and expenses. Covol disputes the limited partners' demands. On December 1, 1999, the parties entered into negotiations and as a result an interim standstill agreement was reached pursuant to which the limited partners and Covol have agreed not to pursue formal proceedings against each other pending the outcome of the current settlement negotiations. It is likely that the outcome of these negotiations will result in relocation of the Utah facility to a new location where it will be operated by one of the limited partners and termination of contractual and operational activities between Covol and the limited partners with settlement payments consistent with amounts reflected in the accompanying consolidated financial statements. Proceeds from this settlement will be used to repay the $4,313,000 note payable due January 2000 to one of the limited partners (see Note 6). It is also expected that the limited partners will continue to purchase binder materials from Covol and use Covol's technology in the production of synthetic fuel when operations of the Utah facility are resumed. Sale of Facilities Effective as of December 31, 1999, Covol sold one of the three remaining synthetic fuel facilities it owned. This facility was located in Price, Utah. Net cash proceeds to Covol after payment of certain debt obligations will be approximately $5,000,000. Covol will report a gain on this transaction of approximately $5,300,000 in the period ended December 31, 1999. On January 13, 2000, Covol executed definitive agreements for the sale of a synthetic fuel facility located in North Fork, West Virginia. Funding under the agreements is expected to occur within several days and will provide sufficient funds to retire the debt incurred in connection with the construction of the facility. The facility is expected to be relocated to the purchaser's site. Additional funds, equal to approximately 50% of the funds received at closing are due to Covol when the facility reaches commercial operations at the new location. Covol will provide proprietary binder materials used at this facility and will receive future royalties based upon production and sale of synthetic fuel at the facility. Also, on January 13, 2000, Covol executed a letter of intent with a major U.S. utility company for the sale of the remaining synthetic fuel facility owned by Covol. Covol believes execution of definitive agreements and funding of the sale will occur within 30 days. Funds from the sale of this facility will be sufficient to repay the debt incurred in the construction and operation of this facility, which debt has a due date of June 30, 2000. Impairment Charge Coaltech owns a synthetic fuel facility on the same property as the facility that was sold. As a result of the anticipated relocation of the facility owned by Coaltech, combined with the sale of Covol's owned facility and the Earthco Complaint (see Note 16), all of which relate to the same property site in Price, Utah, Covol also will record in the December 1999 period an impairment charge of approximately $12,000,000. This impairment charge is expected to consist of the writedown of certain plant and equipment which will remain on the site, having a net book value of approximately $10,000,000 and a minimal expected salvage value, plus the writeoff of the intangible asset related to Utah Synfuel #1 recorded in the exchange transaction described in Note 13, having a net book value of approximately $2,000,000. F-26

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1/21/1412
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9/17/0152
9/30/00264910-K
7/31/0014DEF 14A
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3/31/00265210-Q,  SC 13D/A
2/29/001288-K
1/21/0018
1/17/0028
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1/7/0015PRE 14A
1/4/00118
12/31/9956210-Q,  8-K,  8-K/A
12/20/9918
12/16/9915
12/7/9934
12/6/9934
12/1/9962
11/1/99158-K
10/29/9962S-3/A
10/13/9935
For Period End:9/30/99162DEF 14A,  NT 10-K,  PRE 14A
9/28/99358-K/A
9/17/9934
9/13/99358-K
8/28/9911
8/27/9934358-K,  8-K/A
8/24/9915
8/21/9915
7/7/99358-K
6/30/993510-Q,  10-Q/A
5/6/9933
4/20/9934
3/31/99183510-Q,  10-Q/A
3/24/9918358-K
3/17/9918358-K
1/1/9933
12/31/98163510-Q,  10-Q/A
12/8/983033
11/10/9817
9/30/98196010-K,  10-K/A,  NT 10-K,  PRE 14A
9/9/9817
6/30/9873510-Q
6/12/9833
5/5/983032
5/1/9833
4/21/9833
3/31/983510-Q,  10-Q/A
3/23/98358-K
3/6/9811
3/3/98358-K,  8-K/A
2/20/9832
2/3/9832SC 13D/A
1/9/9833
12/31/971610-Q,  10-Q/A
12/14/9732
12/12/973132
10/28/97358-K
9/30/9795810-K,  10-K/A,  DEF 14A,  NT 10-K
9/18/97358-K
8/28/9731
8/19/97358-K
8/5/9732
8/1/971433
7/7/97318-K
6/30/973510-Q,  10-Q/A
6/27/9731
6/25/9730
5/20/973010-Q,  10-Q/A
3/31/97253410-Q,  10-Q/A,  NT 10-Q
3/20/973132
3/10/9711348-K
3/7/971131
2/21/971532
12/31/967910-Q
12/27/9632NT 10-K
12/20/9631
12/12/9631
9/30/96194110-K,  DEF 14A,  NT 10-K,  PRE 14A
9/10/9631
6/20/9614
6/1/9631
4/24/9634
2/26/9634
2/15/9631
2/1/963031
1/31/9630
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Filing Submission 0001038838-00-000014   –   Alternative Formats (Word / Rich Text, HTML, Plain Text, et al.)

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