Starship can launch something like 150 metric tons to orbit iirc.
Well this is one of the main assumptions I am doubting. We haven’t seen Starship carry anything close to that. AFAIK none of the flights so far were done with a mass simulator, the most it carried was a couple of starlink satellites, which I don’t think would weigh more than like 1 ton.
Also, to what orbit? Low earth orbit, geostationary orbit, or an interplanetary transfer trajectory are completely different beasts. (But I guess for most of the examples you list for economic impact you mean LEO.) And with what reuse profile? Both booster and upper stage reuse, or just booster, or nothing? That obviously factors massively into cost, for the lowest cost you want full reuse.
Upper stage reuse in particular is completely new and unproven tech, they promised that with the Falcon 9 too but never delivered.
I would be interested in e.g. seeing a calculation of a LEO launch with booster return to launch site, and with upper stage landing on a drone ship. (Idk what equations you need here, or if you need some simulator software, the extent of my knowledge is the basic rocket equation, and that I have played Kerbal Space Program. In particular aerodynamics probably complicates things a lot, both for drag on ascent, and for braking on descent.)
What is the claimed specific impulse of the raptor engines, and what might be the actual figures? (And also keep in mind that the vacuum engines of the upper stage will be less efficient at the sea level landing, though probably that does not matter much as you burn most of your velocity via aerobraking.) How much fuel are you carrying in which stage, and what reserve do you need for the landings?
At least seeing these numbers check out, without anything physics defying would already be a plus, without even getting into any of the engineering details.
main uncertainty IMO is the heat tiles...
Agree, in particular I don’t see how they will be fully reusable? (AFAIK right now they are ablative and have to be replaced.) I remember years ago there was some presentation that the ship will be “sweating” liquid methane to cool itself on reentry, this being tossed in favor of a non-reusable solution does not instill confidence in me.
what about the fuel and propellant costs?
I agree that the exact fuel price does not matter much, once you get to the point where it’s the main driver of cost you have already reached the level for transformative economic impact.
Do you know why it takes such a long time to deploy a new rack system at scale? In my mind you slap on the new Rubin chips, more HBM, and you are good to go. (In your linked comment you mention “reliability issues”, is that where the bulk of the time comes from? (I did not read the linked semianalysis article.)) Or does everything, including e.g. cooling and interconnects, have to be redesigned from scratch for each new rack system, so you can’t reuse any of the older proven/reliable components?