Coal

Can wind turbines actually reduce the amount of fossil fuels consumed? A Wall Street Journal analysis concludes that ERCOT utilities will begin to feel the squeeze in their profits this year and to expect the amount of fossil fuels used to generate electricity to be reduced.

Coal-fired power plants that fire low-cost coals or that are equipped with combustion modifications for NO_x controls are challenged with maintaining good combustion conditions while maximizing generation and minimizing emissions. In many cases, significant unit derates, availability losses, and an increase in unburned carbon levels can be attributed to poor combustion conditions that occur as a result of poorly controlled local air/fuel distribution within the boiler furnace. Fortunately, a new generation of combustion optimization technologies is available that uses burner air and fuel controls and spatially distributed combustion monitors to detect and correct local furnace air/fuel distribution imbalances.

This plant’s staff proves that a can-do attitude and high productivity can be compatible with a safer workplace. The proactive approaches they used at the 162-MW Hutsonville plant ranged from improving boiler efficiency to better managing risks to workers.

Omaha Public Power District commissioned Unit 2 at its Nebraska City Station in May of this year. The new 682-MW unit joins Unit 1, which went commercial 30 years ago in the same month. The project is outfitted with all the requisite air quality control systems and sports a very good thermal efficiency. More importantly, the plant will provide reasonably priced power for customers of eight municipal utilities that share ownership of the plant’s electrical output. Those utilities paid for their portion of the construction cost and now receive a like portion of the electrical output from Unit 2 under a unique participation power agreement.

Hard work was required at the 2,600-MW Rockport Plant to make improvements to equipment, materials, and processes. But that hard work has paid off: The plant’s units operate much better, employee safety has improved, the facility is setting generation records with both of its 1,300-MW units, and it earned the PRB Coal Users’ Group Large Plant of the Year honors.

Complying with a corporate environmental policy requires much more than just writing a check for equipment upgrades. It takes a dedicated and knowledgeable staff that’s willing to invest years of work to permanently reduce a plant’s environmental footprint. The staff of Seminole Generating Station have completed multiple, incremental plant improvements over the past decade that have significantly reduced air emissions and minimized solid waste disposal.

Boiler tube failures continue to be the leading cause of downtime for steam power plants. Is your boiler tube failure reduction program showing improvement when compared to programs at peer plants? The EUCG’s recent update of its boiler tube failure study can help you answer that question. The full study is available only to members, but this POWER exclusive presents many of the key results, which could help you improve the operation of your plant.

The expected renaissance for U.S. coal-fired generation has been more evolutionary than revolutionary: Less than half of the announced plants will likely progress to construction. However, the percentages for coal-fired plants aren’t significantly different from those for combined-cycle plants a decade ago, when dozens were ultimately canceled, leaving developers with warehouses full of unused gas turbines. The difference this time: The threat of carbon control legislation has moved many projects to the “wait and see” category.

Once pulverized coal flows have been measured, they can be balanced and optimized. Until then, tuning is simply guesswork. The right way to balance furnace fuel flows is to establish solid baseline performance by proper measurement of fuel flow, fineness, and velocity. Only then can all the coal pipes be accurately balanced and followed by a tune-up of the boiler controls.

Italy’s Enel said in August that it has successfully begun operating a power plant in Fusina, near Venice, in the Veneto region of Italy, that is fueled 100% by hydrogen. The industrial-sized plant’s building site was officially opened in April 2008, after which infrastructure and technology work was carried out on schedule. Initial testing of the turbine using methane gas was conducted in the spring of 2009, and now — after completion of the special pipeline — the plant has switched to 100% hydrogen fueling, Italy’s largest energy company said.

When TVA’s Bull Run Fossil Plant was erected in the mid-1960s, it could boast of having the largest boiler in the U.S., and the plant has enjoyed a long, enviable efficiency track record. Today the public judges coal plants by their emissions. Now that it’s been outfitted with the most advanced air quality control systems, including the latest flue gas desulfurization system design, Bull Run scores a perfect "10" in both categories.

Hirakud Power uses environmentally friendly circulating fluidized bed (CFB) combustion technology to produce electricity for one of the world’s oldest aluminum-smelting operations. This "captive power plant" has engineered a number of technical fixes to its original boiler designs to improve plant reliability and reduce outages and boiler repair costs. It also has made strategic investments in upgraded machinery to reduce auxiliary power consumption. In addition to an excellent environmental track record, as evidenced by being Asia’s first ISO 14001 (BS 7750) – certified power plant, Hirakud Power has solidified its position as an industry leader in CFB boiler operating experience and efficient power production.

The world’s first supercritical circulating fluidized-bed (CFB) steam generator began successful operation at the Lagisza power plant in Poland early this July, according to power equipment and engineering firm Foster Wheeler. The new CFB — believed to be the world’s largest — replaced 1960s-era pulverized coal units at the power plant owned by Polish utility […]

"If you build it, they will come" — the litigants, that is. The lawsuit involving the construction of Southwestern Electric Power Co.’s (SWEPCO) John W. Turk Jr. ultrasupercritical coal-fired power plant in Arkansas gives new meaning to that popular quote from the movie Field of Dreams.

Xcel Energy has completed the third and final project required by its 2003 Metropolitan Emissions Reduction Project agreement: repowering the Riverside Plant with a gas-fired 2 x 1 combined-cycle plant and tearing down the old coal-fired plant. Saved from demolition was the Unit 7 steam turbine system that now serves the new plant. Xcel staff expertly managed the project to an on-time start-up and accepted many important construction tasks, harkening back to the days when utilities took a more active role in the design and construction of projects.

Uncertainty about CO₂ emissions legislation is prompting power plant owners to consider the possibility of accommodating "add-on" CO₂ capture and sequestration solutions for coal-fired plants in the future. Those same plant owners may be overlooking the possibility that future natural gas – fired combined cycles will also be subject to CO₂ capture requirements. This month we examine the capture options. In a future issue, Part II will present the installation and operating costs of different carbon capture technologies.

Carbon capture and storage (CCS) has of late gained steam as the best way to mitigate emissions of the greenhouse gas carbon dioxide (CO2) from fossil fuel power plants, despite evidence that the approach would require much energy and increase the fuel needs of a coal-fired plant by more than 25%. A new study from […]

MIT researchers push for faster commercialization of carbon capture technologies for coal-fired power plants by reducing system costs.

The annual meeting of the Powder River Basin Coal Users’ Group was held in association with the ELECTRIC POWER conference in early May in Chicago. Get a taste of the festivities, technical meetings, and the announcement of the group’s 2009 Large and Small Plant of the Year winners in this conference report.

The New Source Review (NSR) permitting program was originally created as part of the 1977 Clean Air Act Amendments to ensure that new power generation facilities were properly outfitted with all the necessary air quality control systems when constructed. Plants in operation were exempt until they made plant modifications viewed as beyond “routine maintenance,” a term whose definition has been a moving target. Is it time for the NSR to take a back seat to improved plant efficiency and reduced carbon emissions?

Reducing dust from coal conveyors has moved from a housekeeping chore to a safety challenge, especially with Powder River Basin coals. Here’s what you need to know about the latest coal-handling system design.

The EPA has identified 44 "high hazard" coal ash ponds around the U.S., and a recent Tennessee Valley Authority report indicates that the agency should have known its Kingston Plant pond would have been one of them.

An analysis by the Center on Budget and Policy Priorities concluded that two-thirds of the value of carbon emission allowances described by the recent H.R. 2545 will benefit utility business customers and households in the top quartile of personal income. The middle quintile will see increased cost for electricity.

City Water, Light & Power (CWLP), the municipal utilities agency of the City of Springfield, Ill., determined that coal-fired generation was its best alternative for providing long-term reliable and economic electricity to the city’s residents. For negotiating an unprecedented agreement with the Sierra Club that allowed the project to move forward, for choosing the latest in coal-fired technology and air quality control systems as the foundation for the city’s comprehensive energy policy, and for assembling a tightly integrated team that completed the project well before the contractual deadline and under budget, CWLP’s Dallman 4 is awarded POWER magazine’s 2009 Plant of the Year award.

If a number of technical, financial, and regulatory hurdles can be overcome, power generated by integrated gasification combined-cycle technology could become an important source for U.S. utilities. Our overview presents diverse perspectives from three industry experts about what it will take to move this technology off the design table and into the field.

While many CO₂ removal technologies are being researched through laboratory and pilot-scale testing, an existing technology has a significant operating history at commercial-scale facilities, where it is collecting CO₂ from multiple sources, including low-CO₂ concentration flue gas (<3.1% by volume) with high oxygen concentrations (>13% by volume).

A little more than a year after the Bush administration abruptly withdrew its support for the FutureGen project, the Department of Energy has again announced it will back the proposed Illinois gasified coal power plant and carbon capture initiative. Though the 275-MW project may be different in technical aspects — it will be initially designed for 60% carbon capture, not 90%, and gasify only Illinois Basin Coal (Figure 2) — it is still riddled with many of same funding problems. Making matters worse, it may have been revived too late: Since the DOE withdrew its support, several major carbon capture and storage (CCS) projects and alliances have sprouted in the U.S., and these could give FutureGen a run for its money.

The U.S. Geological Survey (USGS), a federal mapping agency, has of late been propounding the difference between "resources" and "reserves." It says that although the two terms are used interchangeably, the distinction is simple: Reserves are a subset of resources. Coal resources, as an example, include those in-place tonnage estimates determined by summing the volumes for identified and undiscovered deposits of coal, whereas coal reserves are those resources considered "economically producible" at the time of classification, even though extraction facilities are not in place and operative.

Hydraulic fracturing — the process of drilling and then pumping fluid deep into a formation to generate fractures or cracks, typically for extracting natural gas from shale formations — has been under fire lately, owing to concerns that it contaminates drinking water. But while Congress debates proposed legislation that would impose new restrictions on the technology, an entirely different concern related to fracturing — or "fracking" — is emerging: It may trigger earthquakes.