Fossil Fuels versus renewable energy

Eco-warriors are besotted with the myth that energy can be clean and renewable. The truth is that any "renewable" energy requires massive environmental impacts.

These impacts consume enormous amounts of environmental resources, which would make the most ardent environmentalist blush with shame if they only knew about them. Greens have so ensconced themselves in a humongous bubble of ignorance that it's doubtful if any but a handful know what I'm about to tell you.

And if that handful does in fact exist, they are keeping what they know to themselves as a closely held secret. Because if the truth got out, it would be the end of the environmental movement.


The vision of environmentalists is a peaceful, harmonious world in which human beings tool along on wind and solar energy alone, burn not an ounce of fossil fuel, and leave no human imprint on the environment at all. It's a beautiful, serene picture which has absolutely nothing to do with reality.

In this mythical world, the energy of the wind and the sun is captured and stored in batteries. There's your first problem, right there. As Mark Mills and Alexander Ackley write in The International Chronicles, "A single electric-car battery weighs about 1,000 pounds. Fabricating one requires digging up, moving and processing more 500,000 pounds of raw materials somewhere on the planet." If, however, you burned gasoline, you could deliver the same number of vehicle-miles over the battery's life span of seven years at 1/10 the total tonnage.

The green machines at some point must be decommissioned, which will generate millions and millions of tons of waste. By 2050, the International Renewable Energy Agency calculates that disposing of old solar panels alone will constitute more than double the tonnage of all today's global plastic waste. And waste is the word. A solar or wind farm that stretches as far as the eye can see can be replaced by a handful of gas-fired turbines, each about the size of a tractor trailer.

Both wind and solar require far more in the way of materials and land than fossil fuels. Just one wind turbine takes 900 tons of steel, 2500 tons of concrete, and 45 tons of plastic THAT CANNOT BE RECYCLED. Wind turbines last about 20 years, and since there is no way to recycle the materials, they have to be dumped in landfills. And with blades that are 120 feet long, they're too big for convenient disposal even there.

A wind farm in Minnesota trucked more than 100 of these monster blades to the Sioux Falls Sanitary Landfill in South Dakota. But the director of the Sioux Falls Public Works Department says they're done. "We can't take any more unless they process them before bringing them to us. We're using too many resources unloading them, driving over them a couple of times, and working them into the ground."

If a wind farm includes 100 turbines, that means there are 500 million pounds of concrete which has been poured into what used to be farmland. How is that concrete going to be disposed of?

There is not even a moderately inexpensive way to get the energy that wind farms generate to the cities which need them. Cities are built near flat farmland, while the wind blows on high ridge lines.

And there are health hazards to these giant bird blenders. Germany, which is shifting radically to wind, has discovered these wind farms produce so much noise that, according to one poor unfortunate soul, it "drives you insane at night." Germany is actually now paying hush money to people who live near these farms. They're getting direct handouts from the government essentially to keep quiet. So the turbines can keep making noise, but the people can't.

Building enough wind turbines to supply one-half the world's electricity needs would require nearly two billion tons of coal to make the concrete and steel, and two billion barrels of oil to make the composite blades. We'd consume immense amounts of hydrocarbons in a radically stupid attempt to avoid consuming hydrocarbons.

Well, at least that leaves solar as an environmentally friendly, sustainable, and renewable source of energy. Except of course for the MINING of silver and indium, which will jump 250% and 1200% respectively in the next several decades. Demand for rare earth minerals required for the manufacture of solar panels will rise 300% to 1000% by 2050 to meet the goals of the Paris Accords.

The production of electric cars will require a 2000% percent increase in the production of cobalt and lithium. This will require mining operations in remote wilderness areas with a high degree of undisturbed biodiversity, which is where the cobalt and lithium are found.

One of the dirty secrets is that wind farms must be heavily propped up with taxpayer subsidies because no one in his right mind would build one otherwise. Warren Buffet, for instance, owns MidAmerican Energy. Said Buffett, "On wind energy, we get a tax credit if we build a lot of wind farms. That's the only reason to build them. They don't make sense without the tax credit."

Engineers joke about discovering "unobtanium," a magical energy-producing element that "appears out of nowhere, requires no land, weighs nothing, and emits nothing."

Bottom line: "clean, renewable" energy is neither. It's an environmental disaster. Fossil fuels, on the other hand, are readily accessible, affordable, and have a much, much smaller environmental footprint than all renewables. Gentlemen, start your engines.

Because RE zealots crowed about Germany’s ‘inevitable transition’ to wind and solar from the outset, it’s no surprise that its disastrous conclusion is attracting attention, much like a freeway pileup.

Germany’s so-called Energiewende (energy transition) has turned into a power pricing and supply calamity. Which was as perfectly predictable as it was perfectly avoidable.

Jonathan Tennenbaum is one smart cookie. He received his PhD in mathematics from the University of California in 1973 at the tender age of 22. He’s also a physicist, linguist and pianist and the former editor of FUSION magazine, lives in Berlin and is a frequent visitor to Asia and elsewhere, consulting on economics, science and technology.

Jonathan reaches the inevitable conclusion that the ‘inevitable transition’ to wind and solar was a disaster just waiting to happen. And points out that the inevitable solution was staring Germans in the face all the time: nuclear power.

Germany’s overdose of renewable energy

Germany now generates over 35% of its yearly electricity consumption from wind and solar sources. Over 30 000 wind turbines have been built, with a total installed capacity of nearly 60 GW. Germany now has approximately 1.7 million solar power (photovoltaic) installations, with an installed capacity of 46 GW. This looks very impressive.

Unfortunately, most of the time the actual amount of electricity produced is only a fraction of the installed capacity. Worse, on “bad days” it can fall to nearly zero. In 2016 for example there were 52 nights with essentially no wind blowing in the country. No Sun, no wind. Even taking “better days” into account, the average electricity output of wind and solar energy installations in Germany amounts to only about 17% of the installed capacity.


The obvious lesson is: if you want a stable, secure electricity supply, then you will need reserve, or backup sources of electricity which can be activated on more or less short notice to fill the gaps between electricity demand and the fluctuating output from wind and solar sources.

The more wind and solar energy a nation decides to generate, the more backup capacity it will require. On “bad days” these backup sources must be able to supply up to 100% of the nation’s electricity demand. On “good days” (or during “good hours”) the backup sources will be used less, or even turned off, so that their capacity utilization will also be poor. Not very good economics.

Much better would be to limit wind and solar to a relative minimum, and rely instead upon controllable, non-fluctuating power sources operating with a high capacity factor, to meet the nation’s base load electricity requirements and to adjust total output in accordance with varying demand. This corresponds to world-wide practice prior to the recent huge buildup with renewable energy.

In theory the ideal backup for wind and solar energy would be to store excess electricity produced when the Sun is shining and strong winds are blowing, and inject it back into the grid when needed. Unfortunately, electricity is a difficult and expensive commodity to store.

By far the most efficient presently available solution for storing excess electric power is to use it to pump water against gravity into a reservoir. When electricity is needed again, it is produced by letting water flow down again via a turbine generator. In this process about 25% of the energy is lost.

Naturally, the costs of construction and operation of such pump storage plants will add to the real costs of providing electricity. Plus, these installations use up a large amount of land area.

Here, too, Germany provides an instructive example. A 2014 study by the Bavarian Ministry of Energy came to the conclusion that pump storage plants were not an economically viable solution. Much better would be to exploit already existing water reservoir resources in Norway and Sweden, where the capacity of pump storage plants can be greatly expanded and new ones built at much lower cost.

This “solution,” however, would require transporting large amounts of electricity over long distances back and forth between Germany and those countries – which in turn would require additional high-voltage lines and cables that have not been built and that no one wants to pay for.

Given the high costs and other obstacles to creating large electricity storage systems, it is not surprising that Germany’s electricity storage capacity amounts today to less than 2% of total electricity output.

There has been much discussion and research concerning alternative ways to store electricity. Theoretically one could be to use excess power to produce hydrogen, store it somehow and then use fuel cells to generate electricity back from the hydrogen. This would be vastly more expensive than pump storage, however, and with much greater losses.

Overdose of renewables?

Today, in order to guarantee stable baseline power and fill the gaps left by its fluctuating wind and solar generators, Germany is forced to rely on (1) CO2-spouting coal and natural gas power plants; (2) its remaining handful of nuclear plants, which it plans to shut down by 2022; and most notably (3) importing electricity from other European nations.

On “good days” Germany floods the rest of Europe with excess power from its wind and solar installations, often at dumping or even negative prices. In this way Germany has turned its huge amounts of wildly fluctuating renewable power sources into a European-wide problem.

Even with the flourishing European electricity trade, however, Germany is still far from being able to close down its coal and gas power plants.

The German Energy Agency (DENA) published a long-term scenario for electricity production in Germany, based on the assumption that so-called renewable sources should account for 80% of total electricity consumption by the year 2050.

Among other things DENA concluded that in order to insure a stable electricity supply, Germany would still need to maintain 61 gigawatts of conventional power plant capacity “in reserve” and for a remaining portion of base-load production. Electricity storage systems would provide only 9% of reserve capacity in 2050.

Despite – and to a large extent because of — the massive expansion of renewables, conventional power capacity could only be reduced by 14% up to 2030 and by a maximum of 37% by 2050.

Given the government’s commitment to shut down nuclear energy in Germany, this would mean keeping a large reserve of CO2 -emitting, fossil fuel-based generation capacity. At the same time the political decision has been made to phase out the coal-power stations which up to now have produced the largest part of Germany’s electricity.

That leaves essentially only petroleum (heating oil) and natural gas as realistic fuels for backup power. Natural gas would take first place because it generates about 50% less CO2 per kWh of electricity than coal or petroleum-powered plants.

With this background one can appreciate the German government’s concern to guarantee long-term supplies of natural gas at stable prices. Hence also the government’s insistence on the North Stream 2 project to build a system of offshore natural gas pipelines from Russia to Germany.

The good news, so to speak, is that for most of the time the backup plants would operate at only a fraction of their installed capacity, with many even standing still on “good days.” That way they would release much less CO2 to the atmosphere.

That’s nice for the environment, but not a very efficient way to utilize equipment, infrastructure and manpower – and not very attractive for investors. Also it’s still far from the green dream of a CO2-free energy system.

Preserving the stability of Germany’s electricity grid while at the same time integrating tens of thousands of fluctuating energy sources distributed over the entire country has been a major technical challenge. It has meant reorganizing much of the electricity transmission and distribution system, which was designed and built to operate in a completely different regime.

It means also the construction of thousands of kilometers of new high-voltage lines, including four projected long-distance transmission lines which are needed to move electricity from the windy north to the industrial west and south of the country. This again adds to the real (systemic) costs of supplying the country with electricity.

There is no doubt that the attempted transition to renewable sources as the foundation of Germany’s energy system – Angela Merkel’s famous “Energiewende” – has already significantly reduced the country’s economic efficiency. The constantly rising electricity prices, taxes and levies only begin to reflect the true costs of the government’s policy. There is also a debate concerning the future stability of the electricity grid.

Merkel and others often argue that a successful “Energiewende” would place Germany in a unique position to export know-how and technology for the ongoing “green transformation” of the world economy. Increased income from export of green technology is supposed to compensate for the costs of the Energiewende. This calculation assumes that the other countries will choose to follow the radical German example in reorganizing their power sectors, which is doubtful.

Meanwhile resistance has been growing inside Germany itself, as local environmental groups and citizens’ initiatives mobilize to block construction of wind turbines, transmission lines, pump power stations and other renewable energy projects.

The environmentalist ideology is coming into contradiction with itself. The unprecedented scale of destruction of the natural landscape by 30,000 gigantic wind turbines has brought a growing realization, that reliance on renewable energy is by no means friendly to the environment – and not necessarily safe.

People don’t want to live near wind turbines, because of unpleasant noise and possibly dangerous infrasound emissions, disturbing optical effects, reports of fires, broken-off turbine blades flying through the air, ice throws, etc. And the dead birds.

In Germany there is political pressure to increase the legally-set minimum for the distance between wind turbines and houses to 1 or even 1.5 kilometers, which would drastically reduce the availability of construction sites. Already, protests and law suits have brought the construction of new wind turbines in Germany to a near-standstill.

Solar energy has encountered much less resistance, no doubt to a large extent because only a few large solar farms have been built in the country. Most of the present capacity comes from roof-mounted solar cells, especially on private houses, where they have become quite popular.

The big problem is how to store the electricity, which is generated only during daylight hours and fluctuates according to the cloud cover. So far relatively few house owners have been willing to pay for batteries and other storage devices. Instead, excess electricity is taken up by the grid at a subsidized price.

Projects for pump storage stations, and for new transmission lines have met with such intense resistance, that there is little chance of fulfilling the original goals of the Energiewende.

The question is, whether it makes sense at all to depart from the tried-and-proven model of a stable electricity system based on continuously functioning sources, a large percentage operating in base load mode.

battery-based transportation technologies.

For decades climate change was a topic for predominantly environmentalists. Since the early 2010s, this has changed dramatically. The transformation culminated in the Paris Climate Agreement of 2015 where the world agreed on a comprehensive path to tackle an existential threat. Consequentially the energy transition has strongly gained in importance as countries around the world are racing to replace their carbon-intensive economies with green alternatives.

The massive installment of wind turbines and solar PVs is the first step. As the energy transition progresses, countries across the globe are confronted with challenges of an energy mix dominated by renewables. The intermittent nature of wind and solar electricity production affects the reliability of the power grid. A solution could be the storage of energy into hydrogen through the process of electrolysis.

Furthermore, the rapid development of electric vehicles has exposed the limitations of battery-based transportation technologies. The significant decrease in the battery production costs has, for the first time in history, made it affordable for the wider public to switch to EVs. Environmental considerations have even pushed the EU towards regulations obliging the car industry to develop more sustainable products. However, the technological limitations of EVs require an alternative.



While battery-vehicles have become the way forward for smaller vehicles, the technology doesn't seem fit for heavy duties and long-range transportation. The characteristics of fuel cell-based vehicles make hydrogen, potentially, a suitable alternative.

The lowering of costs remains the biggest challenge, as was the case with renewables. To make hydrogen a plausible choice to complete the energy transition, the production costs of fuel cells need to be decreased significantly. Already the price of electrolysis-produced hydrogen has decreased by 60 percent in the past 10 years from $10-$15 to approximately $4-$6/kg. While it is a significant development, more needs to be done.

The decreasing costs are not a coincidence as governments and companies are responding towards an urgent challenge and changing attitudes towards hydrogen. The massive global attention for the energy-carrier has even spurred some to indicate a potential ‘hydrogen hype’. The coining of this term shows that the future isn’t fixed yet.

However, that hasn’t stopped a bull market on shares of hydrogen cell-producing companies. According to Adam Collins, an analyst at Liberum, "after years of false dawns, investors are realizing clean hydrogen and fuel cells have an important part to play in the energy transition, particularly heavy-duty mobility and heavy industry."

ITM Power’s share value, for example, are up by more than 45 percent this year, which is their highest since 2007. Swedish Powercell’s value has risen 28 percent in the same period and over 342 percent in the past year. This shows the enormous expectations of investors. And to some extent, there is a solid base for these forecasts to become reality.

There are several reasons why the current cycle is much more promising than in the past where a looming hydrogen economy did not materialize. First, there is a consensus in much of the world that climate change is an existential threat right on our doorstep. This asks for rigorous efforts to limit the most damaging effects of global warming.

Second, the massive installment of wind turbines and solar PVs is creating an abundance of electricity, which at certain moments threatens the stability of the power grid. Hydrogen is touted as a solution for energy storage and the flexibility of the grid to solve the problem of intermittency. Also, the availability of cheap electricity improves the business case for green hydrogen.

Furthermore, it is encouraging that the technology for the creation of a hydrogen economy already exists. The production of fuel cells, for example, is largely done by hand due to the current size of the market which is relatively small. This doesn’t justify the massive investments necessary for automatization and mass production. Therefore, it seems a matter of time before the combination of regulations and market developments create the right environment for the development of a hydrogen-based economy.

primary energy sources

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The production of hydrogen from gas and coal may be necessary to fill a potential gap in the global supply energy in the future, and Australia may be ideally placed to emerge as a major player in the global hydrogen market, Australia’s chief scientist, Dr Alan Finkel has told the clean energy sector at a conference in Sydney.

Speaking at the 2019 Australian Clean Energy Summit, Finkel said that wind and solar have emerged as the most viable new sources of zero-emissions energy going into the future, as the sources have overcome the cost, scale and social challenges faced by other energy sources, including nuclear, biofuels and wave or tidal energy.

Finkel was confident that Australia was well-positioned to become a major global supplier of clean hydrogen, with the abundance of sun, wind resources and land necessary to produce sufficient levels of clean energy that Australia could be in a position to export clean energy overseas.


While Finkel remains confident that clean energy resources will be sufficient to meet the world’s future energy needs, there is still a long way to go before renewables become the dominant source of primary energy.

Fossil fuel supplies still represent around 81% of the global primary energy supply, with renewables from sources like wind and solar needing to grow by 70-times their current levels before they will match current contribution of sources like coal, gas and oil.

However, Finkel recognised a gap in the current supply of clean energy, the ongoing need for a storable transport fuel and suggested that hydrogen would be the best placed to meet that need.

While hydrogen is able to be produced directly via renewable energy sources, using electricity generated by wind and solar projects to convert water to hydrogen via electrolysis, Finkel questioned whether it would be possible to produce hydrogen with the scale and diversity of supply needed to meet the needs of a global energy market.

In raising the question of whether the production of hydrogen from coal or gas would be necessary, Finkel raised concerns about the prospect that the global energy market may become reliant on two sources of primary energy, being wind and solar.

Finkel suggested that the use of coal and gas for the production of hydrogen, when paired with the total, or near total capture of emissions from the production process, could serve as a third primary energy source in the future.

“There are two things that concern me, one is scale, and the other is diversity,” Finkel said.

“It scares me to think in the future we may only have to primary energy sources,”

“Now, the sun will always be shining, and the wind will always be blowing. But who knows what the challenges may be for land access rights, transmission rights, climate change impacting weather patterns, or one of those spectacular volcanos like Krakatoa, that could lead to a month of shade.

“Is there a third? Could we increase our diversity? Well hydrogen from coal and natural gas could be something that has to be given consideration, as it is not reliant on solar and wind as an input, its using fossil fuels repurposed to produce a clean fuel.”

“Of course, it will need carbon capture and storage to work”.

As the chief scientist, Finkel previously completed a review of the national energy market, which recommended the implementation of a Clean Energy Target to support investment in new electricity generation capacity in Australia, while reducing emissions. A recommendation that was ultimately rejected by the Turnbull Government.

Finkel is currently leading the development of the National Hydrogen Strategy, which is expected to the delivered by the end of the year.

gasify solid fossil fuels

Power plants that combust or gasify solid fossil fuels generate large quantities of solid residues, principally ash, slag and desulfurization/sulfur byproducts. More specifically, coal-consuming electric utilities now produce over 100 million tons of coal utilization byproducts (CUBs) annually in the United States. Since 1966, the American Coal Ash Association (ACAA) has prepared annual surveys of CUB production and consumption by its members, which consist primarily of coal-burning electric utilities. These surveys concern the highest-volume CUBs: fly ash, bottom ash, boiler slag, and flue gas desulfurization (FGD) by-products. The data are instructive in indicating trends in production and usage of these by-products in major applications. Table 1 shows the production and use figures for 2012, the most recent year available.




The ACAA data show that fly ash from conventional coal combustion is the single largest material by category to be produced. While a portion of this (44.5%) is gainfully utilized in applications such as concrete aggregate, structural fill, etc., the remaining 55.5% is disposed of in ponds and landfills. Because constituents can subsequently leach from disposed wastes, there is potential for components to migrate to surface and ground waters. Groundwater contamination can occur when rainwater percolates through waste, separates (or leaches) hazardous constituents from wastes, and carries the hazardous constituents into the groundwater supply. Also, accidental releases from coal ash ponds have occurred with regrettable environmental consequences, exemplified by the TVA Kingston coal ash slurry spill in 2008 and Duke Energy’s Eden, North Carolina (Dan River) ash release in 2014.

A review of 46 power plant disposal sites from 12 states in the USA and abroad demonstrated that a number of different waste disposal sites had one to several constituents exceed the U.S. Environmental Protection Agency's (EPA) MCL, SMCL or WQC1 limits by an order of magnitude or more in down-gradient wells, ash pond effluents, aquatic receiving systems, etc.2 Given this type of concern, EPA had initially decided that federal regulations were needed due to some evidence of contamination from power plant wastes, the significant inconsistencies in disposal standards between states, and different disposal methods being used (storage in landfills vs. strip mines), and strong public support for such standards. However, in the Spring of 2000, EPA reached its final decision on whether federal regulations should be established to set the minimum safeguards required at all power plant waste disposal sites, issuing a Final Regulatory Determination that regulation of ash as a hazardous waste was not warranted, and determined that voluntary Resource Conservation and Recovery Act (RCRA) Subtitle D (nonhazardous) national standards would need to be developed for CUBs disposed in landfills or surface impoundments and used in filling surface or underground mines. They also determined that no additional regulations were warranted for CUBs that are used beneficially (other than for minefilling). In the regulatory determination, EPA supported increases in beneficial uses of CUBs, such as additives to cement and concrete, waste stabilization, and use in construction products.

The result of EPA’s determination was a marked trend observed in the following years, in which CUBs use volume increased from 32.1 million tons in 2000 to a peak of 60.6 million tons in 2008. However, in 2008 the TVA Kingston coal ash slurry spill occurred, which prompted EPA to commence rulemaking which caused regulatory uncertainty over coal ash utilization (prompting decreases in CUBs use of 51.9 million tons in 2012, down from 56.6 million tons in 2011 and well below the 2008 peak3). However, in a recent Consent Decree signed by all of the parties to a federal lawsuit that sought to compel a deadline for EPA, the Agency agreed to a December 19, 2014, deadline and continued to signal that its final regulation would be promulgated under the “non-hazardous” Subtitle D of RCRA pertaining to coal combustion residuals. In July 2016, EPA signed a direct final rule on disposal of coal combustion residuals, which because effective October 2016.4 Beneficial use of residuals is an important aspect of the recently finalized CCR Disposal Rule,5 which has demonstrated that regulatory trends and the need to better protect the environment, as well as public sentiment, clearly favor power generation technologies that can demonstrate safe disposal or beneficial use of solid by-products.

integrated gasification combined cycle

The Wabash River Coal Gasification Repowering Project is one of two demonstrations of advanced integrated gasification combined cycle (IGCC) technology in the United States. It was selected by the U.S. Department of Energy (DOE) in September of 1991 as a Round IV Demonstration Project for the Clean Coal Technology (CCT) Program. The IGCC plant is a repowering facility in the sense that it was built to replace a dated conventional pulverized coal power plant. Construction began in July of 1993 near West Terre Haute, Indiana, followed by operational startup in November of 1995. The project demonstration phase was completed and turned over for commercial operation in December 1999. In 2005, the plant was re-started under new management. SG Solutions LLC (SGS) owns and operates the Syngas Plant, whereas Wabash Valley Power owns the power generation portion of the plant, which is operated by Duke Energy.

Project Participants

The Wabash River Coal Gasification Project Joint Venture was formed in 1990 by Destec Energy, Inc. of Houston, Texas and PSI Energy. PSI Energy was an investor-owned utility whose service covered 62 of the 69 counties in Indiana. Along with Cincinnati Gas & Electric Company, PSI was owned by Cinergy Corporation, formed in 1994 and acquired by Duke Energy in 2006. Destec was purchased by Houston-based NGC Corporation, in 1997, and changed its name to Dynegy, Inc. the following year. In December of 1999, Global Energy Inc. purchased Dynegy’s gasification assets and technology. This included Dynegy’s synthesis gas (syngas) facility at the Wabash River Coal Gasification Repowering Project, as well as the right, title and interest in Dynegy’s proprietary gasification technology and related patents. Dynegy’s gasification projects in development at the time were also part of the acquisition. In 2005, the facility was handed over to SGS, who currently owns and operates the plant.

The gasification technology, developed originally by Dow Chemical, was first applied to power applications at its Plaquemine, Louisiana, chemical complex. Following implementation at this facility, the technology was transferred to Destec, a partially held subsidiary of Dow Chemical. The technology was later acquired by ConocoPhillips. CB&I currently licenses this process technology under the name E-GAS™.

The gasification technology, developed originally by Dow Chemical, was first applied to power applications at its Plaquemine, Louisiana, chemical complex. Following implementation at this facility, the technology was transferred to Destec, a partially held subsidiary of Dow Chemical. The technology was later acquired by ConocoPhillips. CB&I currently licenses this process technology under the name E-GAS™.


Site Description

The demonstration site is located in a predominantly rural area on the Wabash River outside of West Terre Haute, Indiana. PSI’s Wabash River Station was originally a mine mouth plant, and most of the new facility is built over land which was previously shaft-mined in the early 20th century. The site is bounded by the Wabash River to the east, woodlands and agricultural areas, a reclaimed strip mine, and residential areas 0.2 miles to the southeast and 1.5 miles to the north. Downtown Terre Haute is about eight miles south and there are no nearby wilderness areas or national or state parks. The coal gasification repowering facility is located immediately northwest of PSI’s Wabash Generating Station on land which was donated by the Peabody Coal Company. This 15 -acre plot contains the gasification island, air separation unit, water treatment facility, and the gas turbine and heat recovery steam generator (HRSG) tandem are located adjacent to the existing station. A previously used ash pond was converted for wastewater and storm water use.

The Wabash River IGCC Power Plant is designed to use a variety of local coals with maximums of 5.9% sulfur content (dry basis) and a higher heating value of 13,500 Btu/lb (moisture and ash free). A high-sulfur Midwestern bituminous coal from the No. 6 seam at Peabody’s Hawthorn Mine in Indiana was selected for initial operation. In addition, petroleum coke and blends of coal and coke were tested at the facility.

Wabash River IGCC Power Plant

Plant Description

The design for the gasifier used in this project was based on Destec's Louisiana Gasification Technology, Inc. (LGTI) gasifier, which was of similar size and operating characteristics. The LGTI gasifier was operated for more than 34,000 hours from April 1987 through November 1995. Experience gained in that project was considered in the design of the Wabash River facility and eliminated much of the risk associated with scale-up and process variables.

Coal is first slurried with water and fed with 95%-pure oxygen to the first stage of the gasifier. The coal is partially combusted in this stage to maintain a temperature of approximately 2,500 °F (1,371 °C). The majority of the coal reacts at this temperature with steam to produce the raw syngas. Ash in the coal melts and flows out of the bottom of the gasifier vessel as slag. Additional coal slurry is added to the second gasification stage where it undergoes devolatilization, pyrolysis, and partial gasification to cool the raw syngas and enhance its heating value. The raw syngas is then further cooled to produce steam for power generation. The steam is generated at a pressure of about 1,600 psia.

Candle Filters

Wabash River Coal Gasification Repowering Project Process Flow Diagram (source)

Environmental Considerations

DOE analyzed environmental issues associated with the project according to National Environmental Policy Act (NEPA) standards. In addition, PSI, Destec, and two environmental consulting firms prepared a detailed environmental information volume providing inputs to an Environmental Assessment for the project. A positive NEPA assessment led to DOE issuing a Finding of No Significant Impact in May of 1993. All Federal, state, and local permits and approvals were obtained in combination with the establishment of a process and environmental monitoring program.

Plant design was conducted with the goal of outperforming the Clean Air Act (CAA) emission standards, which limit sulfur dioxide (SO2) at 1.2 lb/million Btu of fuel input and NOX at 0.15 lb/million Btu. Demonstrated emissions are much under these targets (see linked report below).

Despite power generation at the Wabash River complex being almost three times that of the original unit, the total emissions are a fraction of the pre-powering values as a result of the IGCC system.

Cost/Schedule

Total cost of the project was $438 million, which included construction and operation during the four-year demonstration period. DOE provided $219 million (50%) of the total cost.

A cooperative agreement was reached between Wabash River and DOE in July of 1992 with construction beginning in July of 1993. Operation commenced in November of 1995 and the completion of demonstration activities and turnover to commercial operations began in January of 2000. Unusually severe weather hampered activities in the first year of the construction phase of the project. Seven-day construction schedules were employed with peak construction activity reaching over 1,000 workers on site daily.

Operational History

Over the course of the demonstration, the Wabash River Project processed 1.5 million tons of coal, generating more than 4 million MWh of electricity. Thermal efficiencies of the plant were 39.7% for coal and 40.2% for petroleum coke (higher heating value basis). Plant availability averaged 70% in 1998-99, reaching as high as 77% in any given nine-month average. The plant demonstrated stable operation and was successfully operated on baseload dispatch in the PSI system.

Wabash River IGCC Gas Cleanup System (source)

Initial operations found several problems that have been addressed successfully. Improvements in rod mill operation and installation of a new burner resulted in increased carbon conversion, reducing carbon in the slag from about 10% to around 5 %.

Ash deposition at the inlet to the firetube boiler was corrected by modifying the hot gas path flow geometry and velocity. Breakthrough of particles in the barrier filter system was corrected by replacing the ceramic elements with metallic candles. Early replacement of the COS hydrolysis catalysts, due to poisoning by chlorides and metals, was remedied by the installation of a wet chloride scrubber system and a change of catalyst.

A new mechanical method for cleaning boiler tubes was developed to reduce corrosion and decrease filter blinding. Acid gas removal was improved by expanding the system capacity for removing heat-stable salts from the circulating amine solution.

The expansion bellows between the syngas module and the turbine required redesign to eliminate cracking flow sleeves. Solenoid valves in the syngas purge lines were also redesigned and replaced. Replacement of the fuel nozzles was selected as a solution to cracking combustor liners.