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Integrated Plasma Fuel Cell Process (IPFC)

Integrated Plasma Fuel Cell Process (IPFC). Process/Technology Briefing Presented by James Jordan, President and CEO Louis Ventre, Jr. Executive VP and General Counsel Meyer Steinberg, VP and Chief Scientist, Archer Haskins, VP Marketing HCE, LLC www.hceco.com.

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Integrated Plasma Fuel Cell Process (IPFC)

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  1. Integrated Plasma Fuel Cell Process (IPFC) Process/Technology Briefing Presented by James Jordan, President and CEO Louis Ventre, Jr. Executive VP and General Counsel Meyer Steinberg, VP and Chief Scientist, Archer Haskins, VP Marketing HCE, LLC www.hceco.com

  2. Integrated Plasma Fuel Cell Process (IPFC) A Highly Efficient Process for Producing Electricity, Hydrogen, Gasoline and Diesel Fuels from Coal, Petroleum, Natural Gas and Biomass with Low Greenhouse Gas Emissions Greening Fossil Energy

  3. Agenda • Describe the Integrated Plasma Fuel Cell (IPFC) Process • Compare the Potential of this Process with the Other Fossil Fuel Conversion Technologies • Describe the key components • Discuss Proposed Development and Commercialization Strategy

  4. HCE, LLC Seeks Support to Develop a Highly Efficient and Clean Process for Conversion of Fossil Fuel to Electricity, Hydrogen and Synthetic Fuels • The process is a breakthrough • The process is more efficient than any other fossil fuel conversion process • The process can be demonstrated at a pilot scale in 3 years at a cost of about $18 million • The estimated cost of a follow-on full scale demonstration plant is about $57 million

  5. IPFC Process Flowsheet

  6. IPFC Fischer-Tropsch Synfuel Flowsheet

  7. The IPFC Process Integrates Two Technologies:Hydrogen Plasma Black Reactor – HPBRwith Direct Carbon Fuel Cell – DCFC • Lower Production Cost Resulting from: • High Efficiency • Lower Capital Investment • Low Pollution Discharges • Half CO2 in concentrated form • 5 to 10X less pollution (NOx and SOx than conventional power plant • Varied Applications Resulting from: • Adaptability of Process • Scalability of Process

  8. Lower Production Cost

  9. Lower Production Cost

  10. Highest Powerplant Thermal Efficiency • When compared to other systems, the IPFC promises the highest powerplant thermal efficiencies --- ranging from a low of 70% to a high of 92%! (Values vary depending upon the type of fuel, the amount of hydrogen produced in relation to the amount of electricity, and the heating value of the fuel.) • Natural Gas Combined Cycle powerplants typically achieve 60% thermal efficiency for electricity production. • Integrated Gasification Combined Cycle plants typically achieve 50 - 55% thermal efficiency for electricity production. • Current fossil powerplants (Rankine Cycle) generate electricity in a range of 35 - 40% thermal efficiency.

  11. Comparison of IPFC Process with Rankine Plants and the Advanced IGCC Plant for Likely Fuel Types

  12. Higher Thermal Efficiency Than IGCC for Variety of Feedstocks

  13. Lower CO2 Emissions than IGCC

  14. Lower Capital Investment

  15. Lower Production Cost

  16. Adaptable and Scalable to a Variety of Feedstocks and Applications • Feedstock Fuels – Natural gas, petroleum, coals, lignite, bitumen & biomass • Basic Unit – Produces Electricity and Hydrogen HPBR – Hydrogen Plasma Black Reactor coupled with DCFC – Direct Carbon Fuel Cell • For Electric Power and Transportation Fuels (gasoline and diesel) Add Water Gas Shift Reactor (WGS) and Fischer-Tropsch Reactor • For Electric Power Production Alone Add WGS and SOFC – Solid oxide fuel cell • For Hydrogen Alone Add WGS and water electrolyzer • Scalable Residential to Large Multi-Megawatt Power Plant

  17. HYDROGEN PLASMA BLACK REACTOR HPBR

  18. HPBR How It Works IPFC Process

  19. IPFC ProcessElectric Arc Hydrogen Plasma Black Reactor

  20. IPFC ProcessElectric Arc Hydrogen Plasma Black Reactor

  21. Benefits of HPBR IPFC Process • Continuously cracks oil and natural gas. • Proofs needed for continuously cracking coal and biomass to carbon, hydrogen and carbon monoxide. • The carbon is in a fine particulate form. • The fine particulate pure carbon is ideal for the Direct Carbon Fuel Cell • The Hydrogen generated by the HPBR is in a concentrated form readily usable in other processes, such as upgrading petroleum refining, or as a feed stock for synfuels production or for sale in the commercial market

  22. DIRECT CARBON FUEL CELL DCFC

  23. Fuel Cells Overview

  24. Direct Carbon Fuel CellHow It Works • Carbon flows into the Direct Carbon Fuel Cell carried by a molten carbonate electrolyte. • The carbon then combines with oxygen from the atmosphere, producing electricity and concentrated carbon dioxide.

  25. Small-scale Experimental Work at LLNL has confirmed Proof of Principle of Direct Carbon Fuel Cell • A laboratory-scale Direct Carbon Fuel Cell is shown in the photograph. • It is a fully functional 60 square centimeters Direct Carbon Fuel Cell. • Lab scale thermal efficiencies achieved up to 90% at 1 kW/m2 and efficiencies of ~80% proved at 2 kW/ m2

  26. Direct Carbon Fuel Cell • Inside the barrel shell of the Direct Carbon Fuel Cell, there is an electrode assembly as shown in the schematic illustration.

  27. A Concept for an Industrial-Scale Direct Carbon Fuel Cell

  28. Direct Carbon Fuel Cell (DCFC) Reduces Pollution • Emission is nearly pure CO2 • Ten-fold Reduction in offgas volume per MWH • 5X---no nitrogen in “flue gas” • 2X---80% efficiency cuts all “flue gas” in half per ton of coal • Reduces costs of sulfur removal • DCFC retains regulated emissions in molten salt (e.g., mercury, vanadium, thorium)

  29. Direct Carbon Fuel Cell Economics • Preliminary costs of stacked cells ~$250/kW at 2kW/m 2 • Estimated 5-year life of cell (graphite corrosion at 50µm/year

  30. IPFC-FT ELECTRICITY AND TRANSPORTATION FUELS

  31. Integrated Plasma Fuel Cell Process SynFuels Plant IPFC-FT Electric Power and Transportation Fuel Production HHV Thermal Efficiency and CO2 Emission Reduction _________________________________________________________ Product Ratio Thermal % CO2 Emission Electric Power Efficiency Reduction Fuel Gasoline % from IGCC _________________________________________________________ Natural Gas 0.53 74.5 31.2 Petroleum 1.82 82.8 19.0 N. Dakota Lignite* 1.82 82.0 26.5 Coal Kentucky Bituminous 2.76 79.8 25.2 Coal Biomass 0.20 70.4 - _____________________________________________________________________ Single Conventional PlantsCO2 Reduction by IPFC* Rankine Cycle – Electricity - 38% 76.4% Coal Gasification – Gasoline - 65% 36.4%

  32. Integrated Plasma Fuel Cell Power Plant (IPFC-FT) Electric Power and Transportation Fuel Production HHV Thermal Efficiency % _________________________________________________________ Gasoline and Total Fuel Electric Power Diesel Efficiency _________________________________________________________ Natural Gas 25.7 48.8 74.5 Petroleum 53.4 29.4 82.8 N. Dakota Lignite 52.9 29.1 82.0 Coal Kentucky Bituminous 58.6 21.2 79.8 Coal Biomass 11.9 58.5 70.4 Equivalent IGCC coal plant 60% _____________________________________________________________________

  33. Preliminary Cost Estimate – IPFC-FT PlantElectricity and Gasoline Production Plant ElectricityGasoline Equivalent Fuel Capital Cost Prod. Cost Prod. Cost Crude Oil Cost * Cost $Kw Mills/Kwh $/gal $/Bbl _____________________________________________________________________ Natural Gas $6.00/MMBTU 690 50.15 1.76 55.60 $4.00/MMBTU 690 40.99 1.44 45.50 $4.00/MMBTU 690 50.00** 1.06 33.50 _____________________________________________________________________ N. Dakota Lignite $12.40/ton MF 775 28.50 1.00 31.50 $0.73/MMBTU 775 44.18** 0.00 10.50*** _____________________________________________________________________ * Cost of a barrel of crude oil to refinery to produce gasoline equivalent to listed IPFC gasoline cost. ** Selling price of electricity raised from production cost but not to exceed conventional price of 50 mills/Kwh(e). *** It costs $0.25/gal to refine crude oil. For zero production cost, equivalent crude oil cost is negative. _____________________________________________________________________ IGCC Plant Cost 1300/Kw 46.85 1.65 52.00 1300/Kw 50.00** 1.24 39.10 _____________________________________________________________________

  34. Integration of DCFC in the IPFC Process • The IPFC process development project will scale-up the DCFC for industrial application and integrate it with a continuously circulating carbon-black-laden molten carbonate stream • The IPFC process project will design, fabricate and test an off-gas system to collect the concentrated stream of CO2 for various applications • The IPFC Project will test performance of the DCFC with various ranks of fossil fuels

  35. Design & Fabricate Appropriately Scaled Hydrogen Plasma Black Reactor (HPBR) • Design a Test Program for Various Ranks of U.S. and Chinese Coal • Set up an instrumented experimental unit at Norwegian University of Science and Technology develop off-gas and processing data to determine systems design information for off-gas processing system, molten carbonate system, and a scaled design for the IPFC pilot plant

  36. Hydrogen Plasma Black Reactor (HPBR) at Norwegian University of Science and Technology, Trondheim, Norway

  37. Major Level 3 WBS Tasks of Systems Requirements Definition Task (SRD 1.01) • Complete Conceptual Design Report • Scale-Up of Direct Carbon Fuel Cell (DCFC) • Design & Fabricate Appropriately Scaled Hydrogen Plasma Black Reactor (HPBR) • Design & Fabricate Appropriately Scaled Molten Salt Carbon Transfer System • Design & Fabricate Appropriately Scaled Off-Gas Collection Systems for HPBR and DCFC Components • Testing of Various Ranks of Fossil Fuels in Above Systems • Perform Trade Studies for Coal Prep and De-Ashing Systems • Perform & Complete Preliminary Conceptual Design • Perform & Complete Analytical Systems Model • Perform & Complete Preliminary Life Cycle Cost Analysis

  38. List of IPFC Process Pilot Plant Project Deliverables • Complete Pilot Plant T&E Report • Complete Construction of Pilot Plant • Complete Final E,S&H Report • Complete Final Design of Pilot Plant • Complete Preliminary Design of Pilot Plant • Complete Conceptual Design Report for 1 MW Pilot Plant • Design, Construct & T&E a full-scale DCFC Module • Design, Construct & T&E a multiple module gas collection system • Design, Construct & T&E a multiple module molten carbonate transfer system • Design, Construct & T&E an appropriately scaled HPBR • Design, Construct & T&E an appropriately scaled fuel prep system

  39. Greening Fossil Energywww.hceco.com Thank You H C E

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