Integrated Plasma Fuel Cell Integrated Plasma Fuel Cell Process (IPFC)Process (IPFC)

Process/Technology BriefingProcess/Technology Briefing

Presented byPresented byJames Jordan, President and CEOJames Jordan, President and CEO

Louis Ventre, Jr. Executive VP and General CounselLouis Ventre, Jr. Executive VP and General CounselMeyer Steinberg, VP and Chief Scientist, Meyer Steinberg, VP and Chief Scientist,

Archer Haskins, VP MarketingArcher Haskins, VP MarketingHCE, LLCHCE, LLC

www.hceco.comwww.hceco.com

Integrated Plasma Fuel Cell Integrated Plasma Fuel Cell Process (IPFC)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 EmissionsGreening Fossil Energy

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

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

IPFC Process Flowsheet

IPFC Fischer-Tropsch Synfuel Flowsheet

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

Lower Production Cost

Lower Production Cost

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.

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

Higher Thermal Efficiency Than IGCC for Variety of Feedstocks

Lower CO2 Emissions than IGCC

Lower Capital Investment

Lower Production Cost

Adaptable and Scalable to a Variety of Feedstocks and Applications

Feedstock Fuels – Natural gas, petroleum, coals, lignite, bitumen & biomass

Basic Unit – Produces Electricity and HydrogenHPBR – Hydrogen Plasma Black Reactor coupled withDCFC – 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 AloneAdd WGS and SOFC – Solid oxide fuel cell

For Hydrogen AloneAdd WGS and water electrolyzer

ScalableResidential to Large Multi-Megawatt Power Plant

HYDROGEN PLASMA BLACK REACTORHPBR

HPBR How It WorksIPFC Process

IPFC Process Electric Arc Hydrogen Plasma Black Reactor

IPFC Process Electric Arc Hydrogen Plasma Black Reactor

Benefits of HPBR 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

IPFC Process

DIRECT CARBON FUEL CELLDCFC

Fuel Cells OverviewFuel Cells OverviewPAFCPAFC SOFCSOFC MCFCMCFC PEMFCPEMFC DCFCDCFC

Commercially Commercially AvailableAvailable

YESYES NONO YESYES NONO NONO

Size RangeSize Range 100-200 kW100-200 kW 1kW-10MW1kW-10MW 250kW-250kW-10MW10MW

3-250 kW3-250 kW ModularModular

FuelFuel Natural gas, Natural gas, landfill gas, landfill gas,

digester digester gas, gas,

propanepropane

Natural Natural gas,hydrogegas,hydroge

n landfill n landfill gas, fuel oilgas, fuel oil

Natural gas, Natural gas, hydrogenhydrogen

Natural gas, Natural gas, hydrogen, hydrogen, propane, propane,

dieseldiesel

Coal, lignite, Coal, lignite, sub-sub-

bituminous, bituminous, natural gasnatural gas

EfficiencyEfficiency 36-42%36-42% 45-60%45-60% 45-55%45-55% 30-40%30-40% 80-92%80-92%

EmissionsEmissions Nearly ZeroNearly Zero Nearly ZeroNearly Zero Nearly ZeroNearly Zero Nearly ZeroNearly Zero Concentrated Concentrated Stream of Stream of

CO2CO2

Other FeaturesOther Features Cogen (hot Cogen (hot water)water)

Cogen (hot Cogen (hot water, LP water, LP

or HP or HP steam)steam)

Cogen (hot Cogen (hot water, LP water, LP

or HP or HP steam)steam)

Cogen (80 Cogen (80 degrees C degrees C

water)water)

Electricity Electricity +Cogen(hot+Cogen(hot

CO2)CO2)

Commercial Commercial StatusStatus

Some Some commercially commercially

availableavailable

Likely Likely commercializacommercializa

tion 2004tion 2004

Some Some commercially commercially

availableavailable

Some Some commercially commercially

availableavailable

Likely Likely commercializacommercializa

tion 2008tion 2008

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.

AirOUT

Air IN

- +

Carbon In

Carbon Dioxide OUT

Molten Salt inPorous Matrix

650-800 DegreesCentigrade

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

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.

A Concept for an Industrial-Scale Direct Carbon Fuel Cell

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)

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

IPFC-FTELECTRICITY AND TRANSPORTATION

FUELS

Integrated Plasma Fuel Cell Process SynFuels Plant IPFC-FT

Electric Power and Transportation Fuel ProductionHHV 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 31.2Petroleum 1.82 82.8 19.0N. Dakota Lignite* 1.82 82.0 26.5 CoalKentucky Bituminous2.76 79.8 25.2 CoalBiomass 0.20 70.4 -_____________________________________________________________________Single Conventional Plants CO2 Reduction by IPFC*Rankine Cycle – Electricity - 38% 76.4%Coal Gasification – Gasoline - 65% 36.4%

Integrated Plasma Fuel Cell Power Plant (IPFC-FT)

Electric Power and Transportation Fuel ProductionHHV Thermal Efficiency %

_________________________________________________________ Gasoline and Total

Fuel Electric Power Diesel Efficiency_________________________________________________________Natural Gas 25.7 48.8 74.5Petroleum 53.4 29.4 82.8N. Dakota Lignite 52.9 29.1 82.0 CoalKentucky Bituminous58.6 21.2 79.8 CoalBiomass 11.9 58.5 70.4

Equivalent IGCC coal plant 60%_____________________________________________________________________

Preliminary Cost Estimate – IPFC-FT PlantElectricity and Gasoline Production

Plant Electricity Gasoline EquivalentFuel 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_____________________________________________________________________

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

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

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

Major Level 3 WBS Tasks of Systems Requirements Definition Task (SRD 1.01)1. Complete Conceptual Design Report 2. Scale-Up of Direct Carbon Fuel Cell (DCFC)3. Design & Fabricate Appropriately Scaled Hydrogen Plasma

Black Reactor (HPBR)4. Design & Fabricate Appropriately Scaled Molten Salt

Carbon Transfer System5. Design & Fabricate Appropriately Scaled Off-Gas

Collection Systems for HPBR and DCFC Components6. Testing of Various Ranks of Fossil Fuels in Above Systems7. Perform Trade Studies for Coal Prep and De-Ashing

Systems8. Perform & Complete Preliminary Conceptual Design9. Perform & Complete Analytical Systems Model10. Perform & Complete Preliminary Life Cycle Cost Analysis

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

Greening Fossil Energywww.hceco.com

HHCC EE

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