Integrated Plasma Fuel Cell Process (IPFC)

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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)
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
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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

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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

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IPFC Process Flowsheet
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IPFC Fischer-Tropsch Synfuel Flowsheet
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The IPFC Process Integrates Two
TechnologiesHydrogen 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

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Lower Production Cost
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Lower Production Cost
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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.

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Comparison of IPFC Process with Rankine Plants
and the Advanced IGCC Plant for Likely Fuel Types
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Higher Thermal Efficiency Than IGCC for Variety
of Feedstocks
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Lower CO2 Emissions than IGCC
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Lower Capital Investment
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Lower Production Cost
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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

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• HYDROGEN PLASMA BLACK REACTOR
• HPBR

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HPBR How It Works
IPFC Process
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IPFC Process Electric Arc Hydrogen Plasma Black
Reactor
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IPFC Process Electric Arc Hydrogen Plasma Black
Reactor
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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

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• DIRECT CARBON FUEL CELL
• DCFC

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Fuel Cells Overview
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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.

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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

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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.

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A Concept for an Industrial-Scale Direct Carbon
Fuel Cell
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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)

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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

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• IPFC-FT
• ELECTRICITY AND TRANSPORTATION FUELS

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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 Plants CO2 Reduction by
  IPFC
• Rankine Cycle Electricity -
  38 76.4
• Coal Gasification Gasoline - 65
  36.4

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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
• __________________________________________________
  ___________________

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Preliminary Cost Estimate IPFC-FT
PlantElectricity and Gasoline Production

• Plant Electricity
  Gasoline 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

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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

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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

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

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List of IPFC Process Pilot Plant Project
Deliverables

• Complete Pilot Plant TE Report
• Complete Construction of Pilot Plant
• Complete Final E,SH Report
• Complete Final Design of Pilot Plant
• Complete Preliminary Design of Pilot Plant
• Complete Conceptual Design Report for 1 MW Pilot
  Plant
• Design, Construct TE a full-scale DCFC Module
• Design, Construct TE a multiple module gas
  collection system
• Design, Construct TE a multiple module molten
  carbonate transfer system
• Design, Construct TE an appropriately scaled
  HPBR
• Design, Construct TE an appropriately scaled
  fuel prep system

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Greening Fossil Energywww.hceco.com
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