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
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
Greening Fossil Energy Emissions
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 – HPBR
with 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 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
HYDROGEN PLASMA BLACK REACTOR
HPBR
IPFC Process
HPBR How It Works
IPFC Process
Electric Arc Hydrogen Plasma Black Reactor
IPFC Process
Electric Arc Hydrogen Plasma Black Reactor
IPFC Process
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
DIRECT CARBON FUEL CELL
DCFC
 Fuel Cells Overview
PAFC SOFC MCFC PEMFC DCFC
Commercially YES NO YES NO NO
Available
Size Range 100-200 kW 1kW-10MW 250kW- 3-250 kW Modular
10MW
Fuel Natural gas, Natural Natural gas, Natural gas, Coal, lignite,
landfill gas, gas,hydroge hydrogen hydrogen, sub-
digester n landfill propane, bituminous,
gas, gas, fuel oil diesel
propane natural gas

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

Emissions Nearly Zero Nearly Zero Nearly Zero Nearly Zero Concentrated
Stream of
CO2
Other Features Cogen (hot Cogen (hot Cogen (hot Cogen (80 Electricity
water) water, LP water, LP degrees C +Cogen(hot
or HP or HP water) CO2)
steam) steam)
Commercial Some
commercially
Likely
commercializa
Some
commercially
Some
commercially
Likely
commercializa
Status available tion 2004 available available tion 2008
 Direct Carbon Fuel Cell
How It Works
 Carbon flows into the
Molten Salt in Direct Carbon Fuel Cell
Porous Matrix
- +
650-800 Degrees
Centigrade
carried by a molten
carbonate electrolyte.
Air IN  The carbon then
combines with oxygen
from the atmosphere,
Carbon In
Air producing electricity and
OUT concentrated carbon
dioxide.
Carbon Dioxide OUT
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-FT
ELECTRICITY AND TRANSPORTATION
FUELS
 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%
 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%

_____________________________________________________________________
 Preliminary Cost Estimate – IPFC-FT Plant
Electricity 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
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 System
5. Design & Fabricate Appropriately Scaled Off-Gas
Collection Systems for HPBR and DCFC Components
6. Testing of Various Ranks of Fossil Fuels in Above Systems
7. Perform Trade Studies for Coal Prep and De-Ashing
Systems
8. Perform & Complete Preliminary Conceptual Design
9. Perform & Complete Analytical Systems Model
10. 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
Thank You
H
C E
Greening Fossil Energy
www.hceco.com