Transcript Title text Title text

K-Direct
Presentation Contents
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The K-Fuel Process
K-Fuel Benefits
KFx Production Facility
Typical K-Direct and power plant configuration
Projected CO2 emission reduction
Typical Plant Performance Improvement
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What is K-Direct
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K-Direct is the location of a K-Fuel refinery at a
coal fired power plant site.
The K-Direct plant refines sub-bituminous coal
to low moisture, low Hg , high BTU fuel.
The host power plant supplies the energy and
coal handling equipment needed to operate the
K-Direct plant.
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What is the K-FuelTM Process
Time Tested Equipment & Proven Process
Two
deployment
strategies
One at coal
source
One at coal
user
applications
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Example results of the K-FuelTM process
using PRB Coal
PRB
Coal
Heating value
(Btu/lb)
K-FuelTM
8,0008,800
Moisture content (%) 30
“Enabling”
Process
∆
10,50011,500
~30%
8-10
~70%
Mercury – Hg
(lb/TBtu)
~9
2.6
~70%
Sulfur
(lb/MMBtu)
0.9
0.7
~20%
CO2 generation
(ton /TBtu)
1,434,000
1,179,000
~18%
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K-FuelTM Process:
A Method that Replicates Nature
Coal
Proven Equipment
Based on 70+ Years
Coal Processing
Vent
Lock hoppers
Steam in
Vent
Water
recycled as
steam
Process
water out
Condenser
Vent
Waste
water to
treatment
Hot Dry Coal
K-FuelTM Product
Carbon
Filter
Water for
Reuse
Qualified Hg
Disposal Site
Direct To
Power Plant
To
Storage
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K-FuelTM Process
Time Tested Equipment & Proven Process
165
Processors
Worldwide
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Technology Comparison
K-Fuel™ Refining
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vs. Historical Coal Drying
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Pressure & Temp
• Squeezes out the water
• Removes pollutants
through heat and washing
effect
Stable Product
• Reduces equilibrium
moisture point
• Minimal dust
Chemically and physically
restructures coal as it reduces
H2O, S, Hg
Permanent lowering of the
coal moisture equilibrium
point
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Thermal Evaporation
• Product ‘popcorns’
• Fragile/dusty
• Reabsorbs H2O
• Spontaneous Combustion
Minimal environmental benefits
High Energy Requirement
No CO2 Reduction Benefit
Only removes H2O
Proven Technology
• KFx owns 30+ case patents in approximately 40
countries
• 5 pilot plants have been constructed and refining
process proven successful
• Average time to develop a first-of-a-kind technology
is 20 yrs; K-Fuel & K-Direct are ready to go!
• KFx has invested more than $100 million to
commercialize K-Fuel
• 1st commercial plant operational and producing
K-Fuel
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Example of a K-Direct plant integrated
with a power production facility.
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Typical K-Direct and Power Plant
configuration
Power Plant
K-Direct Plant
Shaker
Separator
Main Steam to Reboiler
Feed Coal Fines < 3/16
Main Steam 2000 PSI
Normally,
coal
fines
will
be
utilized for boiler
fuel with K-Fuel
as an option for
environmental
control
Re-boiler isolates
boiler steam from
K-Plant steam
system
Coal Bunker
Feed Coal from Coal Pile
Feed Coal > 3/16
.25in. x .25in.
Reboiler
Stack
E-38
E-40
E-44
E-46
Coal Feeder
.25in. x .25in.
K-Fuel
Feed to Boiler
CFB
Boiler
Bag
House
.25in. x .25in.
E-22
Pulverizer
E-36
E-39
E-42
E-37
E-47 E-41
E-43
E-45
E-26
K-Plant provides
make-up water to
power plant circwater system
Generator339 MW
Water Treatment System
VSEP
Filter
LP Turbine HP Turbine
multiple K-Fuel
Processors sized
to meet plant fuel
requirements
Circulating
Water System
Carbon
Filter
E-21
Water Box
Condensate return to Hot Well
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K-Fuel Benefits
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Up to 30% less NOX and SO2 compared to PRB feedstock;
and up to 80% less compared to Eastern coals
K-FuelTM has, on average, 70% less mercury than PRB
feedstock and up to 90% less than Eastern coals
Reduces CO2 emissions due to non-evaporative water
removal and increased boiler efficiency.
Enhancement/alternative to post-combustion
control equipment (Significant Equipment Cost Reduction)
Increases boiler efficiency
Reduce O&M costs
No added disposal problems
Handles, transports and stores as well as PRB coal
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Typical CO2 Emission Reductions Using K-Direct
(Based on US EPA CO2 Emission Factors)
Cost Savings
Cost of CO2
Credits
Business
As Usual (BAU)
Fuel
BAU Fuel
CO2
Generated
(Tons/Year)
K-Fuel
CO2 Generated
(Tons/Year)
CO2 Savings
By Burning KFuel
(Tons/Year)
Annual CO2
% savings
*
Medium
Volatility
Bituminous
Coal
4,627,000
4,340,000
286,000
~ 6.2%
$ 2,000,000
5,278,000
4,340,000
938,000
~ 17.8%
$ 6,600,000
SubBituminous
Coal
Example is based on a 600 MWE electric power plant
*Meets current RGGI CO2 Reduction Goals
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Assuming $7/Ton
Typical Plant performance and financial
Comparison of Data
improvement
Current Fuel
This example is based on:
Coal Cost Per MW-Hr.
K-Fuel
Units
$34.34
$36.28
$/MW-Hr
Net Ash Cost Adder per MW-Hr
$0.82
$0.97
$/MW-Hr
Back-End Technology Cost per MW-Hr
$6.31
$1.64
$/MW-Hr
1.
2 unit 300MW plant
Maintenance Cost per MW-Hr
$0.81
$0.21
$/MW-Hr
2.
Burning <2% sulfur eastern
Parasitic Costs
$0.00
$2.54
$/MW-Hr
K-Direct Process Disposal Cost per MW-Hr.
$0.00
$0.10
$/MW-Hr
$42.27
$41.74
$/MW-Hr
bituminous coal
Total Cost per MW-Hr
3.
4.
Equipped with a dry
scrubber
Fuel Flow at Maximum Gross Power
218,160
258,239
Lb/Hr
Equipped with a PAC
Yearly Fuel Usage Based on Capacity Factor
573,324
678,651
Tons/Yr
$ 59,987,984
$ 59,234,578
$/Yr
$
$/Yr
Yearly Fuel Cost
system for Hg control
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Model includes all cost
Yearly Savings or (Costs) using K-Direct
753,406
associated with operating
Total Savings or (Differential Cost) Per MW-Hr
the K-Direct plant.
6.
$0.53
Net MW Gained using K-Direct Fuel
7.59
$/MW-Hr
MW
The example plant is located
Average Power Sale Price
$
on the east coast of the US.
Resultant Yearly Net Revenue Gained or Lost
Based on Increased MW
$ 1,995,198
$
Total Yearly Cost Savings Plus Gained Power
Sales for Each Unit
$ 2,748,605
$
Total Yearly Cost Savings Plus Gained Power
Sales for Entire Station
14(Both Units)
$ 5,497,210
$
50.00
Note: Fuel, reagent and disposal costs used in this example reflect 2008 values
$/MW
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