Clean Coal Technology
Current Progress, Future Promise
National Mining Association
101 Constitution Avenue, NW
S u i t e 5 0 0 E a s t
Washi ng ton, DC 20001
202/463-2600 | www.nma.org
photos: DOE/NREL, NETL
Last updated: March 2003
HIGHLIGHTS
Coal is vital to present and future U.S. economic and
energy security  it currently provides more than half of
the nation s electricity generation and will continue as the
Clean Coal Technologies
largest single source of electricity supply through 2020 and
beyond (source: Annual Energy Outlook 2002, EIA).
provide abundant,
Clean coal technologies (CCT)  the products of research
and development conducted over the past 20 years  have
cleaner electric power
resulted in more than 20 new, lower-cost, more efficient
and environmentally compatible technologies for electric
utilities, steel mills, cement plants and other industries at less cost.
(source: U.S. DOE, Office of Fossil Energy).
CCT helped make it possible for U.S. utilities to meet more
Projected Electricity Supply by Generators, 2002-25
stringent Clean Air Act requirements while continuing to
utilize America s most plentiful domestic energy resource
 coal.
The original Clean Coal Technology Program, which began
in 1986, focused on commercializing processes that helped
reduce sulfur dioxide and nitrogen oxide emissions and
demonstrating more efficient and environmentally friendly
alternatives to traditional pulverized coal boilers. New
programs  such as the Clean Coal Power Initiative
(CCPI)  are essential for building on the progress of
the original CCT Program, finding solutions for reducing
trace emissions of mercury; reducing or eliminating carbon
2002p 2005 2010 2015 2020 2025
dioxide emissions; and increasing fuel efficiencies. Over
Total Coal
the longer term, research will be directed toward developing
coal-based hydrogen fuels. If coupled with sequestration,
source: U.S. Energy Information Administration, Annual Energy
this will allow greater use of coal with zero emissions.
Outlook 2003, Table 8. p=projection
1
billion KwH
6000
5000
4000
3000
2000
1000
0
WHAT ARE
New, coal-based technological innovations are environmentally superior
and more operationally efficient than technologies in common use today.
CLEAN COAL
In general, they fall into the following categories:
TECHNOLOGIES?
Combusti on Post-Combusti on Conversi on
Combining coal with other Using  scrubbers (flue gas Using heat and pressure to convert
substances in the boiler to desulfurization), chemical cleaning coal into a gas or liquid that can be
improve efficiency and remove or precipitators to remove large further refined and used cleanly.
impurities. An example would be quantities of sulfur, other impurities An example would be Integrated
fluidized-bed combustion, where and particulate matter (dust and Gasification Combined Cycle, and
limestone or dolomite are added ash) from emissions before they other gasification and liquefaction
during the combustion process to are released into the atmosphere. technologies.
mitigate SO2 formation.
Basic Fluidized-Bed Combustion Flue Gas Desulfurization Integrated Gasification Combined Cycle
I l l ustrati ons: U. S. Department of Energy,
Cl ean Coal Technol ogy Compendi um,
www.l anl . gov/proj ects/cctc
2
CLEAN COAL TECHNOLOGY
By law, private industry is required to fund
PROGRAM  HISTORY
at least 50% of each project  the reality:
Projects were selected and technology
demonstrations conducted between
industry provided two-thirds of the funding
1986-93  a jointly funded effort by
government and industry to demonstrate
 $3.5 billion of a total of $5.3 billion.
and commercialize new, lower cost options
for controlling emissions of sulfur dioxide
Funding of Original Clean Coal Technology Program
(SO2), nitrogen oxides (NOx) at coal-
Government
based power plants, as well as to improve
4%
power plant performance and efficiencies.
$1.8 billion
The program resulted in 38 pioneering
projects in 18 states that eventually
$3.5 billion
produced 22 commercial successes
(defined by DOE as resulting in domestic
or international sale of the technology,
Private Indu
or the technology continuing to operate
economically at the plant site).
source: U.S. Department of Energy, Office of Fossil Energy, http://www.fe.doe.gov
3
Project Company Location
CLEAN COAL SCORECARD
Gas Suspension Absorption AirPol W. Paducah, KY
Confined Zone Dispersion Bechtel Seward, PA
LIFAC Sorbent Injection LIFAC Richmond, IN
Commercial Successes to Date
Adv. Flue Gas Desulfurization Pure Air Chesterton, IN
(Domestic or international sales made, or technology
CT-121 Flue Gas Scrubber So. Co. Services Newnan, GA
continues to operate commercially at plant site)
NOx Control - Wall-Fired So. Co. Services Coosa, GA
Coal Reburning B&W Co. Cassville, WI
Low-NOx Cell Burner B&W Co. Aberdeen, OH
Gas Reburning/Low-NOx Burn. EERC Denver, CO
Micronized Coal Reburning NYSEG Lansing, NY
Selective Catalytic Reduction So. Co. Services Pensacola, FL
NOx Control - T-Fired So. Co. Services Lynn Haven, FL
SNOX Flue Gas Cleaning ABB Niles, OH
LIMB SO2/NOx Control B&W Co. Lorain, OH
SOx-NOx-ROx Box B&W Co. Dilles Bottom, OH
Gas Reburning/Sorbent Inj. EERC Two sites - IL
Milliken Clean Coal Project NYSEG Lansing, NY
Dry NOx/SOx Control Sys. Pub. Service CO Denver, CO
McIntosh PFBC Project (4A) City of Lakeland Lakeland, FL
McIntosh PFBC Project (4B) City of Lakeland Lakeland, FL
JEA Fluidized Bed Project JEA Jacksonville, FL
Tidd PFBC Project Ohio Power Co. Brilliant, OH
Nucla CFB Project Tri-State Nucla, CO
Kentucky Pioneer Project Kentucky Pioneer Trapp, KY
Pinon Pine Power Project Sierra Pacific Reno, NV
Tampa Electric IGCC Project Tampa Electric Mulberry, FL
Wabash River Repowering Dynegy/PSI W. Terre Haute, IN
1986-93 Clean Coal Technology
Clean Coal Diesel AD Little Fairbanks, AK
Healy Clean Coal Project AIDEA Healy, AK
Project Selections
Liquid Phase Methanol Air Products Kingsport, TN
Adv. Coal Conversion Western Syncoal Colstrip, MT
38 Projects  18 States
Coal Quality Expert CQ Inc. & ABB Multiple Sites
ENCOAL Mild Gasification ENCOAL Corp. Gilette, WY
$1.8 Billion  Federal Government
Integrated Coal/Ore Reduction CPICOR Vineyard, UT
Pulse Combustor MTCI Baltimore, MD
$3.5 Billion  Private Industry/States
Blast Furnace Injection Sys. Bethlehem Steel Burns Harbor, IN
$5.3 Billion  Total Cost
Cyclone Combustor Coal Tech Corp. Williamsport, PA
Cement Kiln Scrubber Passamaquoddy Thomaston, ME
for more information, visit www.lanl.gov/projects/cctc/factsheets/fs_loc.html
4
MAJOR TECHNOLOGICAL
BENEFITS OF CCTP
for more information, visit www.fe.gov/coal_power/cct/
Technology Impact
" Now on 75 percent of U.S. coal-based power plants.
Low Nitrogen Oxide (NOx)
" 1/2-to-1/10th the cost of older systems.
Burners
" Helped utilities comply with more stringent January 2000 Clean Air Act NOx emission
requirements.
" Between 1980-2000, NOx emissions from coal power plants declined 56 percent,
measured by pounds of emissions per kilowatt hour  low NOx burners have played an
increasing role in this success story.
" Achieves NOx reductions of 80-to-90 percent or more.
Selective Catalytic Reduction
" Technology today costs half what it did in the 1980s.
(SCR)
" Systems are on order or under construction on 30 percent of the existing U.S. coal-
fired generating capacity.
" FGD systems now cost one-third what they did in the 1970s.
Flue Gas Desulfurization (FGD)
" More than 400 commercial units have been deployed.
" SO2 emissions from coal-based power plants declined 61 percent between 1980-2000
(based on lbs. of emissions per kWh)  while coal use by utilities rose 74 percent over
the same period. FGD systems have played an important role.
" Now over 170 operating FBC units in the U.S. and 400 worldwide.
Fluidized Bed Combustion (FBC)
" Commercialized  more than $6 billion in domestic sales and nearly $3 billion
in overseas sales have resulted from U.S. public and private investment in FBC
technology research, development and demonstration.
" Removes SO2, NOx inside the boiler  no additional controls necessary.
" Over 1,500 megawatts of coal-based generation operating today; another 1,900
Integrated Gasification Combined
megawatts are gasifying refinery wastes; another 2,200 megawatts are in design.
Cycle (IGCC)
" 16,500 MWw (megawatt equivalent) of IGCC is expected to be operating in the United
States by 2020.
source: U.S. Department of Energy, Office of Fossil Energy
5
ENVIRONMENTAL BENEFITS
DURING THE CCTP ERA
Year Coal Use for Electricity Generation Coal NOx Emissions Coal SO2 Emissions
(Million Short Tons) (Pounds of Emissions per MWh) (Pounds of Emissions per MWh)
1980 569 10.54 27.67
1985 694 7.48 22.30
1990 781 7.09 19.13
1991 784 6.99 18.97
1992 795 6.88 18.29
1993 832 6.80 17.19
COAL COAL COAL
USE NOx SO2
1994 838 6.66 16.93
UP EMITTED EMITTED
DOWN DOWN
1995 850 6.53 13.58
70%
58% 62%
1996 897 6.24 13.64
1997 921 6.12 13.67
1998 937 5.80 13.31
1999 941 5.15 12.42
2000 986 4.61 10.78
2001 967 4.38 10.46
Note: Figures are rounded. Total emissions reductions are due to several factors, which include increased commercialization and deployment of clean coal technologies.
(Sources: Energy Information Administration, Environmental Protection Agency, National Air Quality and Emissions Trends Report, 2001.)
6
CCT IS IMPORTANT,
NOW AND IN THE FUTURE
Electricity demand will increase 53.4 percent over the next 25 years.
Meeting this rising growth rate will require the construction of the equivalent of more than 1,200 new power
plants of 300 megawatts each  the equivalent of about 65 plants each year.
Coal will remain the largest single source of electricity  accounting for 51 percent of power generation in
2025. (source: Table 8, Annual Energy Outlook 2003)
Clean coal technologies will help meet these needs, plus continue the decline in SO2 and NOx emissions
already underway.
The recently announced FutureGen project takes Clean Coal further. FutureGen, a plant to produce
hydrogen from coal and sequester emissions, will be the world s first zero emission coal-fired plant.
SO2 Emission Rate from NOx Emission Rate from
Electricity Generation (lbs/MWh) Electricity Generation (lbs/MWh)
EQUALLY IMPORTANT &
CCT will help utilities
comply with more stringent
10.5
6.6
environmental standards
4.4
and help address climate
3.0
change concerns in the
2001 2025p
2001 2025p
p = projection. These data include emissions from coal and other fuel sources. Estimates
years ahead.
assume no changes to current Clean Air Act requirements. Source: Annual Energy Outlook
2003, Reference Case, Energy Information Administration.
7
How much coal does the U.S. have?
FUTURE CCT FOCUS AREAS
Allow the continued use of plentiful
domestic coal resources to meet
growing electricity demand.
Provide continually improving
efficiencies, cost benefits and
processes that take advantage of
coal s diversity as a liquid, gas or
solid energy resource.
Meet increasingly stringent environmental
challenges and expectations that were
not part of the original CCT program
 especially in the areas of mercury
U.S. recoverable coal reserves are 274 billion tons (according to U.S. EIA),
control and carbon sequestration  while
enough to last 280 years at present rates of use
continuing reductions in SO2 and NOx.
Did you know&
Develop a zero emission coal
Coal represents 95 percent of U.S. fossil fuel reserves?
based hydrogren production facility
Nine out of every 10 tons of coal is used to make electricity?
incorporating carbon sequestration.
The energy contained in 2001 U.S. coal production exceeded the
combined energy of U.S. oil imports and domestic oil production?
8
FUTURE CHALLENGES 
TECHNOLOGY CAN PROVIDE SOLUTIONS
Ozone Particulate Matter Clear Skies Act Mercury Enforcement
By May 2004, Promulgated in Proposal would EPA will promulgate In November 1999,
EPA regulations to 1997, revised reduce and cap NOx, new mercury control EPA filed lawsuits
reduce the regional National Ambient SO2 and mercury regulations for against seven
transport of ozone Air Quality emissions from coal-based power utilities and issued an
will require utilities Standards (NAAQS) power generators plants by December administrative order
in 20 Eastern states are intended to at 70% below 1990 2004. Currently, the against an eighth,
and the District reduce the levels of Clean Air Act levels removal of mercury charging violation of
of Columbia to airborne particulate by 2018. Specific from commercial New Source Review
sharply reduce NOx matter  including technologies will need technology varies (NSR) requirements.
emissions below fine particles, to be developed and by coal type and All the civil actions
levels specified in requiring further commercialized to is highly variably seek retrofit of state-
the 1990 Clean Air reductions in these achieve reductions within each type, of-the-art control
Act Amendments. emissions. of multiple emissions making compliance technologies on more
and pollutants. problematic with than 10 percent of
regulatory options total U.S. coal-based
under consideration. capacity.
The bottom line: Clean Coal Technology development will be more essential
than ever in meeting new long-term Clean Air Act requirements while
providing cost savings to the American consumer.
9
CLIMATE CHANGE: CARBON DIOXIDE
MITIGATION & MANAGEMENT
It is important to address climate change
with technology, while preserving
economic growth. Possible options
include:
Improvements in Mineralization
power plant operating (injecting CO2 into
efficiencies. rocks, which absorb it)
and reuse.
Sequestration  CO2 Development and Development
capture and storage. demonstration of and demonstration of
Currently, only  carbon combustion plant and a zero emission coal based power plant
sinks (forests, oceans, gasification plant through the  Integrated Squestration
etc.) have been shown to separation. and Hydrogen Research Initiative, the
be effective. FutureGen project.
10
MORE EFFICIENT POWER PLANTS
Improved operating efficiencies of new
power generation technologies from the
HELP REDUCE CO2 EMISSIONS
Clean Coal Technology program are 30-to-
40% higher than a conventional coal plant 
Increased power generating
this translates to a nearly equal percentage
efficiencies, in effect, mean
reduction in carbon dioxide emissions.
(source: U.S. Department of Energy)
generating more megawatts
of electricity from the same
amount of fuel. The result
is lower power costs and
reductions in greenhouse
gas emissions.
11
11
CLEAN COAL TECHNOLOGY NEEDS
CONTINUED FEDERAL SUPPORT
To continue the research
momentum generated
by the original CCTP,
To assure continued
which provided numerous
research, development and
technological innovations
demonstration of a new
To allow America to take full
currently benefitting society.
generation of advanced
advantage of its vast, 280-
technologies that are
year supply of coal resources
promising, but too high-risk to
to meet burgeoning
be financed solely by private
electricity demand and
industry.
encourage economic growth,
while meeting more stringent
environmental objectives.
12
FOCUS AREAS FOR NEW
TECHNOLOGY R&D
Efficiency improvements at existing power plants.
Reduction of mercury emissions to required levels.
High efficiency fuel cells operating on synthetic gas.
Generating systems with increased operating temperature.
New computerized controls, improved burner designs, better
emissions cleaning systems, higher performance turbines.
DOE/NREL
Advanced high efficiency combustion and gasification cycles.
Hydrogen production  a clean energy carrier  via gasification.
Prevention, reduction and then capture and/or storage of CO2 (sequestration).
13
MOVING FORWARD
Emphasis on coal utilization technology development
must continue over the next decade.
$2 billion each from
Funding needs
government (as
contained in the
 Clean Coal Power
Initiative ) and
industry.
$1 billion for
the industry/
government
FutureGen
project.
14
POSITIVE INITIATIVES
NEED SUPPORT
 Clean Coal Power Initiative (CCPI) proposed by President Bush: $2 billion
for CCT over 10 years
Both Senate and House included CCPI in bills passed in 107th Congress
as well as investment and production tax incentives for advanced clean
for more
coal technologies  bills did not get out of conference.
information, visit
CCPI and CCT incentive package still has strong bi-partisan support.
Both will be included in stand-alone bills as well as in comprehensive
energy legislation in the 108th Congress.
www.nma.org
Fiscal year 2002 budget for DOE included $150 million for CCT research.
This was combined with FY 2003 funding of $150 million for a combined
$300 million CCT solicitation.
On January 15, 2003, eight projects were awarded a total of $317 million dollars
for CCPI s first phase. Industry will contribute over $1 billion  well beyond the
50 percent cost share requirement. Projects focus on reductions in mercury,
SO2 and NOx; on increasing efficiency and reducing GHG emissions; and on
using coal waste.
A $130 million budget request has been made for FY 2004.
Support for the the Department of Energy s FutureGen, a $1 billion venture to
build a prototype of the fossil fuel plant of the future that will combine coal-
based electricity with hydrogen production in a zero emission process.
15