Attachment 1 

Polk Power Station 

Site Visit Presentation 
Polk Power Station Polk Power Station 

October 7, 2009 October 7, 2009

Welcome EPA Welcome EPA
SAFETY FIRST SAFETY FIRST

Safety Tip for the Day Safety Tip for the Day
Tampa Electric Generation Tampa Electric Generation

z Big Bend Station 1842 Mw

– 4 Coal-fired steam units (+ CT’s)

z Bayside Power Station 1650 Mw

– Repowered NGCC– One 3 on 1– One 4 on 1

z Polk Power Station 920 Mw

– One IGCC– Four peaking CT’s (2007)

z Phillips Power Station 36 Mw

– Two slow-speed diesels

z Total capacity (approx.) 4450 Mw

2007 Summer 
Polk Power Station Polk Power Station

z Unit 1 IGCC, Base load on syngas, intermediate on oil

– Combined cycle, GE 7F, 7221 192 MW

GE D11, steam 128 MW

– Dual fuel, Syngas/Distillate Oil– DOE Clean Coal Technology co-funding $120M– In service 1996

z Unit 2, 3, 4 & 5 Simple Cycle CT, Peaking

– Simple cycle GE 7FA+E, 7241 150 MW each– 2 & 3 Dual fuel, Nat gas/Distillate Oil; 4 & 5 Nat Gas only– Unit 2 in service 2000, Unit 3 2002, Units 4 & 5 2007

z Total site over 4000 acres (previously mined for phosphate)

– 750 acre cooling pond– 80 Tampa Electric employees
Aerial View of Polk Power Statio

Aerial View of Polk Power Statio
N

STEAM TURBINE

UNIT 3 CT

UNDER CONSTRUCTION

OXYGEN PLANT

GASIFIER STRUCTURE

COAL SILOS

SLURRY PREPARA

SULFUR

HRSG

UNIT 2 CT

ADMINISTRATION

CONTROL

YOU ARE HERE

X
Main Air

Compressor

32 MW

Dryers

Coal &

Pet Coke

2300 TPD

Rod Mills

Water &Recycled Char

Slurry

Tanks

Slurry

Pump

Product

Compressors

18 MW

Oxygen

2100 TPD

Cold

Box

Lockhopper

Char &

Slag

Char & Cl

Compressor 

Clean

Stack

Gas Air

Condensate

Pump

1600 psigSaturated

Steam

7000 KSCFH

Clean Syngas

Diluent Nitrogen

5250 TPD

Radiant

Syngas

Cooler

Gasifier

Syngas

Cooler

Final Filter

MDEA Acid Gas Removal

Acid Gas

H2S + CO2

Cooling

Water

55 psig

Steam

Economized

Boiler

Feedwater

BFW Pump

Heat Recov

Steam Gene

(HRSG)

Steam Tu

Raw

 Syngas

COS

Hydrolysis

(COS H2S)

Convective

Comb

Tur

Saturator

Water

Scrubbers

400psig Steam

450 gpm

Slurry

To Sulfuric

Acid Plant

Overall Flowsheet
Low Emissions from Low Cost Feedstocks

for

Low Cost Electricity

Low Emissions

from

Low Cost Feedstocks

for

Low Cost Electricity

IGCC Driver
Polk 1 Performance Environmen

Polk 1 Performance Environmen

z Polk rated the “Cleanest Coal-Fired Power Plant in North 

America” by the Energy Probe Research Foundation

(Total emissions from 2002 TRI data)
Low Emissions Low Emissions

z Typical Emissions (Lb/MMBTU)

Polk Polk Expected

(Permit) (Steady State) New IGCC

SO

2 0.14 0.12 0.02

NO

x 0.055 0.04 0.02 (w/S

Particulate 0.007 <0.004 0.007 Mercury NA NA 90%+ remov(New IGCC values are basis 8,800 hhv btu/kwh net)
Other Environmental Advantage

Other Environmental Advantage

z Beneficial Reuse of Sulfur – H

2SO

4 at Polk

z Beneficial Reuse of Slagz Low Water Use (2/3 that of PC unit)z Minimal solid waste (no gypsum from FGD)z Zero Process Water Discharge
Environmental Opportunities Environmental Opportunities

z Mercury - Cost-Effective Removal on IGCC using 

small activated carbon bed

– Testing done at Polk– Commercially at Eastman to 95+%

z Other Volatile Metals – Will also be removed by 

carbon bed
Environmental Opportunities Environmental Opportunities

z CO

2 removal 

z Solvents for sulfur removal can also remove CO

2

z For high levels of removal would “shift” syngas

CO + H

2

0

→ CO

2 + H

2

z Shift plus CO

2 removal is common for chemicals

CO

2 Sequestration

z Saline aquifer injection – USF feasibility study

Fuel Flexibility Fuel Flexibility

z Polk has operated on over 20 different fuels including:

CoalsCoal BlendsCoal/Pet Coke BlendsCoal/Coke/Biomass Blends

z Slagging gasifier requires somewhat higher fusion tem

(Polk targets 2350 – 2700 F T250 temps)

z Low rank fuels can be used in slurry fed gasifiers, but 

hurt efficiency

z Power block can operate on syngas or distillate oil
Renewable Fuels Renewable Fuels

Biomass Co-Utilization Testsz Eucalyptus Biomass Test - December, 2001

z Bahiagrass Biomass Test - April, 2004

– (Bahiagrass Harvest and Storage Test started 

approximately one year prior)

z No impact on syngas quality or emissionsz Minor issues with material handling
Polk Unit 1 IGCC Factors

0

102030405060708090

100

96 97 98 99 00 01 02 03 04 05 06 

Year

Hours / Period Hours x 100

CT On Syngas Early CT Fleet Issues CT Availability Early CT Fleet Issue

Key Availability Statistics Key Availability Statistics
TEC’s Advancements of IGCC TEC’s Advancements of IGCC

z Refractory life extension to 3 yearsz Successful integration of fines recyclez NO

x below 15ppm with diluent N

2 and saturation

z Successful zero process water discharge systemz Air extraction/integration with GE 7F turbinez IGCC use with sulfuric acid plant with variable %z Leader in clean coal power production > 13M gwhz IGCC ambassadors, 4000+ visitors 
Perceptions and Misperceptions

Regarding IGCC

Perceptions and Misperceptions

Regarding IGCC

z IGCC Has Low Availability – No Longer True

– First generation IGCC plants did have availability challenges in

early operations. Issues involving scale up, material selection, have been resolved. Polk 1 syngas availability is now 80%. (Shave known issues with CSC’s and single train failure modes)

– The next generation IGCC units will be dual train, (also no CS

and will have 85% syngas availability. 

– The dual fuel capability of the IGCC power block adds significa

reliability. The overall power production availability for IGCC is 95% (higher than any other coal fired technology) 
Perceptions and Misperceptions

Regarding IGCC

Perceptions and Misperceptions

Regarding IGCC

z Higher Installed Cost – True

– Current estimates are 10 – 20% higher than SCPC unit with scrub

and SCR. Rapid escalation of materials/labor has affected both IGand PC.

– IGCC’s ability to use large % of pet coke helps overall project 

economics.

z No Single Supplier Or Overall Performance 

Guarantee – No Longer True

– Alliances GE/Bechtel and Conoco/Phillips-Fluor are offering 

comprehensive EPC contracts with performance guarantees.

z IGCC Too Small – False

– Polk 1 is 250 MW net. Next generation IGCC will be 630 MW net

Scale up risk is minimized by using multiples instead of larger unit

gasifiers vs 1 larger). If overall need is 1800MW can use 2x900 SCPC or 3x 630 IGCC.
Perceptions and Misperceptions

Regarding IGCC

Perceptions and Misperceptions

Regarding IGCC

z No Financial Reward For Superior Environmental 

Performance – Somewhat True

– IGCC is capable of lower emissions than other coal based 

technologies and will be the most cost effective at mercury and C

removal. Anticipated environmental regulations will define financivalue.

z IGCC Not Carbon Capture Ready – False

– CO2 removal from syngas is being done commercially at a numbe

plants (Basin Electric, N.D.; Coffeyville Industries, K.S.; Eastman Chemical, T.N.; Japan, China, etc.). Higher H2 syngas is being u

in a number of Combustion Turbines. 

– All the elements of the process are proven and commercial. It jus

remains to use them together in an IGCC for power production. Tsame can not be said for SCPC.
Perceptions and Misperceptions

Regarding IGCC

Perceptions and Misperceptions

Regarding IGCC

z IGCC Is Experimental And Requires 

Unique Skills – False

– Gasification has been used since the 1800’s. The syngas 

produced originally was used for street lighting, is now used fovariety of purposes including; manufacture of chemicals, liquid fuels, and power production. A survey of worldwide gasificatio2004, showed 117 operating plants with a total of 385 gasifiers

– The first generation IGCC plants (combining coal gasification w

combustion turbines for power production) have now been in service for 10+ years. 

– Tampa Electric (a modest size electric utility) has successfully

operated and maintained the Polk Unit 1 IGCC since 1996.
Future

z TEC was planning for the addition of a 630 MW IGCC 

unit in 2013

z High Costs and uncertainty about CO2 requirements 

caused us to defer consideration of any coal-fired options.

z Continued investigation of CO2 capture and 

sequestration options

z Likely NGCC to meet immediate future base load nee
Polk 1 – Technology Summary Polk 1 – Technology Summary

z Gasification technology originally developed by Texac

now owned by General Electric

z Oxygen blown, slurry fed, entrained flow gasifierz Operating pressure 400 psi nominalz Gasifier vessel refractory lined (largest built)z Radiant plus convective syngas coolers for heat recovz Single train configuration (one gasifier supplying one Cz CT is GE 7F w/ MNQC combusters, larger 1st stage 

nozzle
Polk 1 – Technology Summary Polk 1 – Technology Summary

z Diluent N2 plus syngas saturation for NO

x control

z Modest air extraction rate from CT to ASUz Feedstock is 2200 tons/day coal and petroleum coke 

blend

z ASU by Air Products, 2100 tons/day oxygen productioz Sulfuric acid plant by Monsanto, (unique to Florida)z Acid gas removal via MDEA and COS hydrolysis
QUESTIONS?
Attachment 2 

Polk Power Station 

Water Balance Diagram 

Attachment 3 

Laboratory Report of Leachate Samples Collected 

from the Slag Storage Area in May 2010 


Attachment 4 

Polk Power Station 

Unit 1 Wastewater Flow Diagrams 

Forced Ci

Evapo1074 S

Conde

Brine Storage

Tank

127,000 Gal 

Cooling 

Water

Supply

Cooling 

Water

Return

Brine From Brine Sump Chemical Cleaning

Waste Tank

105,000 Gal 

HC

LP Steam

LC

FI

FI

FI

F

S Sample Point

LEGEND:

Water Flow (GPM)

F Steam Flow (Lb/Hr)

T Temperature (Deg F)

P Pressure (PSIG)

F

235 250

2950

140

4 

6.4
Grey Water 

Evaporator

16,250 Sq Ft 

Greywater Feed To Brine 

Concentration System

LP Steam

Steam

Condensate

LC

LC

Steam 

Vent

Condensate

KO Drum Loop Seal

LC

Cooling 

Water

Supply

Cooling 

Water

Return

Condensate Pumps 

and Cooler

Steam Condensate

Grey Water 

Surge Tank

309,000 Gal Grey Water Process Blowdown

Neutralized Weak Acid

Cooling 

Water

Supply

Cooling 

Water

Return

LP Brine Condensate

To LP Pump Seals & 

Purges

HP Brine Condensate

To HP Pump Seals, 

Purges, and Process 

Condensate Drum

FI

FI

Preheater

S

S

S Sample Point

LEGEND:

Water Flow (GPM)

F Steam Flow (Lb/Hr)

T Temperature (Deg F)

P Pressure (PSIG)

1489

F

43.8

44.0

124.8

197.4

0.0

25.9

17.9

130.3

Condensate 

Storage Tank 

180,000 Gal

3.6

40.4

55