Monthly Archives: February 2026

economic prosperity and energy, Coal Power, #Energyreality

The Importance of Coal, Part 2: Coal Power in the Rest of the World

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Coal power in America remains important and I wrote on that last week. This is a followup to provide an overview of the importance of coal as a form of primary energy in the rest of the world. The key phrase is Primary Energy.

Ron Stein and Nancy Perlman wrote an excellent article on the importance of providing primary energy to the six billion people on the planet that are living in poverty. Lifting them from poverty requires energy, just as energy powered the citizens of countries living in the Developed world.

“In poor countries, millions of those in poverty die every year. 
From indoor air pollution from having to burn wood, charcoal, grass, and dung, because they don’t have natural gas, propane or electricity for cooking and heating. 
From bacteria and parasites in their water and food, because they don’t have electricity, water treatment or refrigeration. 
From malaria and other diseases, because their substandard clinics and hospitals lack electricity, clean water, sufficient vaccines and antibiotics, even window screens. “
 
It’s disheartening that the wealthier country governments have chosen electricity generation “winners,” i.e., wind and solar, to generate electricity, paid with taxpayer funds, to support the Government Mandates and Subsidies.”

How about India and China?

China did in fact lift millions from poverty since they entered the World Trade Organization and became the world’s leading country in manufacturing. One example is their use of enormous amounts of coal as the primary energy to produce aluminum. Before the year 2000 China was an insignificant producer of aluminum. Look what they did in 20 years.

How did China power their economy to become the world’s largest producer of aluminum, steel and most manufactured products in such a short time? They did it with coal power. Thomas Shepstone, Jr. and Duggan Flanigan also wrote about energy intensive aluminum production. Here is an overview of China’s energy production during this period of astounding industrial production growth. This chart below is from my July 2025 presentation to the Coal Institute.

China consumes over 50% of the world’s coal. They understand the sources of primary energy that are viable for affordable, Dispatchable and reliable electricity production, so does India. From the IER (Institute for Energy Research)

“China and India – both considered “developing countries” by the IPCC – are burning record amounts of coal and using more kinds of energy to keep energy prices affordable and increase the standard of living for their people.
Wind and solar energy in China and India are complements, not substitutes, to their massive growth in energy, particularly in fossil fuels.
Fossil fuels provided 82 percent and 88 percent of China and India’s energy, respectively, in 2022.”

How about India, Germany and the UK?

From the Economic Times: “India’s coal consumption could more than double ‍by mid-century before plunging ​sharply as the country shifts toward cleaner energy, ⁠long‑term projections published by government think-tank NITI Aayog show.“

Germany’s path to Net Zero has created much loss of industry. Here are a few references:

WUWT on the Decline of German Chemical Industries due to High Energy Prices, and How Germany is Dismantling it’s Core, by Tilak Doshi.

German De-Industrialization post on the “Last Pipe” from Vallourec Factory.

Lars Shernikau’s blog post on the decline of German Industry due to missteps of Green Policies. Dr. Shernikau is a well respected author and world renowned energy expert.

Coal use in the world has steadily increased.

So if Coal Is Such an Obvious Source of Primary Energy, Why is the West Self Sabotaging Their Economies?

I provided a presentation to the ENERUM Energy Forum in Columbus in 2022 to ask this question. A similar presentation to Liberty University in 2023. I am glad to send those presentations. upon request.

Getting back to aluminum production, here is a graph of U.S. and China production. As America shut down many coal plants and electricity costs rose, China was building new coal plants to provide reasonable cost electricity to smelt aluminum in huge quantities. Many folks, including me believe that China Dumped aluminum on the International markets in lieu of counterfeiting U.S. currency. Note the rise of aluminum produced in China during the years 2004-2014 (from chart above). Both of these charts are from a presentation to the Delaware County Bar Association in 2016 to discuss energy, the economy and how it impacts the Real-Estate Market. Yes, I know that sounds abstract, but reasonable cost energy = jobs, especially for energy intensive industries such as aluminum smelting, then the jobs impact the Real-Estate market.

The Self-Sabotaging and excessive environmental laws of the U.S. have not only seriously (I hope not mortally) wounded the aluminum industry, but also steel and heavy manufacturing. Steel production by country is shown below. Why do western politicians continue to do their best to weaken their countries and force manufacturing overseas? It is not only the U.S. it is Australia, Germany the UK and more. President Trump is trying to correct the U.S. problem, but he has much opposition by the Democrats.

The west has been committing energy suicide. Here are links to several articles written by Professor Vaclav Smil, CO2 Coalition’s Gregory Whitestone and Ron Stein. Vaclav Smil for Fraser Institute, “Why Net Zero is Impractical and Unrealistic” and Scam of the Century: Ridding the World of Crude Oil Without a Replacement is Global Suicide”, by Ron Stein and Gregory Whitestone, July 2024. I have also written much with many credible other references on the Self-Sabotaging of the U.S. electric Grid. Here, here and here are three such articles.

Professor Samuele Furfari whom I admire and follow, has written much on the fallacy of hydrogen, wind and solar. Here is a short article he wrote for the CO2 Coalition. Here is an excerpt:

“Over the past ten years, the EU has reduced its energy demand by 6.1 EJ. In contrast, the rest of the world has increased its energy demand by 76.8 EJ – thirteen times more. This is not surprising given that the EU’s competitiveness is currently under threat from the Green Deal. This tragedy is even recognised by the Mario Draghi report, although it does not directly attribute faults to the Green Deal n order to remain politically correct. Instead, the report blames the increase in energy prices, which are nevertheless the consequence of EU energy policy. Outside the European Union, renewable energy sources such as wind and solar power have generated 8 EJ. This figure actually surpasses the change in energy demand within the EU itself. Nevertheless, over the past ten years, fossil fuel consumption has increased by 59 EJ. This means that outside the EU growth in fossil fuels has outpaced that of renewables by a factor of 7.3. In other words, while modern renewable energy is expanding, fossil fuel use is increasing at a rate more than seven times greater. Contrary to the commonly held belief within the EU that the gap between renewables and fossil fuels is narrowing, the reality is that the gap is widening. The evidence suggests that the EU has indeed achieved results in the energy transition, undergoing a profound transformation of its electricity sector and setting benchmarks for renewable energy integration and emissions reduction. However, the EU’s progress is not being matched elsewhere, and its leadership is merely symbolic because the rest of the world is accelerating its use of fossil fuels more than its use of renewable energy. When a leader realises that no one is following them, they must reconsider whether they are truly leading.” I emboldened the line which I thought was most important. It is not only the EU that has chosen the foolish path of Net Zero Carbon, but many other countries and states remain on this course. So, let’s take a look at Australia.

Australia

I saw Ben Tan’s post on LinkedIn where he showed the primary energy used in Australia 1984-2024. It is copied below. This shows the constant need for coal power, steady since 1983.

Two other Australian sources for up to date enelectricity generation by source are Rafe Champion and Ben Beattie. I thank them for their articles, links and information. Here below is the Australian Grid generation by fuel for Feb. 22, 2026. Note that it is over 50 % coal. (at one point 38.5% Black coal and 13.2% Brown Coal) Solar and wind were producing 45% at this same moment. Solar does very well during the sunshiny 6 hours or so of the day and wind does well when the wind is blowing, but the voltage control, base load, sudden increased demand requirements (like turning on a 150 MW electric furnace in a steel mill). Also, the rotational inertia and Grid stability are provided by the coal and gas plants.

Numerous references are included at the end from Rafe Champion, PA Pundits and others on the problems with wind and solar. Although electricity generation is complicated, it is not rocket science. If the politicians would do just a little bit of reading and research and maybe even ask folks like us that do understand, they could make right decisions. However, across the west politicians insist on weakening their countries. Just like the U.S. presidents Obama and Biden (before President Trump began the Herculean job of correcting anti-American Energy policy) and the German and UK politicians. Of course, even many Bureaucrats and state Legislatures to this day, are still stuck on the destructive path of Net Zero Carbon. Even my Conservative (Red) state of South Carolina. Here is a quote From the Santee-Cooper IRP: “As required by S.C. Code Ann. §58-37-40(A)(4)(c), Santee Cooper has evaluated a Net Zero CO2 “

This reminds me of Charlie Reese’s last column on how a minority of legislators and judges can force their Ideology on the citizens. Off topic but voter energy education and voter turnout needs to be improved. As I said, we even have misguided voters and politicians in the deep red state of South Carolina. We have got to improve the energy IQ of the voters.

Recent Articles to Support Building New Coal Power Generation Plants

Rather than repeat my same message, here are recent articles I have written in an attempt to explain the case for new coal plants, including two articles on the need to build new coal plants based on coal being the default source of primary energy. The default source of primary energy because the electricity growth is expected to out pace the production of gas turbines to provide for all new generation and nuclear generation, although a very good approach, will take a decade or more to provide the needed electricity generation capacity.

  1. Ten Hard Truths of Electricity Generation in South Carolina, the Life-Blood of the Economy, Oct. 8, 2025: https://dickstormprobizblog.org/2025/10/08/ten-hard-truths-of-s-c-electricity-the-lifeblood-of-the-economy/
  2. Reality of Building 32,000 MW of New Generation Capacity/Year. Solutions; Build New Coal Plants Now!,  https://dickstormprobizblog.org/2025/10/22/reality-of-32000-mw-year-of-new-generation-demand-solution-build-new-coal-plants-now/
  3. Power for the U.S.A. Reality of Building 32,000 MW each year: https://powerfortheusa.com/2025/10/22/reality-of-32000-mw-year-of-new-generation-demand-solution-build-new-coal-plants-now/
  4. Power for the U.S.A. Advantages of Coal Power, Dec. 21, 2025: https://powerfortheusa.com/2025/12/21/advantages-of-coal-fuel-for-electricity-generation/
  5. 100 Quadrillion BTUs and Why Coal Should be Included in the Primary Energy Portfolio: https://dickstormprobizblog.org/2026/01/28/one-hundred-twenty-quadrillion-btus-and-the-need-for-coal-to-provide-at-least-20-quads-of-americas-primary-energy-part-l/
  6. Dick Storm Presentation to EPRI on the Importance of Applying the Fundamentals for Achievement of the Best Thermal Performance, Feb. 8, 2026: https://dickstormprobizblog.org/2026/02/08/the-importance-of-coal-thermal-performance-considerations-for-heat-rate-and-resiliency/
  7. Thomas J. Shepstone published version of Dick Storm article on Obtaining Best Performance from Coal Plants, Feb. 2026:  https://energysecurityfreedom.substack.com/p/look-at-the-data-the-demise-of-coal

Conclusions

• Wind and Solar are the Highest Cost Power and Cannot Meet Demand, they are a risk to national security and when a region exceeds 30% renewables and the electricity rates are the highest

• More Dispatchable Bulk Power Plants Need to be Built

• Coal, Gas and Nuclear Plants provide the lowest cost, most reliable Power over the long term

• States and Countries on Path to Net-Zero Carbon are Paying a high price

• Natural Gas Prices will likely rise in the future

• Electricity prices will rise with fuel cost as well as from inflation of components and construction costs. 

• Production prices of electricity will follow fuel cost

• A Balanced Generation portfolio is Beneficial as a Hedge Against Fuel Cost Volatility

• America should learn from the experiences of Germany, CA, Hawaii, CT, MA, ME, NH, NJ and other states with high electricity costs

• States and countries that have shut down coal plants have experienced increased electricity production costs. This is not a forecast, this is fact

Thank you for reading and

Yours very truly,

Dick Storm, February 22, 2026

References and articles for further research:

  1. America Out Loud, article: Net-Zero is NOT Affordable by the 6 Billion Living in Poverty: https://www.americaoutloud.news/net-zero-is-not-affordable-by-the-6-billion-living-in-poverty/
  2. Comparison of China and U.S. Energy Policies: https://dickstormprobizblog.org/2023/01/18/comparison-of-china-energy-electricity-generation-with-u-s-a/
  3. Duggan Flanigan and Thomas J. Shepstone, Jr. on the energy intensive production of aluminum: https://open.substack.com/pub/energysecurityfreedom/p/trump-is-saving-american-aluminum?utm_campaign=post-expanded-share&utm_medium=post%20viewer
  4. The importance of Aluminum by the Economic Policy Institute, 2021: https://www.epi.org/publication/aluminum-producing-and-consuming-industries-have-thrived-under-u-s-section-232-import-measures/
  5. The Aluminum Association: https://www.aluminum.org/PowerUp
  6. Dick Storm Blog post, “Wake Up Americans!” Sept. 21, 2023:  https://dickstormprobizblog.org/2023/09/20/please-wake-up-america-your-energy-and-electricity-generation-reliability-are-at-risk/
  7. Energy and Economic Prosperity, Talk to Delaware County Bar Association, July 2016: https://dickstormprobizblog.org/2016/07/25/energy-and-economic-prosperity-my-thoughts-dick-storm/
  8. Thomas Shepstone Published Coal Institute presentation by Dick Storm, July 20, 2025: https://open.substack.com/pub/energysecurityfreedom/p/the-unpopular-but-hard-truths-of?r=kv1a9&utm_campaign=post&utm_medium=web&showWelcomeOnShare=false
  9. Columbus, Ohio Energy Forum, ENERUM, 2022, Dick Storm presentation: Dick Storm Presentation to Columbus Energy Forum, Columbus, Ohio August 2022: : https://www.linkedin.com/posts/richard-storm-00557810_presentation-and-speakers-notes-from-august-activity-7068650158862827520-B-_W?utm_source=share&utm_medium=member_desktop
  10. Institute for Energy Research, 2023: https://www.instituteforenergyresearch.org/fossil-fuels/coal/china-and-india-burn-record-amounts-of-coal/
  11. German De-Industrialization post on the “Last Pipe” from Vallourec Factory: https://www.linkedin.com/posts/activity-7112422447580082176-MMm3?utm_source=share&utm_medium=member_desktop
  12. “Why Net Zero is Impractical and Unrealistic”: https://www.fraserinstitute.org/studies/halfway-between-kyoto-and-2050
  13. Scam of the Century, Ridding the World of Crude Oil Without a Replacement is Global Suicide”, by Ron Stein and Gregory Whitestone, July 2024: https://www.americaoutloud.news/scam-of-the-century-ridding-the-world-of-crude-oil-without-a-replacement-is-global-suicide/
  14. Are You Worried about the Future of America? Jan. 21, 2021 Thoughts on Energy Policies, Industrial and Economic Growth: https://dickstormprobizblog.org/2021/01/21/are-you-worried-about-the-future-of-america/
  15. U.S. War on Carbon Accomplishes Two Things, Weakens America, Enriches China, Jan. 30, 2021: https://dickstormprobizblog.org/2021/01/30/us-war-on-carbon-accomplishes-two-things/
  16. Blue Planet in Green Shackles, What is Endangered, Climate or Freedom”: https://wp.me/p5DzAo-nD
  17. Dick Storm presentation to the Coal Institute, July 2025, Myrtle Beach, SC. Published by Thomas J. Shepstone, Jr.: https://open.substack.com/pub/energysecurityfreedom/p/the-unpopular-but-hard-truths-of?r=kv1a9&utm_campaign=post&utm_medium=web&showWelcomeOnShare=false
  18. Australia Grid, Real Time: https://explore.openelectricity.org.au/energy/nem/?range=3d&interval=5m&view=discrete-time&group=Detailed
  19. WUWT on Power in the West by David Wojick: https://wattsupwiththat.com/2025/08/12/electric-power-fantasies-collide-out-west/
  20. Dr. Samule Furfari on Energy Additions, Not a Transition, Fossil Fuels are the Bedrock of Progress, July 2025: https://co2coalition.org/wp-content/uploads/2025/08/2025-07-Energy-Addition-Not-Transition-Fossil-Fuels-Remain-the-Bedrock-of-Progress.pdf
  21. The Very Real Costs of the War on Coal, Real Clear Energy, July 2025: https://www.realclearenergy.org/articles/2025/07/31/the_very_real_human_impact_of_coal_closures_1125990.html
  22. The Coming Electricity Reliability Crisis and the Importance of Coal, Sept. 12, 2024:  https://dickstormprobizblog.org/2024/09/12/the-electricity-reliability-crisis-and-the-importance-of-american-coal/
  23. The Kingdom of Heaven Runs on Righteousness, The Kingdom of Earth Runs on Energy, Oct. 3, 2024:  https://dickstormprobizblog.org/2024/10/03/heaven-runs-on-righteousness-earth-runs-on-energy/
  24. Charley Reese’s Last Column, “545 vs. 300,000,000 : https://dickstormprobizblog.org/2024/11/27/charley-reeses-last-column-a-classic-commentary-written-over-twenty-years-ago/
  25. Why is Western Civilization Self Sabotaging the Primary Energy that Provides 80% of the fuel for America’s Life-Blood of Reliable Electricity, with the War on Carbon?.     : https://dickstormprobizblog.org/2024/12/17/why-is-western-civilization-self-sabotaging-the-primary-energy-sources-that-provide-80-of-the-fuel-for-americas-life-blood-of-reliable-electricity-with-the-war-on-carbon/
  26. Musings on the Self-Sabotaging Energy Policies and a Reminder of the History of the Rise and Fall of Nations:  https://dickstormprobizblog.org/2025/01/13/musings-on-self-sabotaging-energy-policies-and-a-reminder-of-the-history-of-the-rise-and-fall-of-nations/
  27. The EPA “Endangerment Finding” and why it Needs to Go, Feb. 2, 2025: https://wp.me/p5DzAo-1ZW
  28. The SWAMP MONSTER vs. 300 Million Americans, Feb. 21, 2025: https://dickstormprobizblog.org/2025/02/21/the-swamp-monster-vs-the-best-interests-of-the-united-states-of-america/
  29. Thomas J. Shepstone Substack on Dick Storm’s “Primer on How to Ensure Electricity Security (and How to Destroy It)”:  https://open.substack.com/pub/energysecurityfreedom/p/a-primer-on-how-to-ensure-energy?r=kv1a9&utm_campaign=post&utm_medium=web&showWelcomeOnShare=false 
  30. Thomas J. Shepstone version of Dick Storm article Feb, 2025. Time to Revoke the Endangerment Finding”  :  https://energysecurityfreedom.substack.com/p/its-way-past-time-to-revoke-the-pseudo
  31. Existing EPA-Endangerment Rules Impact South Carolina Electricity Costs and Will Cause Rationing if the EPA Endangerment Finding Isn’t Repealed  Feb. 28, 2025: https://dickstormprobizblog.org/2025/02/28/existing-epa-rules-increase-costs-and-will-cause-rationing-of-electricity-in-south-carolina-if-endangerment-finding-is-not-repealed/
  32. Bjorn Lomberg on the High Cost of Solar and Wind, Climate Change Dispatch, Jan. 2, 2025: https://climatechangedispatch.com/wind-solar-hidden-truth-behind-rising-electric-bills/
  33. Frazer Institute, “Hot Air, Cold Truths, Bjorn Lomberg, March 2025: https://www.fraserinstitute.org/hot-air-and-cold-truths-bjorn-lomborg
  34. Delaware County Insider, Wind and Solar are Expensive, Bjorn Lomberg, May 24,  2024: https://delawarevalleyjournal.com/lomborg-the-true-cost-of-wind-and-solar-energy/
  35. Yahoo Finance and National Post, March 2025, Bjorn Lomberg, Wind and Solar are Expensive: https://ca.finance.yahoo.com/news/bjorn-lomborg-solar-wind-power-100008520.html
  36. Alabama Attorney General is amongst 22 states in appeal to return to coal for power generation revival of the Grid: https://gulfcoastmedia.com/stories/alabama-attorney-general-calls-for-reviving-americas-energy-grid-with-coal,257548?fbclid=IwZXh0bgNhZW0CMTEAAR0XeLob6rYc5WaBBtSyuB7vHctTdzVhTJxJZ96bExtALJBFoqUPAJPKaY0_aem_8TNpNEKQSIdjNrJTJeBF8Q#//
  37. Life Powered article on the Unreliability of Wind & Solar in Texas, March 29, 2025: https://lifepowered.org/reliability-standards-to-reduce-the-cost-of-wind-and-solar-volatility-in-texas/
  38. Joanne Nova on Coal Plant Approvals of the world: https://joannenova.com.au/2025/06/not-dying-global-approvals-of-coal-plants-back-up-to-2015-high/
  39. Vijay Jayaraj on the importance of energy to Developing countries: https://californiaglobe.com/fr/the-lethal-fog-of-clean-air-hypocrisy/
  40. Lars Schernikau, “Unpopular Truths” Newsletter on the decline of German Industry due to failed energy policies: https://sh1.sendinblue.com/3gvdip76f0lpfe.html?t=1744529565190  
  41. PA Pundits on Offshore Wind and National Security, Feb. 22, 2026: https://papundits.wordpress.com/2026/02/22/new-book-explores-how-offshore-wind-undermines-national-security/#like-287902
  42. Future Coal 2025: https://www.futurecoal.org/energy-security-takes-centre-stage-as-global-coal-demand-hits-record-high-in-2025/
  43.  EIA on rising electric prices: https://www.eia.gov/todayinenergy/detail.php?id=67106&utm_medium=email
  44. WUWT on the Decline of German Chemical Industries due to High Energy Prices, Feb. 4, 2025: https://wattsupwiththat.com/2026/02/04/germanys-chemical-reckoning-how-europe-is-dismantling-its-industrial-core/
  45. Thomas Shepstone and Robert Bradley, Feb. 4, 2026: https://open.substack.com/pub/energysecurityfreedom/p/tell-republican-rino-we-dont-need?utm_campaign=post-expanded-share&utm_medium=web
  46. Rafe Champion Substack on Wind Droughts in Australia:
    https://rafechampion.substack.com/p/defusing-the-wind-drought-trap
  47. South Carolina Legislation to force Electric Utilities to a path of Net-Zero Carbon:
    https://www.scstatehouse.gov/sess124_2021-2022/bills/3194.htm

    “As required by S.C. Code Ann. §58-37-40(A)(4)(c), Santee Cooper has evaluated a Net Zero CO2

Coal Power, economic prosperity and energy, Energy, Politics and Economic Prosperity, Regulations

The Importance of Coal: Thermal Performance Considerations for Heat Rate and Resiliency

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The thermal performance of the existing coal fleet can be improved by applying proven and reasonable cost mechanical tuning solutions. Coal power generation has many advantages when done with excellence in operations and maintenance. This article is based on my presentation to the EPRI Heat-Rate Conference last week and it is written for experienced electric power generation professionals, thus this is somewhat technical. The purpose is to show both the importance of coal power and to highlight some of the opportunities to improve coal plant thermal performance.

First, Apply the Fundamentals!

Our approach to coal plant performance improvement has always been: First apply the fundamentals which we refer to as the 13 Essentials for Optimum Combustion and the 22 Boiler Controllable Heat-Rate Variables. More on these later. After these have been applied, then consider modifications and upgrades of bottlenecking components.

The charts of coal use in the world below highlight the absolute importance of coal power as a major source of primary energy. Paraphrasing Mark Twain’s comment on seeing his Obituary, and applying it to coal: “The reporting of the demise of coal has been greatly exaggerated”...

Coal Remains Vital as a Source of American Primary Energy

Some of us nuts and bolts practical engineers knew the importance for coal fuel to meet the demand of last week’s winter storm. The U.S. Grid Dashboard helped document that need. However, this seems new to many academics and government policy makers.

In fact, here is the U.S. electricity generation by fuel for January 30th. Note that coal is shown generating 128,526 MW. This is about 22% of the total generation. During this cold period, this is a very important 22% of Dispatchable and affordable generation.

Coal powered well over 60% of the low country of South Carolina last week. To be fair, SCPSA owns about 322 MW of Summer nuclear plant and that power is not shown on the display below. Like many areas of the U.S. coal, nuclear and gas provided over 80% of the total electricity generation.

The chart below is a screenshot of MISOENERGY. For this region, coal was over 39% during winter storm Fern.

Coal literally saved the Grid during winter storm Fern. And, nearly all of the expert forecasts of electricity Demand show about 100,000 MW of new generation needed by 2030. So, my question is, why aren’t new base load coal plants under construction right now?

The charts above show the importance of coal as recent as last week. However, the Deep State Bureaucrats, NGOs. state Legislatures (including red states like S.C.) and much of the public still resist facing the energy reality that coal offers many advantages for at least the next two decades. Well, let’s move on to getting the best performance from the existing coal fleet by first, applying the fundamentals!

Getting the Inputs Right

Achieving excellence in operating a coal plant takes hard work and vigilance of paying attention to the details. Rankine plants are tough, resilient and forgiving but when attention is paid to the details it can make a huge difference in heat rate. Here is a typical spread of plant efficiencies as performed by an NETL study. 

This is old timey data but, in my experience, it represents the spread between the Best Run and those that are run with Mediocrity. The chart below is from Electric Light and Power, Nov./Dec. 2014. This shows the top 20 Rankine Cycle coal plans for the year 2013. Net Heat-Rate for that year. Excellence in O&M as well as design. Notice, Turk Plant at the top of the list. More on Turk later.

I  coauthored an article in POWER Magazine with Dr. Robert Peltier entitled, “How Stealth Losses in Combustion Can Lower Efficiency”. This article was based on experiences and proven results. It has been shown that by excellence in O&M, Heat-Rates can be influenced by as much as 1,200 BTU/kWh. Later a couple examples will be shown where the magnitude of 500 BTUs/kWh in Heat-Rate improvements were achieved by applying the 13 Essentials and the 22 Boiler Controllable Variables. This was accomplished by testing to identify the opportunities and then correcting them. Most of the improvements have been through optimizing primary airflow, improving coal fineness, correcting air in-leakage and reducing upper furnace exit gas temperatures (FEGT). The reduced FEGT then improves thermal performance by reducing S.H. and R.H. de-superheating spray water flow and reducing cycle losses from soot blowing.

Getting the Inputs Right!

The first step to optimizing combustion and heat rate, is to apply the 13 Essentials. All 13 are important, but nine of the 13 are pulverizer, fuel and fuel line related.  This list of 13 essentials is the best and most important single document for optimizing combustion on a large PC Fired Utility Boiler. I am dead serious. These are NOT optional for a pulverized coal fueled boiler.

Some of the most common opportunities for improvement that we have found and then corrected for mechanical tuning with great results are:

  • Pulverized coal fineness
  • High Primary Airflow
  • High FEGT due to secondary combustion
  • Air In-Leakage
  • Air Heater Leakage
  • Fuel line imbalance
  • Secondary air imbalance
  • Burner tuning optimization

I know that there are other combustion tuning and controls manufacturers believe that airflow management to different zones of the furnace is not important, However, it is our experience that airflow management is in fact, crucial. We know from experience that these do work very well and where we have implemented the 13 Essentials they have always created a positive result for improved efficiency, reduced slagging, less tube metal overheating, best NOx performance, improved ESP (Electrostatic Precipitator) performance and more.

The correction of these individual items then complement each other to provide synergy which compounds the improvements. Such as: Reducing high primary airflows will usually result in better fineness, lower flyash carbon in ash losses, reduced upper furnace gas temperatures (FEGT), reduced sootblowing, less de-superheating spray water flows and reduced dry gas losses as a result of lowered tempering air flows. When all 13 Essentials have been earnestly applied and the O&M Team bought in on constantly maintaining them with vigilance, good RESULTS have been achieved. I will provide a couple examples later in this discussion.

The potential improvements and the synergism between them is shown on the chart below to show how about 600 BTUs/kWh in Heat-Rate can be achieved by focusing on boiler and combustion optimization. The data and examples shown have been proven in full size coal power plants and in at least one complete Utility that adopted the approach over a several year period.

Here is a figure which shows several of the most important “Essentials” of optimum combustion. Key to best coal fineness, best airheater “X” Ratio, fuel balance and good reliability is, a repeatable and optimized Primary air curve. An example of a preferred primary airflow ramp is shown below.

Pulverizer performance is important and it has been our experience, that unless pulverizers are undersized, the fineness and fuel distribution can be corrected to within the parameters of 75% passing 200 mesh and 1.8 #air/#fuel and +/- 10% Fuel line balance. Truly, the pulverizers are the heart of a PC fired boiler.

One of the simplest tests to ascertain whether high carbon in ash is due to combustion issues or pulverizer performance is to run a three-part flyash carbon in ash test. First, obtain a representative ash sample and pass a measured quantity through a 200 mesh sieve. Then measure the LOI (Loss on Ignition) of the coarse and fine particles. If most of the carbon loss is in the coarse particles, then the high loss due to carbon in ash is pulverizer performance related. If high LOI in the fine particles, then fuel balancing, air balancing or high post combustion air in-leakage is the problem. I am not one to promote shortcuts, but this is an easy test to conduct and it is very informative with regard to combustion performance and pulverizer performance. However, the flyash sample MUST be Representative!

Stealth Heat-Rate Losses

Stealth heat rate losses are those losses in Rankine Cycle efficiency due to controllable losses, some are located at the Boiler Island. Here is a list of 22 Controllable Losses that are controllable by optimization of the steam generator and combustion system performance.

Application of these practical steps have been accomplished on numerous single units and on several total utility systems. All Utility boiler furnace exit gas temperatures should be in the range of 2,150 degrees F. to 2,,300 degrees F. Often, the first indication of a problem is in the use of an HVT probe with a 310 ss radiation shield and the metal and thermocouple literally melt. The melting temperature of 310 ss is about 2,900 degrees F.  The pre-requisite for achieving good furnace performance is to apply the 13 Essentials as covered above and when the are, lower FEGT’s are attainable. (FEGT=Furnace Exit Gas Temperature)

The stealth losses compound together because of poor furnace combustion, this leads to flame quenching, overheated S.H. and R.H. tube metals, high S.H. and R.H. spray water flows, higher exit gas loss, slagging and fouling, increased draft loss, increased sootblower operation and consequent cycle steam losses, increased fan horsepower and carbon in ash losses. These seemingly small, individual issues when corrected, compound to create significant heat rate improvements as will be shown later. Never underestimate the adverse impact of poor pulverizer performance on overall unit Heat-Rate!

High primary airflow contributes to poor coal fineness, higher FEGT, increased NOx, high metal temperatures in the S.H. and R.H., requires increased soot blower operation, fouls the convection pass, air heater and SCR and much more. High primary airflows are very commonly found by our test teams. One of the most frequent opportunities for improvement.

Non-optimized combustion then creates Rankine cycle Thermodynamic losses through increased de-superheating water spray flows. The R.H. sprays are particularly harmful to Heat-Rate.

Case Studies of Large Utility Steam Generator Successes

Here is an example of a 450 MW 2400 psi/1000/1000 unit which has a design best heat rate of about 9,200 Btus/kWh. In this case study the 13 essentials were applied but these alone did not correct the high FEGT. To correct secondary air imbalances windbox baffles and perforated plates were installed in the burner inlets. These secondary airflow system changes corrected secondary air maldistribution. The result was about a 300-500 Btu/kWh heat rate improvement. 

However, the largest economic gain came from improved fuel flexibility where lower cost coal with a lower fusion temperature could be burned and this provided better generation economics and increased load factor operation, which also helped to achieve a better heat rate from the increased operational hours at higher loads.

The next case study is a 600 MW class 2400/1000/1000 unit in northern Kentucky. The heat rate was about 1,000 Btu above achievable. Again, first step was the application of the 13 essentials for combustion optimization. But also, a very effective team effort was organized by the plant manager to place priority on all of the heat rate factors on the steam generator and all of the balance of plant. Including the condenser cleaning and cooling tower fill corrections.

The results of the coordinated efforts of the operations and maintenance team plus the heat-rate engineer and Storm Technologies testing, resulted in a step change in heat rate improvement of about 800 Btus/kWh. The primary pre-requisite for this success was TEAMWORK! All of the O&M Team bought in on the approach and the end result was extremely gratifying to all.

The main factors in this unit’s success were: Pulverizer optimization, fuel balancing, optimized primary airflow program (reduced PA flows), secondary air balancing, correcting air in leakage, correction of cooling tower fill problems, reducing secondary combustion, reduced high spray flows, reduced soot blower operation, reduced air preheater leakage and reduced system losses. 

The typical opportunities that are found are worth about 600 Btus/kWh in heat rate improvement. Here is a breakdown of where these opportunities are typically found:

A frequently found opportunity is air in-leakage. Especially on older boilers.  Any air that enters the boiler setting without passing through the air preheater, constitutes a Dry Gas Loss. Also, if it is large enough, can contribute to secondary combustion due to low furnace oxygen content, upper furnace secondary combustion and high FEGT’s. 

The air preheater is the last heat trap on 99% of all the coal plants we have worked. Improving the performance or ultimately replacing the air preheaters with newer, reduced leakage and higher efficiency preheaters can drastically improve overall unit performance.

For older plants and especially those that have poor performing air preheaters such as the Rothemuhle type, then installing an upgraded new air preheater can provide a step change in improved performance. 
It is my hope that New Source Review and any other restrictive Regulations against modifications to improve performance are gone forever. 

Another upgrade option is to change the superheater and/or Reheater surface areas for optimum steam temperatures and overall performance. Also, possible changes in tube lane spacing, sootblower lane erosion protection and upgraded higher alloy tubing.

America’s last new coal plants went into service over a dozen years ago. Three of the newest and highest efficiency units are Duke’s Cliffside, AEP’s Turk and Kansas City Gas and Electric’sIatan. All of these are supercritical and capable of heat rates of about 8,300-9,000 Btus/kWh. About 38-41% thermal efficiency. https://www.powermag.com/plant-of-the-yearkcpls-iatan-2-earns-powers-highest-honor/
The Europeans, Japanese and Americans advanced the state of the art for Rankine cycle plants to approach 42% thermal efficiency. These improvements were in steam turbines, steam generator design and metallurgy. Then, we stopped building coal plants. The Chinese, on the other hand, had the advantage of applying all of the improvements that the west had achieved and then they kept on working to advance the state of the art even further. Indeed they have approached 50% thermal efficiency with their coal plant designs.  However, the Chinese plant Heat-Rates are reported on a fuel LHV basis. To be a fair comparison to the Best units in America, such as Turk or Cliffside the efficiencies should be based on the fuel HHV. These Chinese units (and Turk and Cliffside)  have been featured in Power Magazine.

The American advancement of coal plant design in the modern age, for the best thermal efficiency possible, began with the Eddystone Unit # 1 designed in the 1950’s.

Quest for Improved Thermal Efficiency

In my personal experiences, I began my career in the power industry in 1962. This is when Philadelphia Electric’s Eddystone Station was new. Eddystone started up in 1960. At that time, this was the most efficient power plant in the world. Steam conditions were at throttle pres. 5,000 psi 1,250 degree Superheat and two stages of Reheating at 1,050 degrees F. The design Heat-Rate from 1950’s technology was 8230 Btu/kWh or 41% thermal efficiency.  Since that time, America’s coal fleet has held pretty steady for the “Best” coal plants. Eddystone was the “Best” in 1960 at 41% Thermal efficiency. The most recent U.S. Ultra-supercritical plants, Turk, Cliffside and Iatan are capable of about the same efficiency as Eddystone was. However, I should mention that today’s clean coal plants use much more auxiliary power to drive the Flue Gas Cleanup equipment. FGD, SCR, ESP’s, Baghouses etc. These were not yet invented when Eddystone started up and therefore were not installed at Eddystone. For new plants such as Turk to achieve similar thermal performance with the backend environmental cleanup gear represents a true advancement in the state of the art.

The above chart shows the Thermal Efficiency progress of heat engines, since the days of Edison, Tesla and Westinghouse. As can be seen on the chart, the U.S. gas turbine fleet has progressed amazingly well and has reached design capabilities of over 60% thermal efficiency.

At the end of my EPRI presentation I showed the POWER Magazine information on the Chinese Pingsham, Phase ll coal plant that is advertised as being nearly 50% efficient. This is based on steam conditions of 4,500 psi 1100 degrees F. steam temperatures with two stages of Reheat at 1100 degrees F. (close to Eddystone #1)
The EPRI Heat-Rate Conference is a technical meeting and the people in attendance are very sharp. It was quickly pointed out that the efficiency attributed to Pingsham ll of 49+% is based on fuel LHV and not HHV. Thus, the performance of Pingsham is just a couple points above the AEP Turk Plant in Arkansas. The John Turk Ultra-Supercritical coal plant went into operation in 2012 and is about 39% efficient. The steam conditions at Turk are: 3500psi throttle, 1100 degree S.H. and 1100 degree Reheat. Design Heat-Rate of Turk is 8730 Btus/kWh (39% Thermal efficiency)

My point is, the Chinese have taken advantage of all of the engineering and operational experiences gained in the U.S. and Europe and built on these developments, experiences and knowledge to provide further advancements. Even though modest, the newest Chinese coal plants are in-fact more efficient than the U.S. newest coal plants. The Turk coal plant was started up in 2012 and only one other since then.  Duke Cliffside #6, 2013, which is similar overall efficiency as Turk. Another outstanding coal plant of high efficiency, built around the same time is the Prairie States Plant in Illinois.
Another point is the fact that the EPA restricted efficiency improvements for about 30 years. That is, if a U.S. coal plant implemented improvements to increase efficiency, they would be severely penalized. Now, with an energy friendly administration, the EPA “New Source Review” Rule, should not be a deterrent to implementing performance and even capacity improvements. In my view, the existing U.S. coal fleet should be capable of being upgraded in capacity, reliability, fuel flexibility and efficiency. In my Power Magazine article published in 2009, I showed several examples of plants that could be improved with new S.H. surfaces, larger fans, upgraded pulverizers and modifications such as these. The word “Upgrade” is or at least should not, be a dirty word.

The Demise of Coal Has Been Drastically Exaggerated

Borrowing Mark Twain’s quote on the premature posting of his obituary, coal is needed, it is being widely utilized and it will not be easily replaced as a form of primary energy. Here below is a chart of electricity generation 2000-2023 from the G-20 nations presented by EPRI. Electricity generation from all fuels has steadily increased and will accelerate the electricity growth during the next 20 years.

As mentioned above, the U.S. worked hard at advancing thermal power generation efficiency. Gas turbines and combined cycle plants have made great progress. However, the war on coal stopped American progress for improving coal plant efficiency which effectively stopped in 2012. On the other hand, China continued to improve coal plant efficiency. Here below is one example of applied excellence in obtaining coal plant efficiency. I should point out that the 49+% Thermal Efficiency is based on the fuel LHV. Still, a commendable effort and results to achieve overall thermal performance in the high 40’s% is the Best I am aware of.

Coal: America’s Treasure of Primary Energy, Why Not Use it?

Coal power has at least a dozen solid advantages for electricity generation. Winter Storm Fern during the week of January 30, 2026 proved the importance and resiliency of coal plants. Even older plants that have not had the optimal maintenance once practiced. For reference, here is my list of the top dozen reasons that coal power is important.

Another important reason for new coal plants is that to provide the future demand in electricity growth, it is the most viable sources of primary energy to be utilized. I wrote on this before here and here. The electricity growth forecasts all show increases of about 100 GW needed by 2030 and about 800 GW by 2050. This is a lot of power and not easily built in 25 years. For example, the Roxboro coal generating station is four units and is capable of about 2400 MW when it is in top condition. Here is a photo of Roxboro Generating Plant. The first unit started up in 1966 and the newest one about 14 years later. Over 16 years of duration from the first contract signing till the 4th and last unit became commercial. Picture building 40 plants like this in four years to achieve the needed 100 GW of new Dispatchable generation by 2030. We can hope and wish. Sadly, the limitations of the Supply-Chain of manufactured components and craftspersons make this an impossible task today.

So, what are the alternatives? Here is my view of what it will take. Nuclear is loved by everyone today. However, it took Southern Company about ten years to build Vogtle 3&4 which is about 2,200 MW of new Base Load capacity. This is a great plant, now the largest nuclear plant in the U.S., but building 14 of these each year just doesn’t seem plausible.

Conclusions

Thank you for reading this. There are numerous additional articles listed below in the references.

Yours very truly,

Dick Storm, Feb. 7, 2026

The words “Modifyand Upgrade” re dirty words with the EPA for about 30 years. Thanks to a misguided EPA the U.S. existing coal plants were forbidden to be upgraded in any way other than back end environmental emission eqpment installation. Now, the EPA-NSR should no longer be a fctor. References and for further reading:

1. POWER Magazine article on “Correcting Stealth Losses in Large Coal Power Stations”: https://www.powermag.com/how-stealth-combustion-losses-lower-plant-efficiency-part-1-the-problem

2. Power Magazine, To Optimize Performance, Begin at the Pulverizers: https://www.powermag.com/to-optimize-performance-begin-at-the-pulverizers/

3. Power Magazine, Finessing Fuel Fineness: https://www.powermag.com/finessing-fuel-fineness/

4. Power Magazine, Managing Airflow to Optimize Performance:  https://www.powermag.com/managing-air-to-improve-combustion-efficiency/

5. Power Magazine, To Optimize Performance, Begin at the Pulverizers: https://www.powermag.com/to-optimize-performance-begin-at-the-pulverizers/

6. POWER Magazine, “What if New Source Review Was Repealed”: https://www.powermag.com/what-if-new-source-review-were-repealed/

7. Reasons Why New Coal Plants Should be Built in America: https://dickstormprobizblog.org/2026/01/28/one-hundred-twenty-quadrillion-btus-and-the-need-for-coal-to-provide-at-least-20-quads-of-americas-primary-energy-part-l/

8. Dick Storm blog on the advantages of Coal Power: https://powerfortheusa.com/2025/12/21/advantages-of-coal-fuel-for-electricity-generation/

9. Master Resource Blog: https://www.masterresource.org/heartland-institute/joe-bast-nyt-1999/

10. POWER Magazine article on Pingsham ll : https://www.powermag.com/chinas-pingshan-phase-ii-sets-new-bar-as-worlds-most-efficient-coal-power-plant/

11. ASME Engineering Milestone Historical review of Eddystone #1 325 MW Ultra-supercritical Power plant: https://www.asme.org/wwwasmeorg/media/resourcefiles/aboutasme/who%20we%20are/engineering%20history/landmarks/226-eddystone-station-unit.pdf

12. SWEPCO Fact Sheet on John Turk Plant: https://www.swepco.com/lib/docs/community/projects/TurkPowerPlantFactSheetrev3-21-13v3.pdf

13. POWER Magazine article on John Turk Coal Plant, 2013: https://www.powermag.com/aeps-john-w-turk-jr-power-plant-earns-powers-highest-honor/

14. POWER Magazine article on Iatan #2 Coal Plant, 2011: https://www.powermag.com/plant-of-the-yearkcpls-iatan-2-earns-powers-highest-honor/

15. POWER Magazine article on Duke Energy Cliffside Coal Plant:  https://www.powermag.com/cliffside-steam-station-unit-6-cliffside-north-carolina/

16. POWER Magazine, Top Plant, Prairie State Top Plant 2013: https://www.powermag.com/prairie-state-energy-campus-washington-county-illinois/

17 . Thomas J. Shepstone on Substack which Published article on the Enormity of 100 Quadrillion BTUs: https://open.substack.com/pub/energysecurityfreedom/p/the-enormity-of-100-quadrillion-btus?utm_campaign=post-expanded-share&utm_medium=web

18. Stu Turley, Energy News beat on Grid Risks, Feb. , 2026: https://theenergynewsbeat.substack.com/cp/186686693

19. EPA New Source Review settlements: https://www.gem.wiki/EPA_Coal_Plant_Settlements

20. EPA Settlements on NSR violations by WEPCO 2003: https://www.epa.gov/enforcement/wisconsin-electric-power-company-wepco-clean-air-act-civil-settlement 

21. Dissertation on the Sierra Club Success of Beyond Coal Campaign 2020: https://www.proquest.com/openview/b734be1b4fa402463fbb2ee03a7993e5/1?pq-origsite=gscholar&cbl=18750&diss=y

22. Inside the War on Coal Politico, The Agenda 2015: https://www.politico.com/agenda/story/2015/05/inside-war-on-coal-000002/