Category Archives: Personal Experiences of Coal Plants and Industrial Expansion

The Era of Reliable, Affordable, Energy and Electricity Generation: Part 1

This is my Perspective of Proven, Reliable, Affordable & Abundant Energy & Electricity Generation during my lifetime. Here are some of the significant technical advances, changes, regulations, incidents, events and policies that have shaped energy and power generation over the last eight decades. Some personal experiences are interjected during this era just to show where I am coming from in my perspective. Part 2 will cover my thoughts on the impossible transition to renewables.

A Brief History of the Improved Quality of Life Since WWII

Dr. Euan Mearns wrote in WUWT this short summary of the history of energy and the “Energy Transition as Social Vandalism”(19). An excerpt from the concise and well written essay:

“The mid 19th century also saw the development of early internal combustion engines, although at that time there was insufficient fuel for a motor industry. The Spindletop gusher and subsequent discoveries changed all that. The world was now awash with oil without any real market. Then in 1908, Henry Ford rolled out his Model T to begin the age of the car and mass transit. The Wright brothers’ first powered flight in 1908 led quickly to commercial air travel and eventually to the jet age.

Unparalleled development came with the 20th century and the introduction of nuclear power plants whose uranium fuel contains more than 16,000 times the energy content of coal, oil and natural gas. At the same time, hydroelectric power rapidly expanded and natural gas (the most energy dense of the fossil fuels by mass) became more available for electricity generation and home heating and cooking.

The introduction of gas-fired central heating enhanced the well-being of populations. Whole homes would be heated by hot-water radiators, and no longer would families have to huddle round a dirty coal fire. By 2000, life expectancy in world population had risen to 66 years, 78 years in the now developed countries.”

Looking back, I am awed by the progress that was made for the Betterment of the quality of life for Humankind. I am proud of my small contributions along the way.

Some of the Significant Energy & Electricity Mileposts: 1940-2023

  • Pulverized coal firing for steam generation becomes the predominant method of power generation
  • Mechanical dust collectors are used for collection of particulates
  • 1941 B&W invents and develops Cyclone Burners to fire low fusion midwestern coal with more than 70% of the ash collected as a molten smelt
  • 1943 Combustion-Engineering invents and develops Tilting Tangential Firing
  • Electrostatic precipitators are applied to large coal plants
  • 1949 First G-E Gas Turbine for electric power generation in the U.S. installed at Oklahoma Gas & Electric Belle Isle Plant
  • 1951 U.S. Navy Admiral Rickover obtains funding from Congress to build the first nuclear powered submarine, Nautilus
  • 1953 President Eisenhower’s “Atoms for Peace” initiative
  • Supercritical pressure steam generators become common place
  • 1955 USS Nautilus puts to sea
  • 1955 First “Atoms for Peace Conference” in Geneva
  • Steam temperatures and power generation from Rankine cycle steam plant efficiency approaches 40% design efficiency
  • 1957 Shippingport Nuclear Steam System, the first U.S. Commercial Reactor is proven
  • 1957-59 Philo and Eddystone Ultrasupercritical Units are placed in service
  • 1970 – President Nixon signs law to form EPA
  • Coal pulverizer state of the art advances to single pulverizers with over 100,000 pounds per hour capacity
  • 1973 First Oil Embargo
  • 1977 U.S. Department of Energy is formed with the intention to lead America to energy independence
  • The Strategic Petroleum Reserve is begun
  • 1978 EPA Clean Air Act
  • 1978 President Jimmy Carter signs Energy Policy Act
  • 1979 Three Mile Island Incident
  • 1980 Energy Security Act
  • 1988 G-E Single Cycle Aeroderivative Gas Turbine achieves 41.9% efficiency
  • 1990 EPA-Clean Air Act Amendment
  • 1991-First Horizontal Drilling by Enid Company in OK
  • Low NOx Burners or other NOx reduction systems are installed on most coal plants across the U.S.
  • Flue gas desulfurization becomes standard for coal plants
  • Selective Catalytic Reactors are used to reduce NOx
  • 2010 Hydraulic Fracturing combined with Directional Drilling by Harold Hamm’s company greatly increases shale gas production in ND
  • 2012 The Shale Gas Revolution produces natural gas at lower cost/million Btu than coal
  • 2014 CCGT (Combined Cycle Gas Turbine) units achieve over 60% efficiency
  • 2018 G-E CCGT (Combined CycleGas Turbine) Reaches 64% Efficiency
  • 2020 Natural gas electricity generation provides over 38% of U.S. electricity production
  • 2022 U.S. Congress passes IRA Law and Biden signs, it codifies green energy

Reasonable Cost Energy & Electricity Improves Quality of Life

This is a personal story of electricity generation. Here is my take on how “Living Better Electrically” came to be, during my lifetime. Here is a typical TV ad from circa 1962, the year I entered the workforce.

Electricity Generation 1962-2012 Living Better Electrically

This 50 year period was my personal career, most of which I spent working in the electric power generation business. Including equipment design, manufacturing, startup, testing, operations, maintenance, emissions reduction and upgrading of coal power production equipment. My specialty was large electric utility fuel burning and steam generating equipment. Upon graduation from Williamson in 1962 I was employed as an electrician then as a utility engineer at Mobil Oil Corporation. In 1966 I joined Babcock & Wilcox working in Barberton, Ohio as a Technical Assistant to the Project Engineer in the Nuclear and Special Projects Department. Projects that I worked on as part of the B&W team were the Duke Oconee Nuclear Steam Systems, numerous reactors, steam generators and pressurizers for Navy Nuclear Propulsion Systems and large heavy walled, high pressure, pressure vessels for the Petrochemical industry.

Duke, Oconee #1 Reactor Vessel at B&W Shop in Mt. Vernon, Indiana, from Duke Annual Report 1967

In the 1960’s electricity was very reasonable in cost and nuclear power was proclaimed by the AEC Head (Atomic Energy Commission) Lewis Strauss as soon to be “Too Cheap to Meter”. Commercial nuclear power generation had been proven at Shippingport and was growing exponentially in applications all across the country. The two most memorable engineering leaders that I remember visiting B&W’s Barberton facilities (while I worked there) were Admiral Rickover, the Father of the nuclear Navy and commercial nuclear power generation and Bill Lee, who at the time, was Duke Power Company’s VP of engineering. Mr. Lee was said to have favored the B&W Nuclear Steam System because it was slightly more efficient with the Once through Steam Generator providing a small amount of superheat that competing NSS (Nuclear Steam Systems) did not provide, to the steam supply to the turbine. Duke Power at the time, had commissioned some of the most efficient coal plants in the world and planned to extract the highest possible efficiency from their first nuclear powered steam supply system. This was logical to Mr. Lee and one reason he was attracted to the new B&W OTSG (Once Through Steam Generator) which was designed for a few degrees of superheated steam temperature. My previous blog post discussed the B&W, C-E and Westinghouse nuclear power manufacturing facilities here.

The Most Efficient and Largest Supercritical Coal Power Plants Built 1957-1975

The 1960’s were exciting times for coal fueled power plants too. Two Milestone supercritical power plants were built and started up during this time. The 5,000 psi Eddystone Steam Station (Philadelphia Electric) with a steam generator built by Combustion Engineering and the 4,700 psi Philo Plant (AEP) steam generator was built by Babcock & Wilcox.

Soon after these magnificent accomplishments was the 900 MW Combustion Engineering series of supercritical steam generators at Conemaugh & Keystone plants in western PA. Then the 1,300 MW supercritical steam generators built by B&W for AEP and TVA. Certainly impressive to me at the time with furnaces over 100 foot wide and operation at over 3,500 psi with superheated main steam at 1,000 degrees F. and also Reheated steam supply to 1,000 degrees F.

Duke Power designed, installed, operated and maintained the most efficient coal plants in the world with the additions of Marshall Units 3 & 4 on Lake Norman in 1969 and 1970.

Later, the Belews Creek coal plant was installed and between Marshall and Belews Creek competed for the highest efficiency coal plants in the U.S. Belews Creek Steam Station is a 2.24-GW, two-unit coal-fired generating facility located on Belews Lake in Stokes CountyNorth Carolina. It is or was  Duke Energy’s largest coal-burning power plant in the Carolinas and when it was operated on coal it ranked among the most efficient coal facilities in the United States. During 2006, it was the fifth most efficient coal power plant in the United States with a heat rate of 9,023 Btu/kWh (37.8% conversion efficiency). In 2008, it was the #1 most efficient coal power plant in the United States with a heat rate of 9,204 British thermal units per kilowatt-hour (2.697 kWh/kWh) or 37.1% conversion efficiency.

A Few of My Personal Experiences with Coal Plants in the 1970’s

My first foray into S.C. was as one of three startup engineers for the SCE&G Wateree coal plant in Eastover, SC. This is a coal fueled, two unit supercritical steam supply plant which uses two Riley Stoker supercritical steam generators. These are the only two supercritical steam generators built by Riley. They have been very successful and in fact, at this writing are still in service 53 years after the startup of Unit #1. After that in 1972 I was assigned as lead startup engineer at the 420 MW Sutton Unit #3 near Wilmington ,NC. This plant is shown below during steam line blowing in June 1972. Steam line blowing was one of my favorite activities in the startup of a new plant. The roar of the exiting steam at supersonic velocity was memorable and provided a sense of the enormous power of steam. Steam line blowing is a one time startup operation to remove grit and foreign debris from inside the superheater and reheater tubes and piping, so that when operation begins, solid particles of debris will not damage the steam turbine blades.

Following the startup of Sutton #3, in January 1973 I joined Carolina Power and Light Company as a senior engineer. My first assignment was as the lead startup engineer on Roxboro Unit #3. This is a 720 MW coal Unit with a unique design of two half capacity boilers and one common feedwater supply train with a blended single stream steam supply to one G-E 720 MW turbine rated at 2,400 psi 1,000 degree F. Superheat and 1,000 degree F. Reheated steam to the last 13 stages of the turbine. The Roxboro plant is shown below in a recent photo by Duke Energy. This plant was started up as CP&L and was later absorbed to be part of Duke Energy.

Reasonable Cost, Abundant, Reliable and Dispatchable Coal and Nuclear Provide the lowest Cost Electricity in the World

The Roxboro plant is still in operation and it is rated at 2462 MW generation capacity. Let me digress with a short anecdote. Back in the time frame of about 1975 I was involved in an ASME meeting in Niagara Falls, NY. As part of the group, we were given a tour of the Niagara Falls Hydro plant on the U.S. side of the river downstream of the falls. I was struck at the time with the realization that all of the water feeding several of the Great Lakes provides (on the U.S. side) about the same generation capacity as the Roxboro Thermal Plant did. A real world lesson in “Energy Density”. Roxboro’s four units are rated 2,462 MW, the Robert Moses Hydroelectric plant 2,300 MW. This comparison is one I find helpful when non-energy trained people ask why are coal plants necessary? It helps to explain the enormous energy density of a coal fueled power plant.

Niagara Falls, Robert Moses Hydroelectric Plant, about five miles downstream of Niagara Falls, From NY Power Authority website

Fuel Diversity Helps Keep Costs Down, All Fuels Are Important

I joined Riley Stoker in 1969 and worked at Tampa Electric on the final acceptance work of the Gannon Station Units 5 & 6. Then on to the SCE&G Waterree plant for the startup of Riley’s first and only supercritical steam generator. Wateree is still running today and it was very successful. After startup of Wateree #1, I was sent to the City of Lakeland, Florida to finish the startup of the 80 MW oil and gas fueled Power Plant #3 (now named McIntosh) The unique and difficult design of this unit was that it was a stand alone, single unit with no steam connections to another unit. It was fueled by heavy oil, #6 or also known as Bunker C. The oil required heating to about 220 degrees F. to reduce the viscosity for satisfactory atomization and complete burning in the furnace. Because there was no gas or steam connections, the startup entailed firing on Diesel fuel until the boiler had at least 1000 psi drum pressure. Then the stored energy of the boiler would be used to heat and circulate oil from the Heavy oil supply tank. It sounds simple enough, however when the new controls and safety interlocks were all in startup mode, unproven and with numerous glitches, steam pressure would be lost and the operation on diesel fuel would need to be repeated. Any field engineer with experience in oil firing Utility boilers knows the importance of steam or compressed air cleaning of the Ljungstrom regenerative air heaters to prevent fires. That is the reason I was sent to Lakeland. The previous startup engineer was not careful about airheater cleaning and both airheaters were destroyed by fires. I was sent to replace that unfortunate startup engineer.

Oil firing was common in the 1970’s because it was competitive with coal at $0.50/million Btu. After Lakeland I was sent to lead the startup of Jacksonville Electric Authority’s Northside #2. A 325 MW heavy oil fueled boiler. Then off to CP&L Sutton #3, a 420 MW fueled at startup with heavy oil and with provisions for future coal fuel. America’s power demand was rapidly growing, especially in the south where air conditioning and heat pumps were taking off in popularity. As I recall peak load growth was about 10% per year. To illustrate the rapid growth in electric demand, here is my recollection of the units added at CP&L over a five year period:

  • Robinson #2, 700 MW, 1970 (Nuclear)
  • Asheville Unit #2, 200 MW, 1971 (coal)
  • Sutton Unit #3, 420 MW , 1972 (coal/oil)
  • Roxboro Unit #3, 720MW, 1973 (coal)
  • Brunswick Unit #1, 836 MW, 1975 (nuclear)

During this time period (1970-1977) CP&L was a regional Utility separate from Duke Energy. The total installed capacity of CP&L back during this time was about 6,000 MW. Therefore, the rapid system load growth is illustrated by the addition of five generating units totaling 2,876 MW in generation capacity in just five years. It was a great time to be involved in the power industry… And then came the Oil Embargo and some difficult times for the industry.

City of Lakeland, Power Plant #3, Now there are three Units, including a 360 MW coal unit #3. Picture by Dick Storm about 1971

During 1973 the U.S. government supported Israel in the Yom Kippur War between Israel and the Arab nations.

At the time of the first oil embargo, 1973-1974, the EPA had been creating needed air pollution rules to reduce emissions from coal fueled power plants. Amongst the first pollutants to be addressed, was particulates. Before the Oil Embargo coal cost and oil cost per million Btus was about the same, right at $0.50 per million Btu. Therefore to reduce emissions fast, Utilities had an economic choice of converting coal plants to oil fuel which has nearly zero ash content or install millions of dollars of backend equipment, including electrostatic precipitators. Carolina Power and Light Company took the path of installing electrostatic precipitators on the newest units (Asheville #2, Sutton #3 and Roxboro #3) and converting the older, smaller coal units to being fueled by oil. Many utilities to the north, including VEPCO, PEPCO, Philadelphia Electric and others, chose the fuel oil conversion route to reduce particulates with less capital cost than installing electrostatic precipitators. This could be done with much lower costs to the consumer because the coal and heavy oil costs were about the same on the fuel cost/million BTU. About $0.50/mmb. Fuel cost is the largest single component of electricity production cost. Comprising between 75 and 92% of the production cost. Thus, when fuel costs escalate, so does the electricity production cost increase.

The Oil Embargo made an immediate fuel supply shortage for all petroleum products and including residual #6 heavy fuel oil. This is when, in my recollections, that major “Wheeling of Power” across state lines became common. The Utilities in the states to the north of CP&L were; VEPCO, PEPCO, Delmarva and Philadelphia Electric. They could receive coal generated electricity from Duke Power, CP&L and other southern Utilities across state lines using existing Transmission interconnections by wheeling power. This was before RTO’s (Regional Transmission Operators) were created.

The 1973-1980 time frame was difficult for Utilities and some had to cut once reliable dividends to stockholders and some went Bankrupt (Consolidated Edison in NY had a particularly difficult time) due to the volatile fuel costs.

National Energy Act of 1978

The energy shock of the oil embargo prompted Congress and the President to act on energy policy. Also during this time the Alaska Pipeline was approved and built(15). Jimmy Carter signed the first Energy Act in 1978.

America’s electricity supply has remained reliable and of reasonable cost for all of my lifetime. Below is a chart of world electricity prices in 2009 which shows the comparison of U.S. electricity prices to other industrialized countries of the world.

Shown on the chart of electricity costs above is Denmark and the Netherlands which were two of the first countries to implement wind farms for significant portions of their power generation.

America up to about 2012 used coal fuel for over 50% of our electricity production. Reasonable cost, reliable, abundant and dispatchable coal, generation powered the largest economy in the world. Reasonable cost electricity and GDP tend to parallel each other as shown on the graph below.

Coal Plant Efficiency Rankings

Up until the war on coal, coal plant designers, operators and maintenance personnel took pride in striving for the best overall efficiency. The best yearly coal plant efficiencies were typically from well run supercritical steam pressure units. Duke Power, PEPCO and AEP typically held the top positions. Duke Power’s Marshall and Belews Creek had repeatedly good years. Here is a typical ranking from 2013, Power Engineering Magazine:

I personally remember many meetings with Utility engineering management where the topic of discussion was modifications to the boilers and fuel burning equipment so that fuel changes could be made to reduce the production costs of power and at the same time, reduce emissions. One fuel change that was popular in the 1990’s was to convert coal plants designed for eastern Bituminous coal to fire western Powder River Basin fuel. This reduced emissions of NOx and kept production cost of power reasonable.

The Shale Gas Revolution

The combination of Hydraulic fracturing and Directional Drilling created an enormously large boost in U.S. natural gas production beginning about 2012. Natural gas prices at the Henry Hub dropped from a high of over $12.00/million BTU to about $2.00/million BTU in 2012. This abundance of natural gas fuel at this price, was competitive with well run, efficient coal plants. Then, the E.P.A. ramped up restrictions on coal plant emissions but the consumer was insulated from electricity price hikes because many natural gas CCGT (Combined Cycle Gas Turbine) plants were being built and fuel diversity allowed the Utilities to switch generation from coal plants to new, highly efficient CCGT generating units.

The vastly increased supply of natural gas drove the price of gas down to below the cost of coal on a unit heating value basis. Gas dropped to below $2.00 per million Btu. Also during this time period, gas turbine-combined cycle plant efficiencies increased to the range of 60%. Power generation efficiencies over the years is shown on the graph below. The combination of low cost natural gas and enormous efficiency advantage of CCGT plants greatly increased the use of natural gas fuel for power generation. Keep in mind, the advantage of natural gas fuel is only an advantage when there are pipelines to provide the fuel and there is an abundant natural gas supply. This does not work well in all states, such as Massachusetts and Hawaii.

The combinations of low fuel cost, low Capital cost, low environmental emissions controls cost and greatly increased efficiency together made natural gas fuel more economically attractive than coal for new generating plants. The fuel of choice became natural gas for Utilities that had pipelines and sources of natural gas fuel. Coal fuel accounted for 50% of electricity generation in 2004 but was reduced to 23% by the increased use of more economical natural gas by 2019.

Duke Energy, Buck Station CCGT Plant

America is Blessed with Enormous Energy and Mineral Resources

America has plenty of Coal, oil, natural gas and nuclear fuels to power our economy and our life styles. I have written other blog posts on the relationship of energy and economic prosperity. Specifically, our lifestyles and our industrial production requires on average, about 315 +/- 15 million Btus of energy each year per person This equates to about 100 Quadrillion Btus of energy per year for our country. This level of energy requirement has held steady for about twenty five years. More on the need for 100 Quads of energy/year are here, here, here and here (20, 21, 22, 23) . Up until the manufactured climate hoax and war on carbon, America enjoyed reasonable cost, reliable electricity and also gasoline, Diesel and Jet Fuel supplies. America became energy independent in 2020.

Energy Growth and Clean Air Too!

Protection of the environment is important to all of us, including me. In fact, much of my career was invested in improving efficiency and reducing emissions of coal generating plants. There has been steady progress in cleaning the air and water of the U.S. and I would be remiss if I did not show that during the preceding eight decades in spite of population growth, increases in the number of miles driven and the growth of the economy, the real pollutants have been drastically reduced from the levels of the 1950’s, 1960’s and 1970’s. The chart below was prepared by the EPA.

Two of the Last Clean Coal Plants Built in America

Coal plants are robust, reliable and when properly maintained can run safely and reliably for over fifty years. Several of the plants that I have personal experience with were mentioned above. However, newer designs with greater efficiency and improved emission controls should be built to replace the aging plants. In 2008 there were plans for dozens of new, clean coal plants to be built. Two magnificent examples are the John Turk Plant and the (then called Cliffside) #6 Unit at Rogers Energy Center in S.C.

Duke’s Rogers Energy Center Unit #6 Startup 2013
AEP-John Turk Plant, Arkansas

Example of Many New Coal & Nuclear Plants, Planned and Should Have Been Built 2012-2022

Santee-Cooper Pee Dee Plant, Planned to Be Built near Florence, SC

The Pee Dee Energy Center is one example of dozens of new, clean, efficient coal plants that were planned but cancelled due to political pressure of the environmental activists. I predict that these plants will be sorely missed during the winter peak power generation periods in December 2023 and January 2024. So will the Summer Nuclear Units #2 & 3 be missed.

Slide of Summer 2 & 3 and Vogtle Plant Construction from Dick Storm USCB-OLLI Course

Summary

My contribution to the progress made in the last 80 years was very modest and I will quickly admit that. However, because I worked with many talented and visionary engineers and in hundreds of generating plants around the world, I had a very good position to observe the progress of the giants in our industry. Engineers with a Vision of abundant, clean and reasonable cost electricity generation. To mention a few of these giants: Admiral Hyman Rickover, Bill Lee of Duke Power, Mendall Long of CP&L, Bill McCall of Santee-Cooper and many more fine engineers like them. What were their goals? To improve the quality of life, security, safety, economic growth, ensure that reasonable cost power could be produced for decades into the future, provide Bulk Power at the lowest possible cost to attract industry, increase industrial output, provide good paying jobs in their service territory, and design power plants that provide environmental protection for all of the citizens.

During the last 80 years nuclear power became a reality and today about 19% of our electricity is generated from clean, carbon free nuclear power plants. Many are now over fifty years old, but still reliable and inexpensive producers of vital electricity.

Natural gas generation has progressed from the first simple cycle unit built by G-E in 1949 at about 25% efficiency to today’s combined cycle gas turbine plants that at optimum load points can operate at over 60% thermal efficiency. They are amongst the most efficient machines ever built, of any kind.

Ultra-supercritical, clean coal plants such as Turk and Rogers #6 have been developed to provide reliable, reasonable cost, clean and importantly, Dispatchable power generation. There should have been built more like these Why? Because fuel diversity is important when one fuel becomes short in supply. For example, the 1973-74 Oil Embargo. Today most of the Dispatchable electricity generation is from natural gas which of course, flows through pipelines. Pipelines are reliable but, fuel storage is not practical. Coal plants, on the other hand, can store several months fuel supply on site.

Fuel Diversity is important for electricity generation reliability. I am proud to have worked during these years to do my best to make a small contribution to the great progress that was accomplished.

Part 2 will describe the self induced end of reliability, affordability and dispatch ability of electricity generation. As Dr. Euan Mearns recently wrote in “Watts Up With That”….The “Energy Transition is Social Vandalism”(19)

It is my best hope that America and our politicians will wake up and understand the importance of primary energy from conventional sources.

Yours very truly,

Dick Storm, October 4, 2023

References

  1. You Tube video of a “Living Better Electrically” ad hosted by Ronald Reagan, who was with the G-E Theater on Sunday nights for 8 years 1953-1962: https://www.youtube.com/watch?v=u5Lz1C53RwI
  2. NY Power Authority Facts on Robert Moses Hydroelectric Plant at Niagara Falls: https://www.niagarafallsinfo.com/niagara-falls-history/niagara-falls-power-development/the-history-of-power-development-in-niagara/robert-moses-generating-station/
  3. Duke Energy Roxboro Plant Info: https://www.duke-energy.com/our-company/about-us/power-plants/roxboro-plant
  4. Duke Power Belews Creek Plant Wikipedia: https://en.wikipedia.org/wiki/Belews_Creek_Power_Station
  5. 1973-1974 Oil Embargo History, Arab-Israel War: https://history.state.gov/milestones/1969-1976/oil-embargo
  6. 1973 Oil Embargo by Federal Reserve: https://www.federalreservehistory.org/essays/oil-shock-of-1973-74
  7. Duke Power References of Oconee & Marshall Steam Plant Annual Report 1967: https://www.nrc.gov/docs/ML1526/ML15261A046.pdf
  8. Power Magazine Feature article on the Top Plant, Duke’s Cliffside #6 which started up in 2013. The last new coal plant I can remember being commissioned for commercial service in the U.S. : https://www.powermag.com/cliffside-steam-station-unit-6-cliffside-north-carolina/
  9. Scientific American, March 2023, “Seven Ways Jimmy Carter Improved U.S. Energy Future, or At Least Tried to” : https://www.scientificamerican.com/article/7-ways-jimmy-carter-has-improved-americas-energy-future-or-tried-to/
  10. Power Magazine article on High Efficiency Gas Turbine Developments, 2018: https://www.powermag.com/efficiency-improvements-mark-advances-in-gas-turbines/
  11. POWER Magazine article on the History of Gas Turbines for Electricity generation: https://www.powermag.com/a-brief-history-of-ge-gas-turbines-2/
  12. Politico, 2015 article “Inside the War on Coal”: https://www.politico.com/agenda/story/2015/05/inside-war-on-coal-000002/
  13. Obama’s War on Coal 2008 article in Townhall: https://townhall.com/tipsheet/conncarroll/2014/04/01/obamas-war-on-coal-n1817140
  14. Explanation of Directional Drilling for Hydraulic Fracturing and production of Shale Gas, Drillers.com: https://drillers.com/directional-drilling-everything-you-ever-wanted-to-know/
  15. National Energy Act of 1978, Energy Policy Act and PURPA: https://en.wikipedia.org/wiki/National_Energy_Act
  16. History of the Alaska Pipeline by the American Oil & Gas History Society: https://aoghs.org/transportation/trans-alaska-pipeline/#:~:text=Oil%20was%20first%20discovered%20in,renewed%20in%20November%20of%202002.
  17. New York Times, May 10, 1974, Con-Edison Declares it may go Bankrupt without help, due to Oil Embargo fuel cost escalations: https://www.nytimes.com/1974/05/10/archives/con-edison-says-it-faces-bankruptcy-without-help-con-ed-says-it-is.html
  18. Congressional Report on Financial Condition of Utilities, 1970-1986: https://www.cbo.gov/sites/default/files/99th-congress-1985-1986/reports/doc10b-entire_1.pdf
  19. WUWT, Oct. 3, 2023, “Energy Transition is Social Vandalism” :https://wattsupwiththat.com/2023/10/03/the-energy-transition-is-social-vandalism/
  20. America Needs about 100 Quadrillion Btus of PRIMARY energy each year: https://dickstormprobizblog.org/2023/05/16/back-to-basics-the-u-s-needs-100-quadrillion-btus-year-of-primary-energy/
  21. Energy=Life as We Know and Enjoy it: https://dickstormprobizblog.org/2022/08/22/energy-life-that-is-life-as-we-enjoy-it/  
  22. Energizing the Public to Understand the Importance of Primary Energy: https://dickstormprobizblog.org/2023/03/20/educating-and-energizing-the-public-on-energy-policy-and-the-impossibility-of-powering-america-with-wind-and-solar/
  23. Energy and Economic Prosperity: https://dickstormprobizblog.org/2022/11/18/energy-and-economic-prosperity-2/
  24. Wake Up America:  https://dickstormprobizblog.org/2023/09/21/please-wake-up-america-your-energy-and-electricity-generation-reliability-are-at-risk/
  25. Dick Storm ENERUM, August 2022 presentation:  https://www.linkedin.com/posts/richard-storm-00557810_presentation-and-speakers-notes-from-august-activity-7068650158862827520-B-_W?utm_source=share&utm_medium=member_desktophttps://www.linkedin.com/feed/update/urn:li:activity:7056884647858765824?updateEntityUrn=urn%3Ali%3Afs_feedUpdate%3A%28V2%2Curn%3Ali%3Aactivity%3A7056884647858765824%29

Electric Generation Planning, Then and Now. What Will Be The Monuments to Poor Planning in 2024?

The U.S. has no Energy Policy in 2022. Only a Decarbonization Policy without a Rational plan to achieve a low carbon Energy supply. Keep in mind, Energy is needed for not only electricity generation, but also for Transportation, Industrial production, Commercial and Residential uses. Currently, about 87% of our total primary energy is provided by conventional sources of natural gas, coal, nuclear and hydroelectric. Wind and Solar provided less than 5% of total Primary Energy in 2021. Yet, there are many influential groups calling for policies to “Electrify Everything”.

Let me digress and quote a highly respected Utility Engineering Manager from the 1970’s. That man is Mendall H. Long, a member of the Greatest Generation who after graduation from NCSU served as the youngest Chief Engineer of the Standard Oil Fleet during WWII. After the war he joined Carolina Power & Light and rapidly rose through the ranks from shift supervisor to Manager of Fossil Plant Engineering. Me and many others loved that man and both his engineering skills as well as his wisdom. In the 1970’s CP&L and Duke Power’s electricity growth was almost 10% per year with growing industrial load and use of heat pumps. At CP&L which then was a 4,000 MW regional utility, the Asheville Unit #2 was built about 1970, then the 700 MW H.B. Robinson nuclear plant about 1971, 420 MW Sutton #3 in 1972 and the 720 MW Roxboro #3 started up in June 1973. Except for Robinson, all coal plants and needed to satisfy load growth. That was when Utilities planned for load growth and added generation based on projections of future demand. The four new units built between 1970 and 1973 above totaled 2,040 MW and the total peak generation was in the range of 4,000 MW. The quote from Mr. Long that I remember as he motioned toward some Internal Combustion gas turbines that were built for peaking and backup of the large new coal plants, “Those are Monuments to Poor Planning”. So, I wonder what the “Monuments to Poor Planning will be in 2024? I worked with and for CP&L during those years and the information provided is from my personal experiences and memory.

Lets take a look at what a Rational plan would be to add generation in anticipation of future Demand. In fact, lets take my adopted state of South Carolina as an example.

South Carolina Electricity Generation Planning 2006-2016

Before I retired from full time employment, I participated in consulting, testing, trouble shooting and design of performance improvements for coal power plants at South Carolina Electric and Gas and Santee-Cooper power plants (as well as many other utilities). During this process I got to know and respect a number of senior managers at these Utilities. One such senior manager was Mr. Bill McCall of Santee-Cooper. I remember one technical conference where Mr. McCall gave a presentation on Santee-Cooper’s load growth from both electricity intensive Industrial plants within the Santee-Cooper service territory, such as Alcoa (now Century Aluminum) and Nucor Steel and the rapid growth of housing (like NC in the 1970’s) and commercial enterprises along the coast north and south of Myrtle Beach. Mr. McCall went on to describe how electric demand was growing at unprecedented levels, and it was. He went on to show the need for building the two additional coal units at the Cross Generating Station, increasing the generation capacity of that plant to 2,340 MW and the need for the proposed 600 MW Pee Dee Generation Plant. Then there was the joint effort/ownership of SCE&G and Santee-Cooper to build the two additional nuclear units at Summer Station in Jenkinsville, SC. The significant dates of new units built or planned to be built during this period is shown below:

1984 Santee-Cooper Electric Generation Peak exceeds 5,000 MW

1984 Cross Generating Station Is Commissioned

1995 Cross Unit #2 Becomes Commercial

1999 800MW Rainy Gas Turbine Combined Cycle Plant Approved for Construction

2004 Two 600 MW Cross Units #3&4 Construction in progress

2004 600 MW Pee Dee Energy Campus is approved by Santee-Cooper Board for construction

2007 New Peak Demand record set at 5,563 MW’s, Cross Unit #3 begins commercial operation

2008 SCE&G and Santee-Cooper File appliction for Summer Unit #3 Nuclear Unit (1,100 MW)

2011 NRC approves second Summer Nuclear Unit for a total expansion of 2,200 MW of new nuclear power generation capacity. This is shared capacity of SCE&G and Santee-Cooper with Santee-Cooper having a 45% ownership share. Now, the foregoing new plants to be added from 2007 on would seem to be a good plan for growth. It was until two major problems: 1. The 600 MW Pee Dee Energy Campus was cancelled in 2009 due largely to outside interference and agitation from environmental extremist groupsand 2. Mismanagement of construction of the two nuclear units at Summer by SCE&G. A Rational Plan for new generation capacity of Dispatchable coal and nuclear generation capacity was scrapped. Now, there are increasing public and government pressures to install only wind and solar and to shut down existing coal plants as soon as possible. The 1,045 MW Winyah coal plant is planned to be shut down in 2028. But, at this writing there is no definite plan (that I am aware) to replace the 1,045 MW of coal generation. The illustration below is from Santee-Cooper’s IRP presentation.

When I first became associated with Santee-Cooper in 1971 as one of the test engineers performing acceptance testing at the Jefferies Coal plant in Moncks Corner, the system peak load was about 3,000 MW. Since then as can be seen from the projections to the future, Santee-Cooper’s service territory will grow to over 6,000 MW by 2037.

Who is Accountable for Poor Planning?

In my opinion, there are multiple reasons and organizations that have brought our country to the absense of proper generation planning. Eight major contributors to “Poor Planning” are the U.N.-IPCC, the World Economic Forum, the Main Stream Media, Public Indoctrination by Politicians that follow the “Green Religion”, the U.S. Democrat Party, Environmental Extremist Organizations, Billionaire activists such as Bezos and Bloomberg and Public School Indoctrination of Green Policies. I presented my views to the ENERUM Energy Forum in Columbus in August of this year. One slide I used is copied below:

On a national level, the slide covers many of the major players that have scrapped generation planning, as it was once done by responsible regional utilities. Now, with the emphasis on interconnecting all Utilities with Regional Transmission Operators and a Federal War on Carbon, there is No Rational Energy Policy. Only a policy to attempt to kill coal and gas plants. It is un-American. My respected engineering manager friend Mr. Long would be screaming from his grave if he knew the madness that has taken over in the U.S. Oh, how I miss gutsy managers like Mendall Long!

Getting back to S.C. and the lack of planning here. Here are a couple newspaper reports regarding the cancellation of the Pee Dee Coal plant and the Summer units 2&3 nuclear plant.

Conclusions

  1. America did better eneration planning in the 1970’s than we do now. In spite of the 1973 Arab Oil Embargo, America’s electricity remained reliable, was affordable and it fuled great economic growth 1970-2020.
  2. There is no energy policy. The “Electrify Everything” policy promoted by many here and in Eurpope is based on the myth that wind and solar can provide sufficient power. It can’t.
  3. The Regional Transmission Operators such as MISO, PJM and ERCOT combined with economic incentives for wind and solar have made the Grid fragile and less Resilient.
  4. The Environmental Extremists have made policies to shut down vital coal plants that will contribute to unreliable electricity generation.
  5. The EPA and government is run by environmental extremists that escape accountability for the actions and harm they are causing.
  6. Europe is an example our elected officials could look too to observe the costs and harm that extreme green policies can cause.
  7. Meanwhile, China is growing their economy and is on track to become the world’s largest economy passing the U.S.A. and doing so with massive amounts of coal power.

In closing let me ask you, what do you think the Monuments to Poor Planning will be in 2024?

Respectfully and yours truly,

Dick Storm, November 10, 2022

Texas and Coal Power 6,000+ MW’s of Coal plant Capacity is missed!

Introduction:

My first assignment to Texas was as a young B&W Results Engineer. I was participating as one of the Results engineers to perform acceptance tests of a large (500 MW class) natural gas fueled boiler at the P.H. Robinson Plant near Houston. That was about 1968. After that involvement I watched with great interest as Texas built dozens of 500-750 MW natural gas and oil fueled plants all across Texas. Built by Foster-Wheeler, Combustion-Engineering and Babcock & Wilcox. Then came the Arab Oil Embargo in 1973 and Texas responded to this true energy crisis with an incredibly successful fuel change to power production changing from oil and gas to Texas and Wyoming coal. The huge build out of coal plants went from the late 1970’s till the mid 1980’s and I was impressed. I had the pleasure of working at many of the coal plants operated by various Texas Utility Companies and what impressed me most was the “Can Do” attitude of Texans. Then about 1978 I became very involved as a Field Engineer to help solve combustion and power generation challenges with ALCOA’s massive Rockdale, Texas Lignite Fueled Power Plant. Also in the mid 1980’s involvement with acceptance testing of the 450 MW Gibbons Creek Coal Plant near College Station.

Why am I writing this? It is because I am perplexed after watching for decades how Texans were so practical and innovative, they became enamored with Renewable Wind and Solar Power to a fault. I was not surprised that California had such foolish policies but found it odd that practical Texas would fall into the trap of too much dependence on unreliable, non dispatchable renewables.

In the 1970’s Texas rallied to successfully change from oil and gas fuel to coal. In 2021-2022 I see Texas rallying again to overcome the problem of over-dependence on renewables.

The Good Old Days of Coal Power and Aluminum Production in Rockdale

Here is how coal power in Texas helped to build some of the most productive aluminum manufacturing in North America. A major contributor to the local economy and manufacturer of critical metals for America at the same time providing over 1600 jobs. A story to document the relationship of reasonable cost energy and economic prosperity.

The following is from the Milam County Archives, 1974:

On November 24, 1952, something strange happened in the small, agriculturally-oriented Central Texas town of Rockdale. A visitor, seemingly from a different world, changed the living habits of its people along with the general tempo and appearance of its community. 

The courting days of the 1950’s has now, nearly 22 years later, turned into a love affair unmatched in many communities between industry and townspeople. 

It began innocently enough. The Korean War was raging on and government needed aluminum to make airplanes. Aluminum Company of America needed a new facility to meet the demand. Rockdale, with its large lignite reserves, was the apple in Alcoa’s eye. 

Thousands of acres of the “Cinderella fuel” nestled beneath the earth’s crust gave rise late in 1951 to the establishment of the aluminum industry in Milam County. Aluminum production demands electric power to break down ore, shipped in from South America, to form the lightweight, corrosion-free metal. 

Demand for the metal by government and this abundance of the electrical energy- producing fuel triggered boom-like industrialization when Alcoa’s multi-million dollar Rockdale Works raced into production only 13 months after groundbreaking. 

Tipping the giant vat to cast the first aluminum ingot were the plant’s first boss (now Alcoa board chairman and chief executive officer) John D. Harper and smelting division manager R. T. Whitzel of Pittsburgh corporate headquarters.

Today, Rockdale Works is Aluminum Company of America’s largest worldwide metal producer with eight potlines and the capacity for turning out 280,000 tons annually or 1.5 million pounds per 24-hour, continuous operation day. 

The original four-potline plant was expanded by two more lines in 1956 and the Central Texas smelter became Alcoa’s largest in 1969 with the addition of the seventh and eighth lines. For the first time, Alcoa began producing more aluminum in Texas than in any other state. Rockdale Works and Point Comfort Operations down on the Gulf Coast have a joint capacity for making 455,000 tons annually. 

Rockdale Works has one of the world’s biggest carbon electrode-making facilities and a diversified ingot plant which converts molten aluminum into extrusion, sheet and remelt ingot. The latter produces everything from a 50-pound to a 22,000-pound product. 

A couple of fabricating facilities further enhanced the company’s local investment in the 1960’s. An atomized aluminum powder unit was built in 1966 and has been expanded twice. It’s now the biggest aluminum powder producer in the U. S. Then came a redraw rod facility in 1968 which spews out “raw material” for Alcoa’s electrical conductor-or wire-fabricating plants, primarily its nearby Marshall (Texas) Works. 

The Rockdale story is like many across the Developed World. Reasonable cost and abundant energy is used to fuel a manufacturing facility with the end result of not only manufacturing vital materials but also contributing to employment, funding the local tax base and infra-structure and more. Energy and Economic prosperity go hand in hand. Now, the four power generating units at Sandow Station are shut down. The Rockdale Plant is for sale and aluminum is no longer manufactured here. It was a great run from 1952 till about 2008 when the Chinese took over the aluminum smelting market.

https://www.bizjournals.com/pittsburgh/news/2017/12/22/alcoa-to-close-texas-site-divest-italian-smelter.html

Recent Shutdown of 6,453+ MW of Coal Capacity

Including the Sandow Plant which was adjacent to the ALCOA Rockdale Plant, there were five other robust, reliable coal plants shutdown. These are:

Sandow 1252 MW, Oklaunion 650 MW, Monticello 1,980 MW, J.T. Deely 932 MW, Big Brown 1,186 MW, TMPA Gibbons Creek 453 MW.

Perhaps the renewable wind and solar power capacity made some folks feel good when it was purchased and installed. I am sure it made the environmental extremists happy to see these coal plants gone. However, the people in the great state of Texas sure could have used the reliable electricity that could have been produced from these plants, had they not been prematurely shut down.

Hayden Ludwig published this short video on the Capital Research web site on more sinister reasons of America’s foolish Green Energy policies: https://capitalresearch.org/article/how-china-designed-american-environmental-policy/

It personally saddens me to see the loss of the aluminum manufacturing in Rockdale which essentially was given up to Chinese aluminum smelting capacity. It saddens me also to see the unneccessary suffering of the people of Texas. The environmental extremists may be happy to have successfully hoodwinked the politicians on the evils of carbon. Perhaps now is the time to account for the costs in the loss of American jobs, economic prosperity, the powering of heat pumps, Refineries and Businesses and often overlooked, contributions to the local schools and government infrastructure & tax base.

Dick Storm

February 19, 2021