PRECIP 
NEWSLETTER 

December 2009
No. 407

Staff at the Rockport Power Plant in southern Indiana have turned many difficult challenges into opportunities for improvement. Therefore, states Angela Neville, writing in Power,  it is not a surprise that the Rockport Plant, operated by Indiana Michigan Power, a branch of American Electric Power, was recognized as the Large Plant of the Year at the 2009 Powder River Basin Coal Users’ Group (PRBCUG) Awards Banquet.

This plant, like many other represented in the PRBCUG, wasn’t designed for PRB coal, explained Bob Taylor, former PRBCUG chairman. “A fatality from a dust explosion and numerous other experiences caused them to aggressively learn about the characteristics of PRB coals and implement actions for continuous improvements and proactive approaches to protecting people,” he said.

At one time, the Rockport Plant had the worst safety and health record in the company’s fleet. It also had more fires than most. The engagement and involvement of all employees turned the plant into one of the better performers.

Groundbreaking for the Rockport Plant occurred on August 29, 1977. It was built as a sister plant to several others that were designed to burn bituminous coal. However, before startup, a switch was made to burn lower-cost PRB coal, even though few in the company had any experience with this lower-sulfur but harder-to-handle coal. Unit 1 was placed into commercial operation on December 10, 1984. Unit 2 followed in December 1989. These were the fifth and sixth 1300-MW units built by AEP.

One of the advantages, besides lower coal costs, of using PRB coal is that it helps the Rockport Plant reduce air emissions. PRB coal is low in sulfur content, which is good for meeting the SO₂ limit, and high in moisture, which helps the plant meet its NO_x targets. The plant also uses activated carbon injection to control mercury emissions.

Challenges to using PRB coal included the staff learning the requirements for handling and burning PRB coal. It can self-combust if it is not compacted on the storage pile properly. Dust and slagging can also present problems.

Currently, the Rockport Plant is making another improvement to deal more safely with PRB coal’s volatile properties. It is replacing the old baghouse-style dust collectors with wet extraction-style dust collectors. These will eliminate much of the danger of fires and/or explosions. This new improvement also reduces the compressed air usage in the coal yard by eliminating any need for compressed air that is required on a baghouse-style collector.

Plant Manager Pat Hale attributes the success of the Rockport Plant first and foremost to the large number of talented and competent employees. Also, they have continued to make improvements to equipment, materials and processes that have made the unit operate much better and have improved safety.

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