Coal-Fired Power Plants in Pennsylvania
Armstrong
Location: PA
Operator: Allegheny Energy Supply Co LLC
Configuration: 2 X 190 MW
Operation: 1958-1959 (ret)
Fuel: bituminous coal
Boiler supplier: FW
T/G supplier: GE, WH
EPC: Sanderson & Porter
Quick facts: Armstrong was built at a cost of $44.7mn on a 210ac site on the Allegheny River. Average daily coal burn was about 2,500t. In 1982, West Penn Power Co built a 1,011ft stack at Armstrong. This cost $13mn. The plant was retired 1 Sep 2012.

Photograph courtesy of Power
Posted 26 Sep 2007

Bruce Mansfield
Location: PA
Operator: First Energy
Configuration: 3 X 835 MW
Operation: 1976-1980
Fuel: bituminous coal
Boiler supplier: FW
T/G supplier: GE
Quick facts: Mansfield is 25mi northwest of Pittsburgh on a 473ac site on the Ohio River. The $1.4bn, supercritical plant was built for the CAPCO companies, Cleveland Electric, Duquesne Light, Ohio Edison, Pennsylvania Power, and Toledo Edison. Coal burn is about 24,000 tpd. A 950ft stack serves Units 1&2 and a 600ft stack was installed for Unit-3. A $90mn combustion byproduct disposal system was built for Mansfield incorporating the largest earth and rockfill embankment dam in the eastern USA. The 420ft tall, 2,200ft long structure was built across a valley about 7mi from the plant and FGD sludge and ash is pumped behind it into a 850ac disposal area. FirstEnergy and National Gypsum Co later built one of the world’s largest single-line gypsum wallboard plants near the plant to use recycled gypsum from the FGD scrubbers. The plant is named for D Bruce Mansfield, former President and Chairman of Penn Power.

Photograph by Kiyo Komoda
Posted 1 Jan 2003

Brunner Island
Location: PA
Operator: PPL Generation
Configuration: 1 X 363 MW, 1 X 405 MW, 1 X 790 MW
Operation: 1961-1969
Fuel: subbituminous coal
Boiler supplier: CE
T/G supplier: WH, GE
EPC: Ebasco
Quick facts: This plant is on a 766ac site on the west bank of the Susquehanna River. Units 1&2 have cross-compound steam turbines and Unit-3 is supercritical. At completion, the thee units cost $155mn. 100% of the fly ash and bottom ash from the plant is used for construction material. In Nov 2009, a pair of Wheelabrator wet limestone FGDs were commissioned to serve all three units, thus completing a 3yr, $800mn environmental improvement program. This also included two new ESPs, a new water treatment facility, and new equipment to store and handle limestone and gypsum. The boilers had previously been retrofit with Alstom low Nox burners.

Photograph by Connor Stoehr
Re-posted 9 May 2012

Chester Operations
Location: PA
Operator: Kimberly-Clark Corp
Configuration: 1 X 59 MW CHP
Operation: 1986
Fuel: bituminous coal, culm, pet coke
Boiler supplier: Lurgi
T/G supplier: ??
EPC: Bechtel
Quick facts: This cogen CFB supplies a tissue products manufacturing facility.

Photograph by C Bergesen
Posted 25 May 2005

Conemaugh
Location: PA
Operator: NRG Energy Inc
Configuration: 2 X 936 MW
Operation: 1970-1971
Fuel: bituminous coal
Boiler supplier: CE
T/G supplier: GE
EPC: Gilbert, Ebasco
Quick facts: These are supercritical units with cross-compound turbines. A variety of upgrades and modernization packages have been completed including conversion to balanced draft operation, modifications to the ESPs, conversion to digital controls, installation of low NOX burners and the installation of FGDs in 1994/95. The plant donated a particularly scenic portion of the site, known locally as Buttermilk Falls, to Indiana County for use as a wildlife refuge. Conemaugh burns over 4mn tons of coal per year and is jointly-owned by a eight power companies. Reliant Energy has a 16% interest and operates the facility.

Photograph by Stefan Schlöhmer
Posted 20 May 2006

Cromby
Location: PA
Operator: Exelon Power
Configuration: 1 X 160 MW (C), 1 X 211 MW (O)
Operation: 1954-1955 (ret)
Fuel: bituminous coal, No 6 oil, natural gas
Boiler supplier: BW, CE
T/G supplier: GE, WH
Quick facts: On 29 June 2004, Cromby-1 celebrated its 50th anniversary. To that date, the unit had run for over 350,000hrs, the most of any generator in the Exelon fleet. The first generator on the Cromby site was built in 1904, a 350-kW water turbine known as Rasor’s Meadow Electric Plant. This was replaced in 1918 with a 10-MW machine, retired in 1929. Unit-1 was retrofit with low-Nox burners and SNCR. In the early 1990s, Unit-2 was converted to allow for natural gas combustion. Both units were retired in 2011. Unit-1 was online for over over 400,000hrs during its career.

Photograph courtesy of Power
Posted 20 Feb 2008

Eddystone
Location: PA
Operator: Exelon Power
Configuration: 2 X 350 MW (ret), 2 X 390 MW
Operation: 1960-1976
Fuel: bituminous coal, natural gas, oil
Boiler supplier: CE
T/G supplier: WH, GE
EPC: UE&C
Quick facts: In 1954 Philadelphia Electric Co, Westinghouse, and Combustion Engineering agreed to design and build the world’s second supercritical power station. The main steam conditions at Unit-1 -- 5,200psig (358 bar) and 1,200deg F (650deg C) -- required new materials, designs and systems and remained the highest in the world for decades. Unit-2 had conventional supercritical conditions and Units 3&4 operated at subcritical pressure and temperature. In 2003, the plant was designated a Historic Mechanical Engineering Landmark by the ASME. Unit-1 was closed in 2011 and Unit-2 in 2012. Photograph by C Bergesen
Posted 25 May 2005
Hatfield's Ferry
Location: PA
Operator: FirstEnergy Solutions LLC
Configuration: 3 X 576 MW
Operation: 1969-1971 (ret)
Fuel: bituminous coal, subbituminous coal
Boiler supplier: B&W
T/G supplier: WH
EPC: UE&C
Quick facts: PRB coal burn in Hatfield's supercritical boilers began in Aug 2005. In 2001, Allegheny Energy constructed a passive wastewater treatment system at the plant to control the leaching of dissolved metals from an ash landfill near the station. Allegheny Energy Supply 76.6% ownership share transferred to FirstEnergy in 2000. Monongahela's 23.4% share transferred in 2007. B&W west limestone scrubbers added in 2009 at a cost of $650mn. The EPA granted FirstEnergy an extension through April 2016 to comply with new Mercury and Air Toxics Standards at the site, however, the utility announced plans to retire the plant in Oct 2013. Legislators in PA then asked the the PUC to order require the plant to remain open under a RMR contract. In Sep 2013, PJM said that closing the plant would not impact reliability in the regional grid and the plant closed on 19 Oct 2013.

Photograph courtesy of Allegheny Energy
Posted 3 Jun 2006

Homer City
Location: PA
Operator: Edison Mission Energy
Configuration: 2 X 660 MW, 1 X 692 MW
Operation: 1969-1977
Fuel: bituminous coal
Boiler supplier: FW, B&W
T/G supplier: Westinghouse, GE
Quick facts: The 1,216ft stack on Homer City-3 is the tallest on any power station in the USA The plant was purchased by Edison Mission Energy in 1999 and is interconnected to both the PJM power pool and the NY Power Pool.

Photograph by Kiyo Komoda
Posted 4 Jan 2003

Hunlock Creek
Location: PA
Operator: UGI Development Corp
Configuration: 1 X 23 MW, 1 X 25 MW, 1 X 50 MW
Operation: 1923-1959 (ret)
Fuel: anthracite, silt
Boiler supplier: Foster Wheeler
T/G supplier: WH
EPC: Ebasco
Quick facts: In Jun 2009, the Pennsylvania DEP said it planned to approve the repowring of Hunlock Creek-3 with two gas turbines. At the end of May 2010, the coal-fired boiler was retired and approximately 50 workers let go or reassigned as construction continued on the $100mn repowering project. Units 1&2 were retired in 1975.

Photograph by Pete G Wilcox and courtesy of The Times Leader
Posted 29 May 2010

John B Rich
Location: PA
Operator: Gilberton Power Co
Configuration: 1 X 79 MW
Operation: 1988
Fuel: anthracite culm
Boiler supplier: Pyropower, Foster Wheeler
T/G supplier: GE
EPC: Bechtel
Quick facts: This plant has two 400,000 lbs/hr, early-design CFB boilers. In 1999, the original boiler feed nozzles were completely replaced.

Photograph courtesy of Foster Wheeler
Posted 27 Nov 2005

Keystone
Location: PA
Operator: NRG Energy Inc
Configuration: 2 X 936 MW
Operation: 1967-1968
Fuel: bituminous coal
Boiler supplier: CE
T/G supplier: WH
EPC: Gilbert
Quick facts: These cross-compound, supercritical generators are among the largest coal-fired units in the USA. The facility is located on a 1,459ac site in Indiana and Armstrong counties and is jointly-owned by a group of seven power companies. APC upgrades include modifications to the electrostatic precipitators, addition of a flue-gas conditioning system, low-Nox burners, and SCR. Wheelabrator FGD scrubbers are under construction at the plant.

Photograph by Doug Jackson
Posted 5 Dec 2009

Mitchell
Location: PA
Operator: FirstEnergy Solutions LLC
Configuration: 2 X 75 MW, 1 X 299 MW
Operation: 1948-1963 (ret)
Fuel: subbituminous coal, heavy oil
Boiler supplier: B&W, CE
T/G supplier: GE, WH
Quick facts: Mitchell 1&2 are oil-fired and used infrequently. Unit-3 has a wet lime FGD scrubber supplied by GE Environmental Services. In Feb 2003, a pilot mercury removal plant was completed at Mitchell designed to remove up to 90% Hg at a cost substantially lower than powdered activated carbon injection. The technique involves Hg absorption on and removal with fly ash. The pilot program used various flue gas temperatures and Mg(OH)2 injection rates (for SO3 removal) and evaluated effects oon plant component, and the mobility of the captured Hg. The project was coordinated by NETL and supported by Consol Energy, Allegheny Energy, Alstom Power, Environmental Elements Corp, and Carmeuse North America. The Mitchell site was closed in Oct 2013.

Photograph courtesy of University of Pittsburgh
Posted 27 Aug 2005

Montour
Location: PA
Operator: PPL Generation
Configuration: 2 X 800 MW
Operation: 1969-1977
Fuel: bituminous coal
Boiler supplier: CE
T/G supplier: GE
EPC: Ebasco
Quick facts: Montour has a 1163ac site in Derry Twp. The stacks are 600ft tall and the cooling towers are 370ft tall. In 2000/01, new SCRs and new ESPs were added on both units. On 29 May 2008, PPL announced completion of a $600mn Alstom wet limestone FGD system on Montour. The new FGDs are designed for 97% removal efficiency and will also help control mercury emissions and provide 30 new permanent jobs at the plant. The scrubber project started in 2004. Gypsum from the FGDs will be used by United States Gypsum Co at its $180mn manufacturing facility providing about 150 more jobs. A 12mi pipeline to the West Branch of the Susquehanna River brings cooling water to the plant and PPL built a reservoir called Lake Chillisquaque to serve as a backup water source. The lake is the center of the 1,000ac Montour Preserve which includes a wildlife refuge and hiking trails.

Photograph by Mark Morey
Posted 10 Aug 2003

Mount Carmel
Location: PA
Operator: Mt Carmel Cogen Inc
Configuration: 1 X 44 MW CHP
Operation: 1990
Fuel: anthracite culm
Boiler supplier: FW
T/G supplier: ??
EPC: FW
Quick facts: Mt Carmel was developed and built by Foster Wheeler Ltd which sold the plant in 2001 for about $40mn. The CFB boiler burns about 2,000 tpd of culm with 50-80% ash. Construction was completed less than 18mos after full release of the design engineering documents. Steam is supplied to an adjacent greenhouse.

Photograph courtesy of Power
Posted 11 Jul 2004

New Castle
Location: PA
Operator: NRG Energy Inc
Configuration: 2 X 40 MW, 2 X 98 MW, 1 X 137 MW
Operation: 1939-1964
Fuel: bituminous coal
Boiler supplier: FW, B&W
T/G supplier: WH
EPC: Commonwealth Associates
Quick facts: This 270ac site was developed by Pennsylvania Power Co along the Beaver River in Lawrence Co. The original capital cost for all 5 units was $43mn. They burned 3,000 tpy of 1.2% sulfur coal a day delivered by truck. In 1978, Penn Power added new precipitators and a 750ft chimney at a cost of $39.7mn. Units 1&2 were retired in 1993.The plant was sold to Orion Power and then by RRI Energy,now owned by NRG. Units 1&2 are retired.

Photograph courtesy of Penn Power
Posted 13 Dec 2009

Northampton
Location: PA
Operator: Cogentrix Energy LLC
Configuration: 1 X 110 MW
Operation: 1995
Fuel: anthracite culm
Boiler supplier: Pyropower, Foster Wheeler
T/G supplier: ABB
EPC: Bechtel, Rust
Quick facts: This plant was developed by U.S. Generating Co and Cogentrix at a brownfield site formerly the location of the Universal Atlas Cement Co, which ran what was for many years the largest cement plant in the world. The CFB boiler burns about 545,000 tpy of culm. Steam is supplied to an adjacent pulp and paper plant. The plant is now 100% owned by Cogentrix.

Photograph courtesy of Foster Wheeler
Posted 27 Nov 2005

Piney Creek
Location: PA
Operator: Piney Creek LP
Configuration: 1 X 33 MW
Operation: 1992 (ret)
Fuel: gob, waste coal
Boiler supplier: Tampella
T/G supplier: ABB
EPC: Bibb, Fru-Con, ABB
Quick facts: Construction on the Piney Creek power plant began in 1990, and the unit commissioned on 17 Dec 1992. The plant cost about $182mn to build and the owners completed numerous renovations during its operational life. All power produced was sold and transmitted via the Penelec substation at Piney Creek Dam. The unit used about 625 tpd of waste product from the surrounding bituminous coal producers, and 150 tpd of local limestone was used in the CFB boiler. The plant was shutdown in 2013 and contracted for disposal in Jan 2014.

Photograph by Andy Turner (Panoramio)
Posted 14 Jan 2014

Seward-6
Location: PA
Operator: NRG Energy Inc
Configuration: 1 X 521 MW
Operation: 2004
Fuel: gob, waste coal
Boiler supplier: Alstom
T/G supplier: Alstom
EPC: Duke/Fluor Daniel
Quick facts: The first plant at the site was built in 1921. At completion, Seward-6 had the largest CFB boilers yet built to burn waste coal. Total project cost was about $800mn, funded in part by state-issued bonds.

Photograph courtesy of Power
Posted 18 Sep 2004

Shawville
Location: PA
Operator: NRG Energy Inc
Configuration: 2 X 125 MW, 2 X 188 MW
Operation: 1954-1960
Fuel: bituminous coal
Boiler supplier: B&W, CE
T/G supplier: GE
EPC: Gilbert Commonwealth
Quick facts: Shawville was built by Pennsylvania Electric Co and acquired by Sithe Energies, who sold it to Reliant Energy in May 2000. The large stack is 850ft tall.

Photograph by Mark Morey
Posted 13 Aug 2003

St Nicholas
Location: PA
Operator: Schuylkill Energy Resources
Configuration: 1 X 100 MW CHP
Operation: 1989
Fuel: anthracite culm
Boiler supplier: CE
T/G supplier: ABB
EPC: Burns & McDonnell, Blount Intl
Quick facts: This cogen plant was built to burn culm mined from the St Nicholas Breaker near Mahanoy City, which at completion in 1932 was the largest coal breaker in the world. The material used for the CHP plant is taken by large earth movers to a small breaker that separates rock from the coal. From there, a 1mi conveyor moves about 425 tph of material to the plant. About 80 MW is available for sale to PPL or direct to wholesale customers.

Photograph by jrmski (flickr)
Posted 1 Nov 2008

 
Titus
Location: PA
Operator: NRG Energy Inc
Configuration: 3 X 75 MW
Operation: 1951-1953 (ret)
Fuel: bituminous coal
Boiler supplier: CE
T/G supplier: GE
EPC: Gilbert
Quick Facts: Titus is on the Schuylkill River just off I-176 in Cumru Township. The plant was built by Metropolitan Edison Co and named after former Met-Ed president O Titus. The station was completed in 1951, but did not go fully online until 1953. The cooling tower was added in the 1970s. Titus was closed on 1 Sep 2013.

Photograph by Connor Stoehr
Posted 29 Dec 2012

Wheelabrator Frackville
Location: PA
Operator: Wheelabrator Technologies Inc
Configuration: 1 X 48 MW CHP
Operation: 1988
Fuel: culm
Boiler supplier: Tampella
T/G supplier: ABB
EPC: Rust
Quick Facts: The Frackville CFB unit consumes up to 500,000 tpy of culm in the Schuylkill Valley. The alkaline ash byproduct is used to backfill about a dozen abandoned strip pits per year. Steam is sold to to Pennsylvania's State Correctional Institution at Frackville.

Photograph courtesy of Wheelabrator Technologies Inc
Posted 11 Jan 2012

Abbreviations

Data: industcards, Platts UDI World Electric Power Plants Data Base

Updated 15-Jan-2014

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