American Public Power Association
The Challenge of Building a Coal
Plant in Today’s Environment
Raj Rao
President, Indiana Municipal Power Agency
Chairman, Prairie State Generating Company
Campus Overview
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Site Area: 700+ Acres
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Coal Fuel: Adjacent New Mine
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Water Supply & Discharge: From the Kaskaskia
River – 14 miles from the Site
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Waste Disposal: Rail Transport to Offsite Disposal
Area and Limestone Delivery
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Transmission: Interconnect with Local Utility –
Ameren
 2 – 345 kV “Short” Lines at the Site
 1 – 345 kV “Long Line” across the Mississippi River
 Other Transmission Upgrade Projects
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Base Target Completion Dates:
 Unit 1 – August 2011
 Unit 2 – May 2012
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Prairie State Owners Serve More
Than 2.5 Million People In Nine States
Northern Illinois Municipal
Power Agency 120 MW
Illinois Municipal Electric
240 MW
AMP-Ohio
368 MW
Prairie Power, Inc.
130 MW
Indiana Municipal Power
200 MW
Missouri Joint Municipal
Electric Utility Commission
195 MW
Kentucky Municipal Power
124 MW
Southern Illinois
Power Cooperative
125 MW
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American Public Power Association
Prairie State Energy Campus
Challenge of Building a Coal Plant in Today’s Environment
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Site Selection
Environmental Permits
Partners & Financing
EPC Contractor
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American Public Power Association
Prairie State Energy Campus
Challenge of Building a Coal Plant in Today’s Environment
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Procurement
Construction
Safety, Cost and Schedule
Staffing
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American Public Power Association
Prairie State Energy Campus
Challenge of Building a Coal Plant in Today’s Environment
• Construction
– Bechtel EPC-M
– Peabody-Mine
– PSGC Staff
• Operations
– Experienced Operator vs. Experienced
Staff (Hire)
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American Public Power Association
Prairie State Energy Campus
Challenge of Building a Coal Plant in Today’s Environment
Coal Mine Overview
 Project participants own 200 Million tons of
coal (recoverable) for a dedicated source of fuel
for the project
– Mineral rights to coal are owned
– Reserves located adjacent to the plant to the East, West and
North of the project
– Adequate to supply project for 30 years at approximately 6.5
Million tons per year
– Using continuous mining technology
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In the Beginning:
Future Office
Stockpile
Slope
Basin
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Aerial of the Mine Slope
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Mine Slope – at Brow
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Power Plant Overview October 2007
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19 Months Later
First Unit 2
Structural
Steel
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Major Safety Milestone
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Power Plant Overview
 2 x 800 MW Net Supercritical Units
 Babcock & Wilcox Pulverized Coal
Boilers
 Toshiba Steam Turbine Generators
First
Concrete
Feb. 2008
 Siemens/Wheelabrator Air Quality
Control System
 Balance of Plant with:
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Cooling Towers
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Water Treatment Plant
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Single Shell, Dual Flue Chimney
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14 mile Raw Water Pipeline
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4 mile Railroad
 General Contractor – Bechtel Power
Corporation
Completed Unit 1
Boiler Steel March
2009
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Construction - Project Quantities
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Concrete – approx. 165,000 cubic yards,
enough concrete to fill more than 50
Olympic-sized swimming pools
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Structural and Miscellaneous Steel – approx.
42,000 tons, about half of the steel tonnage
of Sears Tower
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Pipe (A/G and U/G) – approx. 120 miles,
enough pipe to stretch from Lively Grove, IL
to Springfield, IL
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Scheduled Cable – approx. 1,200 miles,
enough cable to stretch from St. Louis, MO
to El Paso, TX
Unit 1 Turbine Pedestal &
Boiler
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Biggest Construction Project in the
Country!
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PSGC Community Outreach
Prairie State Project Poker Run
Sunday, October 5, 2008
137 individuals participated in this PSGC sponsored event
Raising $6,000 for the youth of Tilden
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