High-voltage power transmission infrastructure at dusk.

Clean Carbon to Power · 400 MW

Clean carbon to power: a 400 MW project.

One proprietary low-temperature process runs in front of the boiler, returning clean power, exportable fuel oil, and recovered carbon from coal that would otherwise be burned raw.

Download the brochure The technology →
The opportunity

Power demand on one side. Dirty coal on the other.

Power demand is surging, from data centres and AI to smelting and developing-world growth. India, China, and Africa are scaling coal regardless of Western policy preferences.

Existing coal plants face stranded-asset risk. Bolt-on carbon capture is too expensive, retiring coal creates power gaps, and building new clean generation takes too long.

TiPs converts dirty coal into clean carbon power using existing infrastructure. It is a 30 to 40 year bridge for nations that cannot yet afford nuclear or a full renewables transition.

TiPs shifts coal combustion to a cleaner, capture-ready form using infrastructure that already exists.

400 MW Clean-carbon power built on a single processed-coal line.
~2.94M Tons of coal processed each year across 20 TiPs reactors.
20 TiPs reactors processing coal in front of the power block.
Zero Fly ash. Volatiles are removed before the carbon is combusted.
The technology

The TiPs process

The Thermal-static internal Pyrophinic system (TiPs) is a sealed, low-temperature, vacuum-driven process. It runs in front of the boiler, separating the volatiles as exportable fuel oil before the cleaned carbon is burned for power.

Feedstock Crushed run-of-mine coal
Outputs Power, exportable fuel oil, recovered carbon, and bottom ash
10,000+ Hours operated at full scale across feedstocks: tires, coal, oil sands. TRL 8.
24/7 Continuous feed operation, self-powered after a one-time grid startup.
33% Conservative plant efficiency on the processed-coal power block.
Zero Parasitic load on the power block at steady state. Closed process loop.
The Project · 400 MW Power

How it works here

For power markets, TiPs runs in front of the boiler, not instead of it. Coal that would have been burned raw is processed first. The volatiles leave as exportable fuel oil; the cleaned carbon burns for power.

About 2.94 million tons of coal feed one 400 MW clean-carbon line each year, mine-mouth, with minimal feedstock transport. Carbon credits and carbon sales sit outside the base case as upside.

Because TiPs runs in front of existing boilers, the plant, the grid connection, and the workforce that already serve the site keep working. Existing infrastructure is preserved rather than stranded.

Outputs: 400 MW of power, exportable fuel oil, recovered carbon, and bottom ash sold into cement. Carbon sales are upside only; the base case is power and fuel oil.

The TiPs system behind this project is the same one validated independently on tire feedstock (Tokai Carbon / Sid Richardson analysis, see the End-of-Life Tires page). Feedstock-specific validation is completed as part of each project business case, built on the assay of the actual feedstock.

What a ton of coal becomes

Select a product stream to see its uses and the market it sells into.

  • Carbon · 50%
  • Fuel oil · 25%
  • Mineral ash · 15%
  • Process gas · 10%

Carbon · 50%

Cleaned carbon burned for baseload power. With the volatiles removed first, it burns with no fly ash and capture-ready flue gas.

Use cases

  • Utility baseload power
  • Grid stability
  • Industrial offtake
  • Materials upside for offtake partners

Size of the industry

  • One processed-coal line supports 400 MW of clean-carbon power under a long-term PPA.
  • Bolt-on CO2 capture on raw coal runs roughly $40 to $60 per ton avoided (IEA); capture-ready flue gas cuts that cost where projects add it.

Fuel oil · 25%

The volatiles leave as exportable high-aromatic fuel oil instead of burning in the boiler.

Use cases

  • Industrial heating
  • Marine and bunker fuel
  • Refining feedstock
  • Diluent blending

Size of the industry

  • The global fuel oil market is worth roughly $190B a year.
  • Marine shipping alone burns more than 300 million tons of bunker fuel a year.

Mineral ash · 15%

Bottom ash sold into cement rather than ponded. There is no fly ash to manage.

Use cases

  • Cement and concrete
  • Aggregate

Size of the industry

  • Supplementary cementitious materials are a global market worth more than $17B a year.

Process gas · 10%

Captured process gas keeps the TiPs line self-powered, with zero parasitic load on the power block at steady state.

Use cases

  • Powers the TiPs line
  • Runs feedstock drying
  • Closed loop after startup
  • Zero external fuel

Size of the industry

  • Not sold: it replaces purchased fuel, so the plant runs with zero external fuel after startup.

Product split per ton of coal. The carbon is burned for clean power; fuel oil is exported. Fractions vary with the seam and the actual feedstock assay.

The products

Power and products from one line.

The base case is power and exportable fuel oil. Coal is processed before combustion, so its carbon burns cleaner and its volatiles leave as a saleable oil. Carbon and ash sales are upside for materials offtake partners.

Power

400 MW of clean-carbon baseload from processed coal, sold under a long-term PPA.

  • Utility baseload
  • Grid stability
  • Industrial offtake
  • Mine-mouth supply

Fuel oil & diluent

Exportable high-aromatic oil sold as an industrial fuel grade.

  • Industrial heating
  • Marine and bunker fuel
  • Refining feedstock
  • Diluent blending

Carbon & minerals

Bottom ash sold into cement now; recovered carbon as a materials upside for offtake partners.

  • Bottom ash to cement
  • Carbon to concrete (upside)
  • Metallurgical carbon (upside)
  • Carbon credits (upside)

The base case is built on power and fuel oil. Carbon, ash, and credits are upside, never the base case.

TiPs vs the incumbents

How TiPs compares

A coal power plant has an incumbent route: burn the coal raw. TiPs replaces it with a cleaner, capture-ready combustion that recovers value first.

TiPsPyrolysisRaw coal combustionRaw coal + bolt-on CCS
Process Sealed, low-temperature processing in front of the boiler.High-temperature thermochemical cracking, 400 to 800C.Raw coal burned directly in a boiler, 850C and above.Raw coal combustion with CO2 capture bolted on.
Products Power, fuel oil, recovered carbon, bottom ash.Fuel oil, low-grade char, syngas.Heat and power, with fly ash and bottom ash.Power, plus captured CO2 at high cost.
Material value Volatiles exported as oil; carbon burned cleaner.Partially destroyed, lower-value byproducts.Destroyed in combustion.Destroyed in combustion.
Environmental No fly ash, capture-ready flue gas, lower NOx and SOx.Energy-intensive, higher emissions.Fly ash, NOx, SOx, and particulate emissions.Regulated pollutants remain, capture is costly.
Deployment Modular, mine-mouth, on existing infrastructure.Large centralized plants.Large centralized plants.Large capture plant per facility.
400 MW Clean-carbon power from a single processed-coal line.
TRL 8 Technology readiness proven across 10,000+ hours of full-scale operation.
Modular Reactors are added as the project scales. Existing infrastructure is preserved.

Take the full project with you.

SENS delivers clean carbon power at scale. Whether you represent a utility, a mining operator, a host-country government, or a project finance fund, we invite you to explore what TiPs can do with coal in your region.

SENS · Clean Carbon to Power Full project brochure, including the project economics (PDF)
More project types

One process, four projects

End-of-Life Tires

End-of-life tires become tread-grade N330 carbon black, high-aromatic oil, and closed-loop process gas.

Explore →

Municipal Solid Waste

A city's sorted waste becomes industrial carbon, fuel oil, and potable water, with nothing sent to landfill.

Explore →

Coal to Clean Carbon

Run-of-mine coal becomes solid industrial carbon, fuel oil, and process gas, before any combustion.

Explore →