In the 1980s, the U.S. Department of Energy began a vigorous multiyear program, culminating in a 1992 50 MW demonstration coal combustor at the Component Development and Integration Facility (CDIF) in Butte, Montana. This program also had significant work at the Coal-Fired-In-Flow-Facility (CFIFF) at University of Tennessee Space Institute.
This program combined four parts:
# An integrated MHD topping cycle, with channel, electrodes, and current control units developed by AVCO, later known as Textron Defence of Boston. This system was a Hall effect duct generator heated by pulverized coal, with a potassium ionisation seed. AVCO had developed the famous Mk. V generator, and had significant experience.
# An integrated bottoming cycle, developed at the CDIF.
# A facility to regenerate the ionization seed was developed by TRW. Potassium carbonate is separated from the sulphate in the fly ash from the scrubbers. The carbonate is removed, to regain the potassium.
# A method to integrate MHD into preexisting coal plants. The Department of Energy commissioned two studies. Westinghouse Electric performed a study based on the Scholtz Plant of Gulf Power in Sneads, Florida. The MHD Development Corporation also produced a study based on the J.E. Corrette Plant of the Montana Power Company of Billings, Montana.
Initial prototypes at the CDIF were operated for short durations, with various coals: Montana Rosebud, and a high-sulphur corrosive coal, Illinois No. 6. A great deal of engineering, chemistry, and material science was completed. After the final components were developed, operational testing completed with 4,000 hours of continuous operation, 2,000 on Montana Rosebud, 2,000 on Illinois No. 6. The testing ended in 1993.