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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Coal to Carbon Fibers

This report documents activities carried out by Oak Ridge National Laboratory and by Ramaco Carbon LLC under CRADA project NFE-20-08273 entitled “Coal to Carbon Fibers.” This project’s main objective was the demonstration of commercially relevant utilization of coal as a precursor for high-value-added products, such as carbon fibers. The specific objectives included the following: • Deploy a production platform for the conversion of coal into carbon fibers in a way that utilizes preexisting base technologies and accelerates the commercialization of coal to carbon fibers. • Rapid deployment and utilization of versatile conversion test beds for accommodating preexisting base technologies for both the conversion of coal-to-pitch (proven donor solvent liquefaction techniques) and conversion of pitch-to-fiber (proven melt spun and melt blown techniques). Results from the generation of an isotropic pitch from a subbituminous coal through the low severity direct coal liquefaction process are presented. Carbon fibers were produced from this isotropic pitch through melt spinning and melt blowing.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

Exploratory Investigation of Coal in Nonequilibrium Plasma

Coal is an abundant natural resource and there is motivation to find new uses for it that do not intrinsically involve combustion. One approach is to explore new ways of processing coal, and in this work, we focus on the transformation of coal in a nonequilibrium plasma generated from an equimolar mixture of nitrogen and hydrogen. The outcome of the nonequilibrium plasma reaction is fundamentally different than a thermal control reaction carried out using the same gas composition, pressure, and temperature range. The nonequilibrium plasma produces a gas mixture that is enriched in acetylene and its derivatives. Furthermore, when compared to the thermal control experiment, the solid char byproduct of the nonequilibrium plasma has a very reactive surface and is spontaneously combustible at ambient temperature. Experiments performed to characterize the reaction kinetics of coal in the plasma suggest that the mechanism proceeds through a sequential process by which the coal particle temperature rises to a point where devolatilization can occur, the devolatilization reaction happens, followed by parallel reactions of released organic vapors in the plasma phase and surface activation. In conclusion, the reaction rate appears to be limited by the time it takes for the coal particle temperature to rise, consistent with previous results reported for reactions of coal in thermal plasma.

Acetylene↗
DOE OSTI2025

Chemistry imaging and distribution analysis of rare earth elements in coal using LIBS and LA-ICP-MS instruments

Currently, demand for rare earth elements (REEs) increased significantly. Coal is actively evaluated as potential economic sources for extraction of REEs. Here, in this work, laser-induced breakdown spectroscopy (LIBS) was evaluated for rapid estimation of REEs content and their distribution in the natural coal samples. The results were compared with similar laser ablation–inductively coupled plasma–mass spectrometry (LA-ICP-MS) measurements. Thirteen coal samples (nine standard samples and five natural samples) were used in this study. Powder samples were pressed into pellets while coal chunks were directly ablated for data recording. Pellets of the powder standard samples were used to optimize the data acquisition system and then data recorded with this optimized system was used to identify the proper data acquisition and analysis models. After establishing the proper data acquisition system and analysis model using the standard samples, natural coal samples in powder form and their chunks were utilized to record LIBS and LA-ICP-MS spectra. Multivariate calibration models were developed using four of the natural samples, which were evaluated by predicting the REE content in the fifth sample. Principal component analysis was performed on the LIBS data obtained from the natural samples and it classified all the samples with high accuracy. Two-dimensional (2D) elemental mapping on coal chunk samples was also performed using both LIBS and LA-ICP-MS to study the distribution of REEs in the samples. The resulting elemental images and their correlations can be used to infer mineral distributions.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

The Coal Industry Perspective [Slides]

This report provides an overview of the global coal industry, with additional focus on the United States. Some of the areas it covers include coal prices, consumption, production, stockpiles, imports, exports, reserves, and productivity measures. It provides juxtapositions between the United States and other countries' coal industries. In addition to providing a current snapshot of the U.S. coal industry, this work portrays both historical and projected aspects of the coal industry.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

Light, High Performance and Scalable Coal-Derived Composites for Construction: Precast and Cast-in-Place Applications

The overall objective of this project was to produce a coal-based construction material that has up to ~95 weight percent (wt. %) coal with physical, chemical, and thermal properties exceeding those of ordinary Portland cement (OPC)-based construction materials. Additionally, the project aimed to minimize external binders by implementing novel mixing techniques, while exceeding the performance/cost ratio of OPC. Finally, the project was to demonstrate production of precast products via the design and fabrication of products via a bench scale process. Consistent with some of these objectives, the project successfully fabricated samples of coal-based composite materials with >80 wt% coal with physical, chemical and thermal properties on par with cement-based concrete. Select samples demonstrated compressive strengths with >7,000 psi and flexural strength of >420 psi. The composite materials minimized external binders and also demonstrated durability, as evidenced by resistance to acidic and basic solutions. Finally, larger slab and beam type samples were produced using a process developed by the Recipient, although, the process was not semicontinuous in nature. Taken together, the results of this project suggest that domestic coal has potential to serve as a replacement for cementitious materials utilized in incumbent construction technologies, which could significantly reduce the energy and emissions of the construction industry

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2026

Integrated Life Cycle and Techno-Economic Assessments of Central Appalachian Legacy Mine Sites for Biomass Development and Waste Coal Utilization

This project, funded by the U.S. Department of Energy – National Energy Technology Laboratory (DOE-NETL) under award DE-FE0032212, evaluated how legacy coal mine lands and coal refuse piles in Central Appalachia (West Virginia and Pennsylvania) can be reclaimed and repurposed to support biomass development and beneficial utilization of waste coal, with the long-term goal of supporting net-zero or net-negative greenhouse gas (GHG) pathways. The project had two primary objectives: 1. Characterize legacy mine sites (including site conditions, waste coal/refuse resources, and soil/ecosystem indicators) and develop reclamation and best management practices (BMPs) for biomass cultivation; and 2. Conduct integrated machine learning (ML)-assisted life cycle assessment (LCA) and techno-economic analysis (TEA) to quantify environmental and economic outcomes for multiple biomass and waste-coal utilization pathways. Across West Virginia, the team identified ~625 coal refuse sites covering ~19,705 acres, and developed methods to estimate refuse pile volume using digital elevation models (DEMs) and geospatial workflows. A large subset of sites received volume estimates totaling ~1.6 billion m³.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

Coal Enhanced PEEK Filament Production for Additive Manufacturing in Industrial Services

The project (Award DE-FE0032146), led by Baker Hughes in collaboration with the University of Wyoming, aims to develop composite PEEK (Polyether-ether-ketone) materials enhanced using coal-derived graphene-based additives suitable for additive manufacturing (3D printing). Coal char (CC), graphene oxide (GO), and reduced graphene oxide (rGO), derived from Powder River Basin (PRB) coal, were successfully integrated into commercial PEEK feedstock. The composite PEEK materials demonstrated tensile and flexural strengths and modulus, Shore hardness, and thermal properties similar to unfilled PEEK. Dielectric strength of 0.5% GO/PEEK is twice that of unfilled PEEK. However, tensile elongation and Izod impact toughness of the composite materials are lower than unfilled PEEK. The 10% CC/PEEK material also shows good recyclability albeit with slightly increased glass transition and cold crystallization temperatures. Filaments of the composite PEEK materials were fabricated using a Filabot system. 3D printing of the composite PEEK initially encountered feeding stoppage caused by the non-uniform diameter of the filament, which was resolved by reducing the nominal diameter from 1.75 to 1.65 mm. The printability of the composite PEEK filaments is limited in geometry and build time, driven by differences in base PEEK feedstock from the commercial PEEK filament at printing conditions. Prototype part printed using the composite filaments shows inconsistent bead width and bead interruption resulting in porosity. Preliminary process and economic evaluation using PRB coal char estimates the cost of GO to be $0.5/lb. Considering the small fraction expected in the composite PEEK, the GO cost is several orders of magnitude lower than the commercial PEEK filament. It is recommended that the printability of composite PEEK filaments to be improved by optimizing the composite PEEK material at the printing conditions and reducing the variations in filament extrusion. Also important is to identify the mechanisms of how coal-derived additives affect the composite PEEK performance and printing characteristics to allow customized material design and processing for target performance.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

Manufacturing Valuable Coal-Derived Products in Southern Appalachia

This project’s objective is to develop and deploy new technologies for manufacturing rare earth elements (REE), critical minerals (CM), and valuable non-fuel, carbon-based products (CBP) from coal and/or coal waste in the SoApp Basin, thus revitalizing distressed SoApp coal communities and reducing reliance on foreign imports of REE and CM. Resource availability and technological advances alone will not ensure this objective is met. The right mix of business climate, market forces, and policy will also be needed. This report identifies the critical technologies, infrastructure, supply chains, human capital, and policy gaps that must be addressed to manufacture REE, CM, and CBP from coal resources and wastes in SoApp The primary goal of the project is to characterize the resource base in the SoApp Basin.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

The Co-Firing of Pine Biomass and Waste Coal in 100 and 600 MW Power Plants: A Sustainable Approach to Reduce GHG Emissions

Climate change is a global issue that has gained much attention recently. Co-firing biomass with coal/waste coal reduces the electricity sector’s GHG emissions sustainably. This study uses commercial software to model waste coal and biomass co-firing in 100 MW and 600 MW power plants. The objective is to assess the effects of fluid types (subcritical and supercritical), plant capacities (100 MW and 600 MW), boiler types (pulverized coal and circulating fluidized bed boilers), biomass and waste coal co-firing ratios (0:100, 20:80, 40:60, 60:40, 80:20, and 100:0), and carbon capture and storage efficiencies (0%, 90%, 95%, and 97%) on performance parameters such as net plant efficiency, heat rate, net plant CO2 and SO2, and particulate matter emissions. The feedstocks selected for this investigation include anthracite waste coal and loblolly pine biomass. As the biomass fraction increases from 0% to 100%, co-fired power plants net efficiency increases by 3–8%. Supercritical plants had a 6% higher net plant efficiency than the subcritical plants. The study found that the biomass’s high heating value decreased the fuel flow rate and reduced plant CO2 emissions by 10–16%. With 100% biomass power plant feed and 90% carbon capture and storage efficiency, CO2 emissions drop by 83% and SO2 and PM emissions drop to zero.

Bhoi, Prakashbhai R. (ORCID:0000000333104888)↗
DOE OSTI2025

Highly crystalline, low-ash, graphite from coal using an Fe 2 O 3 -based catalytic process with recovery and reuse of catalyst and process acid

This study presents a sustainable process for producing highly crystalline, low-ash graphite from sub-bituminous coal using an Fe 2 O 3 -based catalytic method. The process integrates coal mineral removal, catalyst regeneration, and reagent recycling into a closed-loop system. Acid-soluble Fe-residue and mineral impurities are eliminated from the solid graphite through HCl treatment, followed by hydrolytic distillation to regenerate Fe 2 O 3 and recover HCl for reuse. Coal-derived silica is removed with a KOH rinse, yielding low-ash graphite suitable for high-performance applications. The closed-loop catalytic graphitization, where the recovered Fe 2 O 3 and HCl are used in subsequent graphitization runs, produces graphite with a degree of graphitization exceeding 95%. The L a and L c crystallite sizes reach 65–78 nm and 44–48 nm, respectively, with BET surface areas of 4–10 m 2 /g and an ash content below 0.1 wt.%. Lithium-ion battery testing reveals that anodes fabricated with this graphite deliver an initial discharge capacity between 384.5 and 421.2 mAh/g, averaging 395.0 ± 19.1 mAh/g, along with initial coulombic efficiencies of 85.0–89.1%. After 100 discharge–charge cycles at 0.25C, reversible capacities remain between 358.8 and 369.7 mAh/g, while coulombic efficiency stays above 99.9%. The findings highlight that coal can serve as a viable precursor for high-quality graphite production under relatively mild conditions, avoiding the need for extreme temperatures or aggressive reagents such as hydrofluoric acid, commonly employed in conventional processes. This work demonstrates both technical feasibility and environmental benefits, emphasizing its potential to support large-scale, sustainable graphite production for applications such as lithium-ion batteries.

Catalytic graphitization↗
DOE OSTI2024

Coal-derived carbon anodes for lithium-ion batteries: Development, challenges, and prospects

Lithium-ion battery (LIB) development has increased rapidly, requiring low-cost anode materials with a high capacity, high-rate performance, and stable lifespan. Carbon-based anodes possess various exceptional morphologies and structures, making them promising candidates for meeting the technical demands; however, conventional synthetic carbon anode processes need expensive feedstocks that increase anode cost and limit commercialization. Coal, the most affordable and abundant carbon resource, has attracted increasing attention as the primary feedstock for producing high-value carbon anode materials. This article reviews the lithium storage mechanisms, characteristics, and productions of some high-valuable carbon anode materials for LIBs from coal and coal derivatives. The high-value carbon anode materials reviewed in this article are graphite, graphene, mesophase microbeads (MCMB), carbon fiber, and hard carbons. Furthermore, the remaining challenges and prospects of using coal-derived carbon materials to create high-performance and low-cost lithium-ion batteries are also discussed.

25 ENERGY STORAGE↗
DOE OSTI2026

NETL Coal Energy Atlas: A Collection of Coal/Energy Related Maps

The NETL Coal Energy Atlas contains a comprehensive collection of coal and energy-related maps and graphics curated by the National Energy Technology Laboratory (NETL) Systems Analysis group. It serves as a living document providing an overview of the U.S. coal and energy sectors. The volume is structurally organized into six key thematic areas. Ultimately, the atlas functions as a modular baseline for data integration, allowing researchers to drill down into specific regional locations or customize geographic base layers for advanced systems analysis.

bituminous coal↗
DOE OSTI2024

Systematic characterization of selenium speciation in coal fly ash

Millions of tons of coal fly ashes (CFAs) are produced annually during coal combustion in the U.S., which are commonly beneficially used in the concrete industry or disposed of in ash ponds. CFAs contain trace amounts of a range of toxic heavy metals including selenium (Se). Because the toxicity of Se is dependent on its speciation, investigating Se speciation in CFAs as affected by coal source and combustion conditions can help understand the related environmental and human health impacts during disposal or beneficial reuse. In this study, a set of representative CFA samples were characterized for Se speciation using synchrotron X-ray absorption spectroscopy (XAS) and micro-X-ray fluorescence spectromicroscopy (μ-XRF/XAS). Se-containing particles were highly heterogeneous, and individual particles might contain multiple oxidation states including Se(0), Se(IV), and Se(VI). Principal component analysis was performed for sample characteristics including Al 2 O 3 , SiO 2 , CaO, FeO, loss on ignition, average particle size, Se concentration, and Se oxidation state. Selective catalytic reduction (SCR), which is used to limit nitrogen oxide (NO x ) emissions during coal combustion, was found to be associated with the presence of reduced Se oxidation states, with up to 90% Se(0) observed in samples with SCR. Alongside SCR, FeO content may also influence Se speciation.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2026

A Data-driven Phytotechnology Framework for Identification and Remediation of Leached-Metals-Contaminated Soil Near Coal Ash Impoundments

This project developed and evaluated advanced remote sensing and machine learning approaches to identify, monitor, and address environmental contamination associated with coal combustion residual (CCR) impoundments and landfills at coal-fired power plants. In Phase I, historical and multi-temporal Sentinel-2 satellite imagery, groundwater monitoring data, and environmental variables were integrated to detect vegetation stress potentially caused by toxic metal leaching from coal ash disposal sites. Multiple vegetation and biophysical indices were analyzed to determine their effectiveness in identifying abnormal vegetation growth patterns linked to contamination. Results from case studies conducted at coal ash–impacted power plant sites in North Carolina and Virginia demonstrated that satellite-based vegetation monitoring can serve as an effective early indicator of environmental stress associated with metals such as arsenic, cadmium, cobalt, lead, lithium, radium, and thallium.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

Addressing Critical Challenges of Coal Mines for Underground Pumped Storage Hydropower Using Numerical Calculations

Using existing coal mines to build underground pumped storage hydropower (UPSH) power plants could help reduce the costs associated with starting a new PSH operation. This innovative approach can leverage the existing infrastructure of coal mine facilities available in many regions of the United States. However, technical challenges associated with water quality, mineral chemistry and integrity of subsurface topologies have thus far prevented any of these facilities from going online. Rye Development is investigating the feasibility of UPSH at existing coal mine facilities. In this project, Rye Development received the technical assistance from Oak Ridge National Laboratory to investigate the impacts of minerals, metal particles, and chemical substances in water flow on hydraulic equipment and assess the overall structural integrity of hydraulic equipment in former coal mines.

13 HYDRO ENERGY↗
DOE OSTI2025

Estimating the Total Value Proposition of Coal Fly Ash and Produced Water

Here we describe the total potential "sale" value of produced water and coal fly ash due to the mineral content they contain. Produced water is water that is co-produced during oil and gas operations. Coal fly ash is the solid powder that remains after coal is burned. Both coal fly ash and produced water matter partly because of they contain critical minerals that have economic value and could be extracted. Here we calculate the total potential value of all the mineral products, critical minerals and other products such as salts, so that we can gain a more complete economic outlook on both feedstocks. Poster presented at the American Geophysical Union (AGU) Annual Meeting held in New Orleans, Louisiana, December 15 to 19, 2025.

critical minerals, lithium, rare earth elements↗
DOE OSTI2024

Life Cycle Greenhouse Gas Emissions of Coal-Biomass Co-Firing Power Plants with Carbon Capture and Storage

The United States has set a target to achieve the net-zero economy by 2050. Bioenergy with Carbon Capture and Sequestration (BECCS) is one of the promising negative-emission routes in the mitigation portfolio to help meet this goal. Coal-biomass co-firing with carbon capture and storage (CCS) is a key BECCS technology to realize the carbon mitigation at fossil-fuel power plants. The mitigation potential of co-firing option is affected by numerous critical factors, such as biomass properties, co-firing level, and carbon capture rate. The objectives of the study are to characterize and estimate the life cycle greenhouse gas (GHG) emissions and performance of coal-biomass co-firing power plants with CCS, determine the breakeven co-firing level at power plants necessary to achieve net-zero life cycle emissions, and quantify the variabilities and uncertainties in life cycle emissions. The scope of the life cycle assessment includes the fuel supply, combustion-based power generation, and CO2 transport and storage. A fuel-based life cycle module is developed and embedded in the Integrated Environmental Control Model (IECM), a fossil-fuel power plant modeling tool. This study then applies the enhanced IECM to conduct the process-based life cycle assessment for an array of biomass co-firing scenarios. Deterministic analysis indicates that reaching net-zero life cycle emissions in a biomass co-firing plant without CCS deployment is challenging. Combining biomass co-firing and CCS deployment can significantly lower the overall life cycle emissions of power plants. Net-zero life cycle emissions can be achieved with a 20 wt.% co-firing level and 90% CCS when the Powder River Basin coal is co-fired with energy crops or forestry residues. However, the breakeven co-firing level for net-zero emissions depend on the selected fuel properties. Fuel supply and plant operation are the critical stages influencing the life cycle emissions of power plants with 90% CCS. Deployment of deep CCS beyond 90% CO2 capture can remarkably reduce operational emissions and the breakeven co-firing level. With 99% CCS, the breakeven co-firing rate can be reduced to 12% on average. These findings highlight the trade-offs between technical performance and environmental impact of biomass co-firing at coal-fired power plants and emphasize the role of deep CCS in achieving a net-zero emissions future.

Wu, Wanying↗
DOE OSTI2025

The short-term comprehensive impact of the phase-out of global coal combustion on air pollution and climate change

With the continuous intensification of global warming, the reduction and ultimate phase-out of coal combustion is an inevitable trend in the future global energy transformation. This study comprehensively analyzed the impact of phasing out coal combustion on global emissions and concentrations of air pollutants, radiative fluxes, meteorology and climate using Community Earth System Model 2 (CESM2). The results indicate that after the global phase-out of coal combustion, there is a marked decrease in the concentrations of sulfur dioxide (SO 2 ), nitrogen oxides (NO x ) and fine particulate matter (PM 2.5 ), with some regions experiencing a reduction of exceeding 50%. There is no significant change in global ozone (O 3 ) concentration. There are decreasing AOD and positive radiative fluxes globally in the short term, though the cloud contributes minor negative radiative fluxes. The global air temperature may increase by approximately (0.02 ± 0.15) °C on average with regional and seasonal variations, and the precipitation may potentially increase by approximately (2.7 ± 40.6) mm yr −1 globally and over 20% in equatorial regions in the short term. But combined with the decreasing trend of cloud water content in the Northern Hemisphere, it indicates a potential increase in the extremity of precipitation events. In conclusion, this study provides references for global control of air pollution, mitigation strategies of climate change, and transformation of energy structures under the objective of “carbon neutrality”, such as focusing on the negative climate impacts of exacerbating regional warming and increasing extreme precipitation resulting from the rapid reduction of aerosols in the short term.

01 COAL, LIGNITE, AND PEAT↗