Graphite Production From North Dakota Coal Resources
Presentation for Domestic Production of Synthetic Graphite Roundtable, University of Kentucky Center for Applied Energy Research (CAER), Lexington, Kentucky.
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Gulf Coast Basin CORE-CM Initiative (Final Report)
This report describes critical mineral/rare earth element resources, including Gulf Coast coal resources, and waste streams including coal ash from power plants, red mud from alumina processing, heavy mineral concentrates from sand mining industry, zeolite, graphite, and produced water with oil and gas.
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Biogas Utilization in Refuse Power Plants (BURP 2 )
The BURP 2 project investigated the technical and financial viability of co firing biogas with waste coal for power generation while using carbon capture and sequestration to achieve net negative emissions. A comparative assessment integrating geospatial mapping, technoeconomic analysis, and life cycle analysis was carried out to evaluate retrofitting an existing coal fired facility in West Virginia, versus developing a new greenfield power plant in Kentucky located near a low quality coal resource. The study found that CO 2 capture rates of 90% or higher, in combination with biogas feedstocks such as animal manure, could significantly reduce global warming potential compared to plants using neither biogas nor CO 2 capture systems. Economic feasibility depended heavily on federal tax credits and proximity to fuel sources. In both greenfield and retrofit scenarios, access to biogas played a key role. Because the retrofit site was located close to existing biogas resources, it represented a feasible option, whereas the greenfield site, being far from pipelines or biogas sources, would require prohibitively expensive biogas transport infrastructure. Overall, the research showed that repurposing waste or low-quality coal with renewable biogas and CO 2 capture systems could provide a viable approach for reducing carbon emissions in power production, if biogas resources are easily accessible and available in sufficient quantities.
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Life Cycle Assessment of Methanol from Fossil, Biomass, and Waste Sources, and Its Use as a Marine Fuel in Dual-Fuel Engines
Methanol is gaining interest in the marine sector from energy security and reducing emissions perspective. This study provides a comparative life cycle assessment of methanol as a marine fuel, across GHG and criteria air pollutant emission metrics, when it is used in a dual-fuel engine. Twelve methanol pathways from four different feedstock categories were considered, including (1) cellulosic biomass forest residues and clean pine mix, corn stover, switchgrass, and miscanthus; (2) organic wastes renewable natural gas from wastewater sludge, swine manure, food waste, and landfill gas; (3) fossil resources coal and natural gas (NG); and (4) e-methanol using captured carbon dioxide. When used in a dual-fuel engine with pilot fuel, life cycle GHG emissions for woody biomass-based methanol were approximately 19 gCO 2 e MJ −1 , while emissions from waste-based sources ranged between −154 and 31 gCO 2 e MJ −1 . Methanol from renewable sources showed a GHG reduction potential between 58 and 226% compared to conventional NG-based methanol (122 gCO 2 e MJ −1 ), primarily due to the avoided emissions from conventional waste management. When carbon from process emissions were captured, the reduction could be up to 327%. All pathways exhibited lower NO X , and particulate matter emissions compared to the baseline marine fuel (MGO 0.1% sulfur), while woody biomass and coal pathways had higher SO X emissions.
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Tunable electrochemical pathway for high-purity REMs and CMs
This report details a comprehensive research initiative focused on developing a technical research plan for the efficient and sustainable production of rare earth elements (REEs) and critical materials (CMs) from coal-based resources, specifically lignite coal from the Williston Basin in North Dakota. The project’s methodology centers on the design and evaluation of a tunable electrochemical pathway (TEP), an innovative approach aimed at achieving high-purity rare earth oxides (REOs), rare earth salts (RES), and CMs. This research is crucial for addressing the growing demand for these materials in clean energy technologies, electric vehicles, and high-tech applications, while reducing the United States’ reliance on foreign supply chains.
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Transforming Uinta Basin Earth Materials for Advanced Products (TUBE-MAP)
The objectives of this project were to quantify, assess, and plan to enable the transformation of Uinta Basin earth resources, such as coal, oil shale, resin, rare earth elements, and critical minerals into high value metal, mineral, and carbon-based products. The specific major goals were 1) basinal assessments and initial planning (Task 2), 2) basinal assessment for waste stream reuse with associated plan development (Task 3), 3) basinal strategies development for infrastructure, industries, and business (Task 4), 4) technology assessment, development, and field-testing plan (Task 5), 5) technology innovation center plan (Task 6), and 6) stakeholder outreach and education plan (Task 7).
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Tunable Electrochemical Pathway for High-Purity REMs and CMs
This report details a comprehensive research initiative focused on developing a technical research plan for the efficient and sustainable production of rare earth elements (REEs) and critical materials (CMs) from coal-based resources, specifically lignite coal from the Williston Basin in North Dakota. The project’s methodology centers on the design and evaluation of a tunable electrochemical pathway (TEP), an innovative approach aimed at achieving high-purity rare earth oxides (REOs), rare earth salts (RES), and CMs. This research is crucial for addressing the growing demand for these materials in clean energy technologies, electric vehicles, and high-tech applications, while reducing the United States’ reliance on foreign supply chains. The project was structured into four key tasks, each designed to build upon the previous one and contribute to the overarching goal of developing a viable technical research plan.
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Sustainable recovery of Rare Earth Elements (REEs) from coal and coal ash through urban mining: A Nature Based Solution (NBS) for circular economy
The demand for rare earth elements (REEs) has surged in recent years, driven by their crucial role in various industrial applications and their uneven geological distribution. As a result, urban mining from secondary resources, particularly coal and coal ash, has gained traction as a sustainable solution within a circular economy framework. This study highlights the significant presence of REEs in coal and coal ash, revealing that certain samples contain REE concentrations that rival traditional ores. Notably, coal ash has the potential to yield approximately 312,000 tons of REEs annually, far exceeding global demand. The research delves into advanced techniques for analyzing REEs, including elemental, isotopic, and mineralogical studies. Additionally, it explores innovative extraction methods such as the use of green solvents, nature-based solutions, and bioleaching and biosorption. By leveraging coal and its byproducts as secondary resources, this study underscores the opportunity to reduce dependence on conventional mining, enhancing the sustainability of REE recovery. Here, a comprehensive literature review was conducted to highlight technological advancements and emerging opportunities that can address current challenges in this field.
Circular economy↗
Advanced Processing of Coal and Coal Waste to Produce Graphite for Fast-Charging Lithium-Ion Battery Anode
The University of North Dakota (UND) Energy & Environmental Research Center (EERC), in collaboration with the UND Center for Process Engineering Research (CPER), conducted a project to validate two technologies capable of converting North Dakota lignite and lignite coal waste to high-quality graphite for fast-charging lithium-ion battery (LIB) anode. The project was conducted over about 3 years from April 7, 2022, to July 6, 2025. The two technological paths pursued in this project include path A – direct conversion of coal or coal waste to graphite by the upgraded carbon ores to products (UCOP) process being developed at the EERC and path B – lignite-derived coal tar pitch (CTP) conversion to graphite (CTP2G) process being developed at CPER. The results from this project validate the two technological approaches and are expected to be an integral part of a portfolio of emerging technologies for making high-quality graphite not only from North Dakota lignite, but from all ranks of U.S. domestic coal and coal waste resources. The quality of the graphite produced by these technologies is high enough for various applications, including batteries for the fast-growing electric vehicle industry, energy storage applications, electric arc furnace electrodes for steel production, and graphene production, among others. Although the two technologies can produce high-quality graphite, they are fundamentally different in that the UCOP technology provides a direct path to transform coal to graphite, while the CTP2G technology needs to go through a CTP intermediate and a coking process for the intermediate, which requires a special facility to accomplish. For application in the industry, the UCOP process is designed to be more flexible, with feedstock to include potentially any carbonaceous material such as all coal ranks and biochar, while the CTP2G process is designed to utilize CTP as the starting precursor. The key project accomplishments include the following: • Successful preparation of high-quality synthetic graphite from North Dakota lignite coal/coal wastes and lignite-derived CTP. • Patent application has been filed for the UCOP process and an internal invention disclosure has been filed for the CTP2G process. • The produced graphite performs better than a commercial battery-grade sample in LIB coin cells, especially fast-charging capability, stability, and long-duration cycling. • Coin-type Li-ion half-cells with CTP2G graphite showed excellent performance, with >370 mAh/g capacity, >90% initial coulombic efficiency, and 93%/67% retention at 1C/2C rate, which outperforms commercial graphite in charging speed, stability, and cycling. • Results of fabricated 18650 cells were consistent with the observations in coin cells. • Preliminary techno-economic analysis (TEA) estimates for the UCOP technology indicate a manufacturing cost of about $\$$39/kg based on 50-metric ton/year capacity. • Preliminary TEA estimates for the CTP2G technology indicate a market price of about $\$$7107/ton ($\$$7/kg) based on 22,000-ton/year production capacity.
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FOA_2364_CORE-CM_data_FE0032056 (ICPMS and pXRF FINAL data submission)
ICPMS and pXRF data for samples related to the Cherokee Forest City Basin Core CM project headed up by the Kansas Geological Survey. Submission contains all usable pXRF and ICPMS data collected during the project.
Cherokee Forest City Basin; Critical Minerals; Iow↗
Powder River Basin CORE-CM: Advancing Strategies for Carbon Ore, Rare Earth Element and Critical Mineral Resource Development in the Nation's Largest Coal Producing Basin
Powder River Basin CORE-CM: Advancing Strategies for Carbon Ore, Rare Earth Element, and Critical Mineral Resource Development in the Nation's Largest Coal Producing Basin
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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.
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Grid Reliability and U.S. Coal Fleet Attributes: Considerations for State Regulators
This briefing paper provides state utility regulators with a comprehensive and current understanding of the reliability attributes of coal as a generation resource, potential reliability impacts associated with near-term coal plant retirements, and possible mitigation strategies to ensure a stable and resilient energy system.
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Petrology and geochemistry of the Middle Pennsylvanian (Langsettian) Clintwood coalbed, Pike County, Kentucky
Abstract The Middle Pennsylvanian, Langsettian sub-stage Clintwood coal, along with its correlatives, was one of the more important energy resources in eastern Kentucky. The coal thickens from the NE-SW-trending Belfry anticline in central Pike County to the southeast, towards the Virginia-Kentucky border. Much of the thickness increase is in the bright lithotypes below a dull lithology. The bright lithologies transition from a bright clarain + vitrain + fusain lithology to a clarain + fusain lithology to the southeast. Half of the lithotypes in the three analyzed sections exceed 1000-µg/g Rare earth elements + Y + Sc (REYSc) (ash basis). The La N /Sm N vs. Gd N /Yb N and La N /Sm N vs. Ce N /Ce N * plots suggest that the top lithotype may have had best indication of an oxidizing environment. Positive Gd N /Gd N * and Eu N /Eu N * in some of the lithologies suggests that there may have been a hydrothermal influence in the sediment sources and/or in the diagenesis of the coal. Consideration of La N /Sm N and Zr (µg/g; ash basis), Zr vs. Sr, and V/Cr vs. inertinite/(inertinite + vitrinite) indicates that the dull lithotypes existed in a distinct geochemical environment compared to the brighter lithotypes. The isolation of the dull lithotypes from the bright lithotypes is supported by principal components analysis on inertinite/(inertinite + vitrinite), La N /Sm N , V/Cr, Sr, and either Zr or Ln(100(TiO 2 )/Al 2 O 3 ).
Hower, James C. (ORCID:0000000346942776)↗
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↗
Technoeconomic and life cycle energy analysis of carbon fiber manufactured from coal via a novel solvent extraction process
Coal is a versatile energy resource and was a driver of the industrial revolution that transformed the economies of Europe and North America and the trajectory of civilization. In this work, a technoeconomic analysis was performed for a coal-to-carbon-fiber manufacture process developed at the University of Kentucky’s Center for Applied Energy Research. According to this process, coal, with decant oil as the solvent, was converted to mesophase pitch via solvent extraction, and the mesophase pitch was subsequently converted to carbon fiber. The total cost to produce carbon fibers from coal and decant oil via the solvent extraction process was estimated to be $\$$11.50/kg for 50,000-tow pitch carbon fiber with a production volume of 3750 MT/year. The estimated carbon fiber cost was significantly lower than the current commercially available PAN-based carbon fiber price ($\$$20–$\$$30/kg). With decant oil recycling rates of 50% and 70% in the solvent extraction process, the manufacturing cost of carbon fiber was estimated to be $\$$9.90/kg and $\$$9.50/kg of carbon fiber, respectively. A cradle-to-gate energy assessment revealed that carbon fiber derived from coal exhibited an embodied energy of 510 MJ/kg, significantly lower than that of conventionally produced carbon fiber from PAN. This notable difference is primarily attributed to the substantially higher conversion rate of coal-based mesophase pitch fibers into carbon fiber, surpassing PAN fibers by 1.6 times. These findings indicate that using coal for carbon fiber production through solvent extraction methods could offer a more energy-efficient and cost-competitive alternative to the traditional PAN based approach.
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Predictive Assessment of the Chemical Composition of Coal Ash in Reserve at U.S. Disposal Sites
In the United States, more than 2 Gt of coal combustion residuals (i.e., coal ash) are stored in hundreds of disposal units. Recent federal regulations mandate the closure or retrofitting of most coal ash impoundments, presenting significant challenges for waste management. These regulatory pressures also present opportunities to reuse coal ash. However, the quality and quantity of discarded coal ash across the U.S. are not well known, even though this information is crucial for spurring its reuse for conventional and new material applications. This study describes a predictive model for the major element composition of coal ash in reserve at disposal sites of major U.S. coal-fired power plants. This model was constructed from coal purchase records of 705 power stations from 1973 to 2022 and was trained on coal ash composition data, showing that coal ash elemental composition is strongly associated with the source of feedstock coal. The model showed regional shifts in the major element contents of ash produced by power plants in the last 50 years, particularly for calcium and iron (expressed as %CaO and %Fe2O3), as power stations changed their source of coal over this time frame. Our approach enables an estimation of chemical composition for ash stored in waste impoundments at individual power stations. Such information can help to delineate the regional market resource potential of supplementary cements for concrete and other material innovations that would utilize coal ash harvested from disposal sites across the U.S.
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Evaluation of coal-associated sediments, wastes, and AMD sludge in the Southern Appalachian Basin as feedstock materials for REE and Li recovery
Critical minerals (CM) such as rare earth elements (REE+) and Lithium (Li) are essential to technological innovation, energy transitions, global economic and defense security, necessitating the search for unconventional resources and efficient recovery methods to avert supply chain disruptions. Here, this study evaluates coal-associated sediments (underclay and roof rock) and wastes from the Pennsylvanian Pottsville Formation of the Southern Appalachian Basin (SAB) as potential feedstocks for CM recovery. A total of 34 samples (15 underclays, 12 roof rocks, 5 Acid Mine Drainage (AMD) sludges, and 2 coal mining wastes) were characterized using XRD, XRF, ICP-MS, and μ-XRF analytical methods. The REE+ and Li concentrations of these materials ranged from 46.8 to 334.4 ppm and from 11.1 to 519 ppm, respectively, with one underclay sample (Hendrix 3456) yielding the highest values for both. Bulk mineralogy for all samples was dominated by aluminosilicate clay phases, particularly illite and kaolinite. All samples exhibited REY def, rel% values >26% and C outl indices that ranged from 0.69 to 0.94, classifying their REE ore potential as Category II (Promising) as defined by Seredin and Dai (2012). Extractability tests (EPA method 3051 A) yielded low REE+ and Li recoveries, with maximum values of 3.3% and 3.6%, respectively, suggesting associations with resistant minerals like clay and phosphates. Elemental mapping indicates that REE+ is associated with phosphate, whereas statistical analysis suggests that REE+ are associated with aluminosilicates, suggesting heterogeneous associations or minimal phosphate contribution. Li also correlated positively with Al 2 O 3 , indicating an aluminosilicate host. This study highlights the potential of coal-associated sediments in the SAB.
Clay minerals↗