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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Computed Tomography Scanning and Petrophysical Measurements of Eastern Williston Basin Twin Buttes and Hagel Formations
The computed tomography (CT) facilities and the Multi-Sensor Core Logger (MSCL) at the U.S. Department of Energy’s (DOE) National Energy Technology Laboratory (NETL) in Morgantown, West Virginia, were used to characterize core from two wells that represent coal resources across North Dakota. These include the MC23080C Well in Mercer County and the 23-B001 Well in Oliver County. The primary impetus of this work was to capture a detailed digital representation of the core from the MC23080C and 23-B001 Wells. The collaboration between the NETL and the Energy and Environment Research Center (EERC) enables other research entities to access information about this potential carbon ore, rare earth, and critical mineral resource plays in the Williston Basin. All equipment and techniques used were non-destructive, enabling future examinations and analyses to be performed on these cores. Fractures, discontinuities, and millimeter-scale features were readily detectable with the medical CT scanner acquired images. Imaging with the NETL medical CT scanner was performed on entire cores. Qualitative analysis of the medical CT images, coupled with X-ray fluorescence (XRF), gamma density, and magnetic susceptibility measurements from the MSCL were useful in identifying zones of interest for potential future analysis. Higher-resolution industrial and micro-CT images were acquired from selected zones along the depth of the core to visualize the structure in higher detail. The ability to quickly identify key areas for more detailed study with higher resolution will save time and resources in future studies. The combination of methods used provides a multi-scale analysis of the core, with the resulting macro- and micro-descriptions relevant to many subsurface energy-related examinations traditionally performed at NETL.
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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↗
Carbon Ore-Derived Critical Materials for Clean Energy Technologies
Conference presentation at American Institute of Chemical Engineers (AIChE) Annual Meeting, San Diego, California, October 27–31, 2024. Trends in the manufacture of electric vehicles that use graphite-based LIBs are rising steeply in the United States and globally, but the U.S. domestic supply chains for graphite, the largest component in an LIB by mass, is severely limited and faces complicated geopolitical dynamics with foreign sources. Consequently, the United States has designated graphite as a critical mineral to focus attention and resources to develop technologies to meet the challenge of limited domestic graphite supply chains. Results obtained so far based on the UCOP process have successfully validated the technology at the laboratory scale, with the produced graphite material showing up to 95% degree of graphitization, high carbon purity of ~99.98%, residual ash content of ≤0.02%, negligible moisture, low trace elements, and high electrochemical stability. These results suggest that the emerging UCOP technology is a promising approach to effectively synthesize high-quality graphite from abundant coal and coal waste resources in the United States to create a sustainable domestic critical graphite supply chain. A brief description of the status of UCOP process development and representative results will be presented.
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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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