Research offers hope for new future of anthracite

May 6—PRIMROSE — Peering into the depths of a strip mine in Cass Twp., Blaschak Coal Corp. Chairman J. Gregory "Greg" Driscoll sees the past and future of anthracite coal.

There, in century-old workings "daylighted" by a giant Marion 7450 electric dragline shovel the size of a house, lie secrets with the potential for a role in the nation's energy and economic future.

As anthracite enjoys growth spurred by international turmoil, research continues toward finding new, non-traditional uses for the vast reserve of hard coal beneath northeastern Pennsylvania.

The U.S. Department of Energy launched a 10-year research project that includes identifying new uses for anthracite.

One of the primary areas of research involves critical minerals, including and rare earth elements, that have applications in cellphones, semiconductors and navigation systems.

Some of the DOE research involving rare earth elements, an area in which China is dominant, has national security implications.

DOE is working with Penn State's Center for Critical Minerals to develop methods of extracting and purifying these assets, including rare earth elements.

The project envisions the establishment of technology innovation centers to find uses for coal derivatives in making carbon fibers, furnace electrodes and the fuselages of aircraft.

Joseph Stoffa, who manages DOE's advanced coal processing and carbon utilization program, says anthracite has potential in conversion to graphite, too.

"Anthracite has the advantage of being the closest to graphite in structure," he said.

Graphite is used in electrodes in lithium-ion batteries, which are critical to the emerging electric vehicle industry. Electrodes are best made of pure carbon, which is in short supply due to increasing technological demand.

U.S. Rep. Dan Meuser, R-9, Dallas, points to research in developing new methods of producing carbon nanotubes, high-strength molecules used as additives to synthetics.

"As the research continues to develop, and the potential use of anthracite in these sorts of applications increases, so will the demand for coal," said Meuser, recently named co-chair of the coal caucus for the 118th Congress. "For decades, coal has played an important role in the lives of the people of northeast and central Pennsylvania, and I'm hopeful that emerging technological advances will result in an economic boon for the region."

The road back

Three decades ago, the U.S. was the leader in production of rare earth elements.

For a variety of reasons, including the lack of environmental and workplace regulations, China has forged ahead and now produces about 90% of the world's supply.

To reduce reliance on offshore sources, the DOE conducted a feasibility study to assess the potential recovery of rare earth elements from coal, coal byproducts and waste materials.

After reporting its findings to Congress in 2015, DOE embarked on an effort at the National Energy Technology Laboratory to demonstrate the technical and economic feasibility of recovering rare earth elements from coal-based materials.

The initiative, renamed the Critical Materials Sustainability program, is in the second year of a 10-year period.

The overall goal of the program is to produce 1 to 3 metric tons per day of high purity mixed rare earth oxides and salts in domestic separation facilities by 2026.

"The U.S. is trying to rebuild our world dominance in critical mineral extraction and usage, and bring that technology development back on shore," said Jessica Mullen, NETL technology manager for rare earth elements and critical minerals.

In its initial phase, the program will focus on understanding the coal "infrastructure" of various regions and develop technologies for extracting critical minerals. In subsequent phases, it will develop workplace initiatives and training programs in various locations throughout the country.

"The anthracite coal region is definitely a part of that," Mullen said.

The 17 rare earth elements, subcomponents of critical minerals, are identified by the U.S. Geological Survey as critical to national security or energy development.

They're not actually rare, Mullin notes, just hard to get.

From computer chips to the vibrating magnet in cellphones, rare earth elements are ever-present in an increasing array of technological devices.

"Critical minerals are in everything," Mullen said. "Every hour of your daily life, you are interfacing with critical minerals."

More demand

Touring Blaschak Coal's operation near Mahanoy City, Driscoll is positive about the state of the anthracite industry.

"I'm bullish on anthracite," said Driscoll, Blaschak's chairman since 2019.

Supply chain problems during the pandemic and sanctions against importing Russian coal in the wake of the Russia-Ukraine war increased demand for Pennsylvania anthracite, he said.

In addition, he predicts, demand will increase from overseas as Germany, France and Turkey install clean burning electric arc furnaces. Anthracite, which does not have to be converted to coke, is the preferred fuel for those furnaces.

Projects funded by the federal infrastructure bill, such as bridges, will require more domestic steel and boost demand for anthracite, Driscoll believes.

In 2021, an estimated 3.7 million tons of anthracite was mined in Pennsylvania, up about 4% over 2020, according to the latest state Bureau of Mines report. Industry analysts project an upward demand for anthracite through 2030.

Blaschak, which is owned by the Milestone Partners private equity firm in Villanova, and Reading Anthracite Co. are among the top producers of anthracite in the world, according to industry analysts.

Blaschak mines about 1 million tons a year, before processing, at strip mine operations in Mount Carmel, Primrose and Lattimer. The company is closing the Lattimer mine and opening a new one near Eckley.

Blaschak recently invested $4 million in a new Caterpillar 6020 excavator with a payload of 23 tons, which is expected to be delivered next month.

While traditional markets are strong, Blaschak is looking to new markets to sustain it in the future.

Working with Lehigh University's Energy Research Center, Blaschak is exploring the use of anthracite-based activated carbon in high performance supercapacitors and for use in scrubbing mercury from coal-fired power plants.

Dr. Carlos Romero, center director, said the facility has done several studies with Blaschak, funded by grants from Ben Franklin Technology Partners and the Pennsylvania Infrastructure Technology Alliance.

One Lehigh University research project in which Blaschak participated showed anthracite-based carbons were successfully used as electrode material for supercapacitors.

Supercapacitors are considered promising energy storage devices and have potential applications in automobiles, memory systems and wind turbines.

A second study at Lehigh University, also supported by Blaschak, examined the absorbent qualities of anthracite coal-based activated carbon in not only removing mercury from coal-fired power plants, but also cement kilns, industrial boilers, waste incinerators and steel mills.

"Due to the high cost of chemical preparation, an affordable alternative activated carbon with a high mercury capturing capacity would be beneficial to environmental security," the study found.

Future potential

A realist, Driscoll has no illusions about the resurrection of King Coal. An industry that produces around 4 million tons of coal a year is not likely to ever match the 100 million tons a year mined a century ago.

That said, Driscoll says even modest gains would have major effects.

"Let's dream," he said. "If anthracite production could be increased by 5 million tons a year, that would create 2,500 jobs and 6,700 indirect jobs in the region."

Contact the writer: rdevlin@republicanherald.com; 570-628-6007