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. The work also assessed restoration potential, land cover, and ecological impacts such as buried streams, identifying substantial stream burial and associated hydrologic and habitat impacts. Field and laboratory work included selecting and visiting seven representative sites, collecting approximately 20 soil samples per site, and analyzing soil fertility and constraints relevant to biomass production. Results showed that many sites were acidic, phosphorus and boron were generally limiting, and fertility varied widely across locations. Based on weighted comparisons, some sites (e.g., in Wyoming County) showed comparatively better soil fertility conditions than others (e.g., Fayette PA and Webster WV). The project also advanced environmental and economic modeling tools. It supported LCA modeling (including cradle-to-hopper and hopper-to-grave components) informed by the NETL CUBE framework, and developed engineering process models for multiple utilization pathways including bio-coal/briquettes, hydrogen (H₂), construction materials, and biochar. Economic impact analysis was conducted using input-output modeling to estimate regional economic effects. Overall, the project delivered integrated datasets, site characterization products, reclamation/BMP knowledge, and modeling capabilities that can support future deployment of biomass production and waste coal utilization strategies in Appalachia, while quantifying GHG reductions and regional economic benefits.