UW SER Advances Coal Refinery Field Demonstration Plant, Unlocking New Markets for Wyoming Coal

Researchers at the University of Wyoming School of Energy Resources (SER) spent much of the fall semester overseeing the construction of a coal-to-products field demonstration plant at the Wyoming Innovation Center (WyIC) near Gillette. The demonstration plant is a major step forward in creating new and diversified markets for Wyoming coal.

The coal refinery process developed by SER's Center for Carbon Capture and Conversion (CCCC) integrates flash pyrolysis and solvent extraction technologies to produce both intermediate feedstocks and finished products from coal. The integrated process yields beneficial liquids and solids that then are used to manufacture valuable, non-energy products, such as building and construction materials, asphalt products, synthetic graphite and agricultural soil amendments.

The facility also will provide material for in-depth research on concentrated critical mineral/rare earth element recovery from unconventional feedstocks.

With the aim of developing new, additional revenue streams and uses for Wyoming coal, CCCC researchers have successfully worked for a decade refining the novel process and developing the coal-derived carbon products with support from the state of Wyoming and private investment, most notably from Peabody, and partnerships with the Wyoming Department of Transportation.

"There are so many benefits resulting from these projects supporting both the energy and agricultural sectors in Wyoming, as well as new industries in manufacturing, processing and engineering," says CCCC Director Trina Igelsrud Pfeiffer. "By constructing this integrated coal processing field demonstration plant at the Wyoming Innovation Center, we are not just testing technology -- we are building a foundation for a diversified economy for Wyoming."

Construction of the pyrolysis portion of the coal refinery field demonstration plant is nearing completion. The construction team will work as needed through the winter to be ready for the delivery of the pyrolyzer in the spring. Start-up and commissioning activities are anticipated in August.

WyIC, a facility dedicated to advancing carbon products using coal and its by-products, is the perfect location for the project, providing ample space for scaling up lab research into commercially viable products. It's also adjacent to some of the largest coal mines in the Powder River Basin.

The facility is managed by Energy Capital Economic Development (ECED).

"This is precisely what this facility was designed to support," says ECED CEO Rusty Bell. "As the largest project at WyIC, this initiative, alongside our other current tenancy hosting an SER-led project, exemplifies our mission to bridge the gap between research and commercialization utilizing Wyoming coal."

Meanwhile, construction of the solvent extraction portion of the coal refinery field demonstration plant is planned to begin in late 2026 and will occur concurrently with operation of the pyrolysis unit. Once fully integrated, the two processes will efficiently process Wyoming coal from multiple basins, providing sufficient feedstock to support downstream product development, scale-up operations and applied research.

"Scaling up our technology has reached a critical juncture as we work to ensure these products transition from the lab to being economically viable and efficient on a commercial scale," Igelsrud Pfeiffer says. "Simultaneously, we have been diligently developing several downstream initiatives, such as our coal-to-asphalt product, that must also be proven on a larger production scale. The ripple effects that this field demonstration will have once completed are tremendous and are expected to extend well beyond the facility itself."

Scale-up and successful testing of the facility in the Powder River Basin mean it can be replicated and adapted for other Wyoming coals, providing a lifeline for mines scheduled to close.

One such entity is the Kemmerer Mine in southwest Wyoming. As a demonstration of its confidence in the program, Kemmerer Operations LLC recently contributed philanthropic support, establishing the Kemmerer Mine Carbon Innovation and Technology Fund to subsidize activities that advance coal-to graphite research, including applied research, resource assessments, pilot projects and related materials development.

"We are very grateful to Kemmerer Operations for their generous support," says SER Acting Executive Director Scott Quillinan. "This gift underscores the importance of industry support, strategic partnerships and investment in driving high-impact research forward."

With the project nearing a significant implementation phase, its completion is essential to realizing statewide economic and research benefits.

"With the finish line now in sight, continued and immediate support is more critical than ever to ensure this project remains on track," Quillinan says. "We are hopeful that the state will help to maintain our momentum and carry this work fully into operation."

To learn more about the project and other technologies under development in the CCCC, visit www.uwyo.edu/ser/research/centers-of-excellence/carbon-capture-conversion/index.html.