Core Natural Resources Reimagines Coal Through Technology

Few understand just how drastically technology has played a role in reshaping the coal industry. Through the use of highly engineered controls and equipment, as well as AI, the industry has evolved greatly. Coal mining has undergone significant changes over the years, and Core Natural Resources (formerly CONSOL Energy), one of the largest coal producers in North America, leverages these innovations to operate at the high level it does. Core uses technology and innovation to make the mining process not only more efficient but also significantly safer and more sustainable than in the past. Although some of this technology isn’t entirely new, the way it is applied and optimized is constantly evolving.

The demand for coal is growing, as global coal production and usage last year set an all-time record. Key drivers include the growth of AI (and its large energy needs) as well as global population and energy expansion, which create the need for coal in both power generation and non-power-generation applications. These include steel, concrete, water filtration, fertilizers, and many other items that touch all our lives each day. In fact, the transition to renewable energy sources, like wind and solar, is creating demand for coal through the massive infrastructure buildout needed to make them a reality.

The majority of Core’s mines are operated through a method called longwall mining, a highly mechanical underground mining method where a large wall of coal is cut using a shearer and conveyed to the surface. This mining method has continually been improved through automation, making these mines and their operations even more efficient. With this technology, some aspects of mining can even be managed remotely from above the surface, sometimes even without a physical human present at the mining location. 

Outside of the actual mining process, automation can also be used for the pre-mining process for risk assessments, simulations, and modeling. Equipment, like self-driving trucks and battery-operated equipment, is also increasing in popularity, but it is still evolving for more widespread use. Recently, the U.S. Department of Energy (DOE) has launched an initiative to help create the “mine of the future” and is providing federal funding to help mines accelerate these kinds of developments. 

These upstream advancements are a major focus at Core, and the company has also made significant strides in recent years to reimagine the downstream uses of coal through its Innovations team. While most people already don’t realize that coal touches everyday life in a vast number of ways, such as the examples cited above, Core has taken this a step further by thinking outside of the box and reimagining how coal might be used to meet future needs in applications like aerospace, battery manufacturing, and even composite decking. 

Aerospace Engineering

The Innovations team produces a rigid carbon foam material called CFOAM®, a low-density product that is heat, fire, and corrosion resistant with a high strength-to-weight ratio and electromagnetic shielding capabilities. Among many potential applications, CFOAM is currently used commercially in aerospace tooling because it can easily be machined into complex shapes. CFOAM tooling has been used in the manufacture of many military, commercial, and prototype aircraft and spacecraft, and it is growing as a tooling platform as the aerospace industry increasingly turns to high-performance, carbon-based materials.

C-BATT™

Through a joint venture with X-BATT, Core is working to develop Obsidia™, a breakthrough anode material that aims to solve performance and supply chain issues affecting lithium-ion batteries. Unlike battery-grade graphite, which is largely imported from China, Obsidia can be 100% sourced and produced in the U.S., and it offers increased energy density and improved cycling capabilities compared to graphite.

Coal Composite Building Products

Core is innovating new materials, such as coal plastic composite decking, that use waste coal resources to displace less sustainable materials (such as plastic or pressure-treated lumber) and meet rapidly growing demand for new construction and infrastructure.

Mining is no longer the industry it once was. Through advancements in technologies such as automation and AI, and the innovation of potentially disruptive new applications, Core Natural Resources is redefining the industry and coal’s capabilities. From autonomous longwall operations to creative products like CFOAM, C-BATT, and composite decking, Core is bringing coal further into everyday life. As the industry continues to evolve, these innovations showcase coal’s versatility as a resource that can help meet society’s most pressing needs of today and into the future.