Ok TheDS, if you were to design a black hole powered star ship, what would the minimum size black hole be? Think of a World ship, say a cylinder that rotates for gravity, it would have some matter that it feeds into the black hole at the same rate that the black hole evaporates to convert matter into energy.
The manufacture of black holes might be made easier if gravity was a 4-dimensional or 5-dimensional force at short distances. If you had a series of particle accelerators that make temporary black holes and then quickly merge them into large black holes before they decay, and merge those in turn into still large black holes and so on and so on, increasing the mass or each resultant black hole so that it radiates slower. Above a certain mass you could simply force feed the black hole till it grows larger still until its relatively stable and converts only a small percentage of its mass into energy such that that percentage is equal to the inflow of matter.
Sorry I didn't see this sooner.
I don't have the math or figures available to me to give hard figures, so consider this to be back-of-the-envelop, wildass-guess calculations.
IIRC, the minimum mass a star can be to form a black hole is on the order of 10 solar masses, and the resulting hole is around 3 solar masses. No idea how long such a hole would last, but considering the observations necessary to support this, it's probably billions to trillions of years.
In our solar system, we have about 1.01 solar masses of material available. Take a look around you right now. That big rock you're sitting on is an insignificant mote compared to Jupiter, which is a mote compared to the sun. The sun puts out an amount of energy equivalent to the antimatter annihilation of 4 MILLION TONS of mass PER SECOND. Think about that. That's more energy than has existed on the planet in its entire 4.5 billion year lifetime, asteroid impacts and nuclear weapons included.
So, the short answer is: I wouldn't. The numbers boggle the mind, and I'm not even an engineer, who I'm sure would laugh you right out of his office for making such a proposition.
Actually having and feeding a black hole would create loads of radiation. I don't think you'd be allowed within 100 parsecs of an inhabited system, if you could even figure out a way to move it. But I suppose if you have the ability to catch/build one and not kill off the crew, then you can figure out some way to channel the energy in one direction and make a thruster out of it, or warp spacetime in some way. See, that's the other problem here: anything you or I say that makes it possible can be used to justify just about anything.
As to merging black holes into bigger ones, I really can't see a scenario where that's a good idea. Collisions like this tend to make big bada-booms, kinda defeating the purpose, and we're not talking about aggregating soap bubbles, we're talking about aggregating moon-masses or thereabouts. The rate at which you have to feed a black hole to make it gain mass, when it's moon-mass MIGHT be at the rate of X moons per second, but as I said earlier, I don't have the numbers to tell you for sure. Maybe (seriously) you could ask Dr. Hawking; I have no idea if he accepts fan-mail, but it's worth a try.