CCR, CCP, CCS, CCPS, ELG, COAL ASH, SWM, O&M, SWM
Confirmed & Invited Speakers | Track H
This Track provides presentations on current technologies and strategies for Coal Ash, CCR, CCP, ELG, SWM, O&M, Impoundments, Ponds, and Liners.
Advisory Board
Coal Ash | ACCA | CCR | CCS | ELG
Thomas Adams
Recent Developments in SCM Supply (Confirmed)
Recent Developments in SCM Supply
Thomas Adams – ACAA
The demand for supplementary cementitious materials (SCM) continues to grow. The demand for higher performance from concrete mixtures has created a necessity for the use of coal ash, natural pozzolans, slag cement, and silica fume in order to achieve owner and designer goals. Carbon reduction efforts by the cement and concrete industry rely on increased SCM use. Coal ash has historically provided the largest volume of SCM to concrete producers, more than double all the SCM available in the U.S. This presentation will cover recent initiatives to close the gap between supply and demand.
Curtis Wilie
Coal Ash as a production enhancement for oil and gas production (Confirmed)
Coal Ash as a production enhancement for oil and gas production
Curtis Wilie – Enhanced Solutions Services
Coal Fly Ash Micro-Proppant Technology for Production enhancement Curtis Wilie, Jim Crenshaw, Enhanced Solution Services, LLCHouston TexasThomas Robl, Anne Oberlink and Robert JewellThe University of Kentucky, Center for Applied Energy Research, Lexington, KentuckyABSTRACTEnhanced solution services and the University of Kentucky Center for Applied Energy Research are collaborating in the development of micro proppant technology based on the use of Class F fly ash. Fly ash can be tailored into an ideal micro-proppant as it is inert, strong, smooth, round, and relatively light weight. Its size allows it to prop much smaller fractures than conventional proppants. The processing of Class F ash has produced fine silt sized proppants with hydraulic conductivities of fine sand, void volumes of over 50%, and bulk densities of less than 1.1 gm/cm3. Most significantly fly ash forms a stable slurry that can pumped without settling at very low rates and still deliver significant hydraulic conductivity. This eliminates the need for viscosity modifiers resulting in simpler and less costly post fracking cleanup, lower horsepower requirements and smaller site footprints. ESS, LLC has been using both processed and run of plant fly ash as the primary proppant in fracking operations since 2017 Using our patented approach, over 70 well stimulation projects in over 22 different formations have successfully been executed in Texas, Oklahoma,Kansas, and Israel. with current plans for applications in Kentucky. This technology when combined with plugging and abatement strategies promises a greener future for unconventional oil and gas production.
Paul Lear
Hydraulic Containment at CCR Sites: Now More than Ever
Hydraulic Containment at CCR Sites: Now More than Ever
Paul Lear – Forgen
Hydraulic containment involves controlling the movement of contaminated groundwater, preventing the continued expansion of the contaminated zone. Given the recent EPA comment on CCR Rule Part A and Part B extensions, CCR impoundments and landfills undergoing closure or closed in-place with CCR in contact with groundwater could benefit from hydraulic containment.Several techniques are available for achieving hydraulic containment. A overview of these hydraulic containment techniques will be given to familiarize the audience with these technologies and their pros and cons.An example project where in-place soil mixing was utilized to establish a one mile long, vertical, low permeability hydraulic control around a site, containing two former landfills and adjacent to riverine wetlands, to prevent contaminated groundwater from entering a nearby river will be discussed to demonstrate the applicability of hydraulic containment.
Tom Kierspe
COAL ASH HARVESTING FOR BENEFICIAL REUSE – CHALLENGES AND LESSONS LEARNED
H5.5 COAL ASH HARVESTING FOR BENEFICIAL REUSE – CHALLENGES AND LESSONS LEARNED
Tom Kierspe, P.E.
Issues and options to close and clean up legacy ash ponds can generate a great deal of attention from neighbors and local community organizations, environmental advocacy groups, ratepayers, economic development agencies, and ash users. Fortunately, the knowledge base for harvesting and beneficiation of CCP impoundments has continued to increase and thereby removed much of the uncertainty about the technical capability to beneficially reuse the CCP material. Now, based on years of commercial operating experience, there are many lessons learned surrounding characterization and management of the stored CCPs, harvesting practices, and other considerations that, taken into consideration, can serve to increase the likelihood of a positive outcome for all stakeholders. Minimizing overall cost, optimizing removal timeframes, and operational efficiencies for closure are just some of the factors that can be positively influenced by drawing on actual experience.
In this presentation, the challenges and lessons learned from active reclamation and beneficiation projects will be reviewed, as well as the potential benefits from incorporating this knowledge into future projects.
The SEFA Group, 219 Cedar Road, Lexington, SC 29073
KEYWORDS: Coal Ash Beneficiation, Beneficial Reuse, Encapsulated Reuse, Coal Ash Recycling, Thermal Beneficiation, Pond Reclamation, STAR Process, Stakeholders, CCP Impoundments, Characterization
Jim Aiken
Update on EPA Part A, Part B, and Consent Order Determinations with Applications for CCR Legacy Rule (Confirmed)
Update on EPA Part A, Part B, and Consent Order Determinations with Applications for CCR Legacy Rule
Jim Aiken – Barr Engineering Co.
The 2015 EPA CCR Rule was originally intended as a ‘self-implementing’ rule that left many critical decisions up to the owner and their designated qualified professional engineer (QPE). Without a permitting program, and without clear guidance on how EPA is interpreting the rule, the default compliance paradigm has been the use of general industry practice as a standard of care. More recently, the EPA’s determinations (Part A, Part B, and Consent Orders) have provided much more insight into what the EPA considers compliant-and in some cases-appears to require a new standard of care. This presentation summarizes the four main categories cited by EPA as deficient, including Site Characterization, Reporting/Certifications, Statistics, and Alternative Source Determinations as well as a tally of EPA’s findings in each category. We will summarize each deficiency type and offer ideas on improving compliance. For example, a common type of deficiency can be described generally as “a lack of rigor” in evaluating data and testing alternative hypotheses. Enhanced data collection and analysis techniques may offer a more defensible basis for conclusions in the event of future EPA or state enforcement actions. The insight offered by this analysis may be used to inform compliance under the anticipated CCR Legacy Rule, which brings in a new type of CCR unit called the CCR Management Unit or CCRMU. Defining and monitoring CCRMUs will require a degree of rigor that we believe can borrow from the insight gained from evaluation of the EPA’s previous determinations.
Mark Rokoff
Setting the Stage: Proposed Legacy CCR Surface Impoundment Rule (Confirmed)
Setting the Stage: Proposed Legacy CCR Surface Impoundment Rule
Mark Rokoff – Burns & McDonnell
On May 18, 2023, the EPA published their proposed Legacy CCR Surface Impoundment Rule which has created quite a stir in the scope and breadth of what is intended to be required (and the corresponding schedule to execute). There is a lot to understand and subsequently begin planning for based on the proposed requirements throughout the fleet. Mark Rokoff will present a deeper dive into new rule to aid in understanding and implementation. The presentation will focus on the following:
- Stage setting: Review a modern history of the CCR Rule and discuss why and how we got here
- Overview of the Rule: A high-level overview of the content of the rule and key issues
- Detailed Summary: An intentional presentation of the rule, what is included, how it applies, what needs to be done and the proposed timing (with a bit of commentary)
- Preparation: A conversation of next steps to prepare for implantation and a discussion of what may come. Intended to be a comprehensive conversation on the new legacy CCR Rule and address how to prepare.
Impounded CCP Harvesting | CCP | CCR
Kyle Flynn
Beneficiation of Harvested Fly Ash Using a Triboelectric Belt Separator (Confirmed)
Beneficiation of Harvested Fly Ash Using a Triboelectric Belt Separator
Kyle Flynn – Separation Technologies
Tribo-electrostatic separation has been used for the commercial beneficiation of coal combustion fly ash to produce a low carbon product for use as a cement replacement in concrete for twenty-five years. With 24 separators in 18 coal-fired power plants and cement plants across the world, Separation Technologies’ (ST) patented electrostatic separator has been used to produce over 20 Million tons of low carbon product that has been recycled for use in concrete or cement production.To date, commercial tribo-electrostatic beneficiation of fly ash has been performed primarily on dry “fresh” or “production” ash. Reductions in the quantity of dry fly ash generated and requirements to empty historical ash landfills and ponds has created the need to develop a process to reclaim and beneficiate landfilled or ponded ash.
ST has developed and commercialized a new process for beneficiation of reclaimed fly ash from landfills and ponds that utilizes fly ash drying and deagglomeration technology together with the ST tribo-electrostatic carbon separation technology. ST has installed a demonstration of this new process at the Talen Energy Brunner Island power station near York PA. The ST fly ash beneficiation process offers both utility and cementitious materials customers an environmentally friendly, low-carbon emission, fly ash recycling technology which enables cost effective landfill and pond reclamation.
John Ward
H 3.2 Coal Ash and Politics: Two Things That Aren’t Polite to Discuss at the Dinner Table
H3.2 Coal Ash and Politics: Two Things That Aren’t Polite to Discuss at the Dinner Table
John Ward – John Ward Inc
| Implementation of the U.S. Environmental Protection Agency’s 2015 regulation for coal combustion residuals disposal is well under way, but that hardly means the science is settled. Several additional CCR related rulemakings remain open at EPA and recent actions by the Agency interpreting aspects of the 2015 rule have created uncertainty and attracted litigation. This presentation will summarize the current regulatory state of play and discuss potential future impacts of political shifts in Congress, the presidency, and U.S. Supreme Court. |
Michael Hunter
H 3.3 Cost-effective, Green, Concrete Domes for Bulk Storage of CCPs
H3.3 Cost-effective, Green, Concrete Domes for Bulk Storage of CCPs
Michael Hunter, CEO – Domtec International, LLC
This paper focuses on optimizing bulk storage of Coal Combustion Products (CCPs). It discusses state-of-the-art, green (climate friendly), storage structure solutions for plants, terminals and ports using concrete domes in both domestic (USA) and overseas markets.
Various successful storage projects will be discussed including for fly ash, limestone, coal, and FGD gypsum. The benefits of dome storage will be addressed as well as various methods for product handling and reclaim, including automated reclaim systems mechanical and pneumatic (screws, stacker-reclaimers, and fluidized floors, etc.).
The paper will also demonstrate how concrete domes are truly a ‘green’ storage structure alternative.
3 short Questions
- How are concrete domes a more efficient type of storage structure?
- In what ways are concrete domes considered ‘green’?
- What is a concrete dome’s productive life span?
Co-authors: Zac Fillmore, Ted Parkinson
Bill Fedorka
H 3.4 Six Years of Service, Supply, and Success: Processing Harvested CCR from Impoundments
H3.4 Six Years of Service, Supply, and Success: Processing Harvested CCR from Impoundments
Bill Fedorka – The Sefa Group
The positive economic and technical benefits of utilizing fly ash as a replacement for cement in concrete has an extensive and successful history. However, the availability of fly ash for use as a supplementary cementitious material (SCM) in concrete has decreased dramatically. Harvested CCR from legacy disposal and storage sites has proven to be a valued source of material.
The SEFA Group began testing the use of harvested CCR as a replacement for production fly ash in 2012. In 2014, SEFA decommissioned its CBO Plant at Santee Cooper’s Winyah Station and constructed a STAR® facility designed to operate with 100% reclaimed fly ash as its primary raw feed source.
Since commercial operation in 2015, nearly two million tons of CCR from onsite ash impoundments has been reclaimed and processed at the Winyah STAR® Plant. It has consistently produced a product ash below 1.0% loss on ignition (LOI), while meeting all relevant specifications for use in ready mix concrete as a replacement for Portland cement.
In late 2020, and early 2021, SEFA commissioned three (3) new STAR Facilities in North Carolina that use 100% reclaimed CCR as raw feed. Combined, these facilities are capable of processing upwards of 1.5 million tons per year of legacy CCR. Since coming online, nearly 1 million tons of coal ash have been permanently removed from the environment and recycled for encapsulated use in the concrete products market.
Chris Poling
H 4.4 Taking on the Challenge of Ponded Ash Benefication & Generating Cementitious Fly Ash
H5.4 Taking on the Challenge of Ponded Ash Beneficiation & Generating Cementitious Fly Ash
Chris Poling – Ash-TEK
There are several technical challenges that must be overcome to beneficiate landfilled and ponded coal ash. These ashes undergo a series of chemical and physical changes which makes recovering them for beneficial re-use a challenge. After years of exposure to the elements many of the alkalis have dissolved and then re-deposited themselves as oxidation on the surface of the particle. The overall reactivity of the ash has been significantly reduced due to the high moisture content of the storage pond or landfill. The original qualities which prevented the ash from being used in concrete still exist in terms of ammonia, sulfur and/or high LOI or other contaminants.
The PABS offered by Ash-TEK and supported by LafargeHolcim delivers a consistently high quality ash which has repeatedly demonstrated improved performance above and beyond that of freshly generated ash in terms of strength, workability and water demand. The benefits include:
– elimination of groundwater contamination
– increased property values
– lower cost cementitious material
– contribution to the circular economy
– increased local employment
– Reduced GHG emissions compared to Portland Cement
The system is portable, patent pending, simple, and will be commencing industrial operation in 2023.
Randall Stremmel
Beneficial Reuse of CCR to Manufacture LEED Construction Material without Creating Another Waste Stream (Confirmed)
Beneficial Reuse of CCR to Manufacture LEED Construction Material without Creating Another Waste Stream
Randall Stremmel – Brixx Technology
This abstract discusses the research and development undertaken by Brixx Technology to utilize coal combustion residuals (CCR) in manufacturing sustainable building materials. The study aimed to determine the feasibility of producing eco-friendlier alternatives to existing reuse programs. The process involved a systematic approach to meet ASTM specifications for commercial building materials while ensuring economic viability. Initial experiments were conducted on a pilot scale, validating the feasibility of producing high-quality products using off-spec, F-class, and landfilled ash. The process involves combining fly and bottom ash with proprietary binders, water is added, and the mixture is pressed into desired shapes, followed by hydrothermal curing to form durable building materials. Mechanical properties were validated through internal and accredited laboratory testing. A mass production facility was established in India, demonstrating consistent quality and financial feasibility, followed by a facility in the United States in Ohio. Environmental benefits include reduced energy consumption, shorter production times, and elimination of waste streams. Alternative uses of CCR, combined with other industrial waste, were explored successfully. Future directions involve sequestering CO2 in the manufactured products. The study showcases the potential of CCR-based building materials for sustainable construction practices.
CCP Risk Assessment | CCR | Cement | Ponded Ash Beneficiation | CCPS & CO2 Uptake
Ari Lewis
H 2.1 Risk Assessment at Coal Combustion Product Sites for Remedy Selection and Public Communication
H2.1 Risk Assessment at Coal Combustion Product Sites for Remedy Selection and Public Communication
Ari Lewis – Gradient
The 2015 federal coal combustion products (CCPs) Rule does not include a specific provision for the use of risk assessment at CCP storage sites. However, issues related to remedy selction and potential future revisions to the CCP Rule raise the possibility of using risk assessment to support various closure-related activities, including remedy selection and implemenation, alternate liner demonstrations, and risk communication. In the absence of specific guidance from the federal government risk assessors will need to consider relevant state guidance, constituents of interest, populations of interest, exposure assumptions, and the appropriate use(s) of measured and modeled environmental data.
Tiffany Duffy
H 2.2 Beneficiation of CCPs through CO2 Uptake & Mineralization
H2.2 Beneficiation of CCPs through CO2 Uptake & Mineralization
Tiffany Duffy – Carbon Upcycling
| This presentation will introduce the CCP beneficiation process developed by Carbon Upcycling Technology. The technology utilizes the CO2 from a power plant’s flue gas stream and CCP waste streams to improve the performance and marketability of low-quality materials. Information will include an explanation of the technology, real-world applications, and verified performance as a solution to recycle and reuse CCP waste streams. |
Jack Ma
H 2.3 Considerations for the Successful Pond Closure and Water Treatment Under Today’s CCR Rule
H2.3 Considerations for the Successful Pond Closure and Water Treatment Under Today's CCR Rule
Jack Ma – UCC Environmental
This paper discusses the key considerations for the coal combustion residuals (CCR) pond closure and impoundment water treatment. In the development of CCR rule, the EPA’s technical evaluation concluded that closure-in-place and closure-by-removal of coal ash ponds were the best options to protect our environment for generations to come. It is worth noting that the common denominator of closure-in-place and closure-by-removal is the dewatering process and water treatment. The development of cost-effective technologies to treat ash pond water and reliably remove arsenic, selenium and mercury from water have been prioritized by coal fired power industry as environmental standards are currently very low in North America with a potential to be even lower. In addition to provide insights on various physical and chemical technologies for ash pond water treatment, this paper highlights the lessons learned from one full-scale case study with arsenic as one of the primary treatment goals. The full-scale treatment process was configured as a robust system consisting of flow and constituent equalization, multi-chemical injection for the pH control and particulate coagulation, staged filtration for the solids separation, and activated media adsorption of dissolved arsenic. The development of project specific treatment technologies should be prioritized to ensure full compliance with regulatory limits while minimizing the costs attributed to ash handling and water treatment.
John Hagan & Mike Lynch
H 2.4 Insurance Coverage for CCR Investigation and Remediation
H2.4 Insurance Coverage for CCR Investigation and Remediation Costs
John Hagan and Mike Lynch – K&L Gates
Insurance policies may provide utilities with significant funding for CCR-related investigation and remediation costs. In particular, a utility’s historical liability policies purchased decades ago may pay for the property damage (including contamination of soil and groundwater) that has occurred. Our presentation will identify key issues relating to insurance recovery for CCRs, answer common questions, and offer tips from our decades of experience helping utilities secure coverage for environmental claims.
Co-Author: Michael Lynch, K&L Gates
David Donkin
Managing Outage Wash Water Treatment with Existing Infrastructure (Confirmed)
H1.1 Lessons Learned from Using Bottom Ash Dewatering Systems to Treat Outage Wash Wastewater
David Donkin – UCC Environmental
The coal-fired electrical utility sector is faced with the regulatory requirement to retire their coal ash sluicing ponds under the finalized Coal Combustion Residuals (CCR) regulation in the Spring of 2021. Wet-to-dry ash handling solutions are being implemented throughout the fleet to allow ponds to come out of service. However, the final disposition of outage wash wastewater, specifically the wastewater generated from washing boiler internals, air pre-heater, economizer and precipitator systems must also be considered. Historically these washwaters were simply directed to the CCR pond along with other ash materials and treated by dilution and settling prior to discharge. This option is longer available. The primary constituents of concern are total suspended solids, iron, copper and other heavy metals, and pH control. In addition, outage wash wastewater presents unique challenges with respect to wide flow variations and contaminant loading changes throughout a wash. A temporary or permanent retro-fit of existing wet-to-dry bottom ash handling systems can allow these systems to serve as a wastewater treatment system in order to meet water quality requirements with respect to outage wash wastewater streams. UCC Environmental’s lessons learned from over 2 years providing these retrofits and treating wastewater from outage washes will be reviewed.
Marc Theisen
H 1.2 Engineered Soil Cover Systems for Sustainable CCR Closures
H1.2 Engineered Soil Cover Systems for Sustainable CCR Closures
Marc Theisen – Profile Products LLC
Design and construction of cost-effective cover systems are critical to successful CCR closure projects. Traditional cover system designs involve placement of highly specialized barrier and drainage systems capped with 12-18” of cover soils, then topped with 4-8” of a “vegetative soil layer”. On large closure projects the costs of procurement, transportation and placement of suitable topsoil can be exorbitant. Emerging topsoil alternatives such as Engineered Soil Media can make even marginal soils suitable for vegetative establishment while offering significant cost savings. Vegetation is the most sustainable consideration for CCR closures, providing immeasurable environmental benefits as expounded in this presentation.