Materials Science and Engineering Commons^™

Rare Earth Element Distribution And Mineral Host In Coal Derived Ash From South African Power Stations, Sanki Biswas, Nicola Wagner, Oftense Moroeng

World of Coal Ash Proceedings

The global shift toward low-carbon energy systems, electric mobility, and digital technologies has sharply increased the demand for critical minerals, including rare earth elements (REY) vital for permanent magnets, batteries, wind turbines, photovoltaic cells, semiconductors, and modern defence applications. Coal by-products—particularly coal fly ash (CFA) and coal bottom ash (CBA)—are emerging as promising secondary sources of REY, but their economic viability depends on effective enrichment and extraction methods. South Africa’s coal-fired power plants generate nearly thirty million tonnes of coal-ash each year. This study investigates REY concentrations in CFA and CBA collected from five major power stations (PS-1 to PS-5) …

Lessons Learned From Managing Ash Pond Closure Waters, Danny Stephens, Tom Geeza, Phil Benson, Ashwin Ranna

World of Coal Ash Proceedings

The water management issues created by ash pond closure are complex and can create technology selection and operational management challenges. Ash dewatering activities produce highly variable effluents, depending on ash composition, aging, and dewatering and stormwater management techniques. Effluent limitations can also be highly variable, depending upon the size of the receiving body and the anticipated composition of the effluent stream. The user often faces competing risks: installing an unnecessarily complex and expensive treatment plant, being limited on closure activities by limitations in water treatment capabilities, or both. This paper presents several lessons learned from assessing ash closure water management …

Epri Ccp Beneficiation Research Update, Benjamin Gallagher, Patrick Webb

World of Coal Ash Proceedings

Coal combustion products (CCPs) are frequently utilized as supplementary materials in cement and concrete manufacturing. With an estimated 2 billion metric tons stored in repositories across the United States, interest in beneficial use has expanded beyond class F fly ash to include ponded and high-LOI ash. Beneficiation provides a critical pathway for managing CCP repositories, particularly under closure-by-removal strategies, and where ash sources have historically been difficult to process. Research conducted at EPRI’s Ash Beneficial Use Center (ABUC) examines the feasibility of processing these ash types into usable products and offers insights into repository variability and classification. Furthermore, the study …

Risk Evaluation Of Small Coal Combustion Residual Management Unit (Ccrmu) Fills, Andrew Bittner, John Kondziolka, Qian Zhang, Masoud Arshadi

World of Coal Ash Proceedings

US EPA expanded the scope of CCR regulations in 2024 to areas of historical CCR placement not regulated under the 2015 CCR rule, including CCR used as fill. US EPA presented new risk analyses specific to CCRMU fills and defined different regulations for CCRMU fills from 1 to 1,000 tons, noting uncertainty as to whether there was a size of CCRMU fill below which acceptable risks could be expected. This research fills US EPA's stated data gap by modeling and analyzing impacts from small CCRMU fills. Modeling was conducted using the same methods, models, and most of the same inputs …

Consolidation Modeling To Support Closure Planning Of An Upstream Raise Ccr Surface Impoundment Containing Fgd Material, Tanya Walkenbach, Craig Schuettpelz, Todd Stong, Shane Stockdill

World of Coal Ash Proceedings

Rainbow Energy Center’s (REC’s) Coal Creek Station has managed calcium sulfite flue gas desulfurization (FGD) material in composite-lined upstream raise surface impoundments since 2001. The upstream raise surface impoundment utilizes bottom ash (drainage zone) and fly ash (structural zone) produced at Coal Creek Station to contain the FGD placement. FGD material was hydraulically sluiced to the center of the 110-acre Upstream Raise 92 (UR92) coal combustion residual (CCR) unit between 2001 and 2021. The FGD was deposited to a maximum thickness of approximately 100 feet in the center of the unit. Significant consolidation of FGD material occurred with subsequent FGD …

Investigating The Performance Of Processed Stockpile Fly Ash For Low Carbon Concrete, Michael Mccarthy, Arfas Habeeb, Laszlo Csetenyi, Roderick Jones

World of Coal Ash Proceedings

Reducing embodied carbon in concrete has increasingly focused on clinker substitution through the use of supplementary cementitious materials (SCMs). However, the local availability of fly ash, a widely used SCM in the UK, offering benefits in this role, has reduced over the past decade, as coal-fired electricity generating plants have gradually been taken out of service. Attention has, therefore, increasingly focused on fly ash from stockpile and landfill sites to maintain supply, i.e., material not used following production and put into storage. Most UK fly ash originated from the burning of bituminous coal, producing low-lime siliceous material, which although undergoing …

Solar Solution For Closed Ccr Units And Adjacent Land, Chris Fairey

World of Coal Ash Proceedings

Solar Solution for Closed CCR Units and Adjacent Land Chris Fairey1, Kenny Hughes1 1Watershed Geo, 1125 Sanctuary Pkwy, Suite 180, Alpharetta, GA 30009 KEYWORDS: Solar, Racking, Brownfield, Greenfield, Slopes, PowerCap® ABSTRACT With the reduction in coal fired power generation, there is a consistent trend in the industry to supplement generation with solar power. The property located within and surrounding these decommissioned power plants offers a significant opportunity to create a renewable solar power asset. The PowerCap® Nail to Rail System, developed by Watershed Geo, is an advanced solar racking solution designed for sites that do not require environmental closure such …

Investigation Of A Historical Coal Combustion Residuals Management Unit (Ccrmu), Todd Stong, Shane Stockdill, Erin Hunter

World of Coal Ash Proceedings

Rainbow Energy Center’s (REC’s) Coal Creek Station has managed coal combustion residuals (CCR) in various engineered impoundments and landfills since plant operation began in 1978. Since then, waste containment methods have evolved resulting in significant changes to their CCR management practice. In the late 1980s and early 1990s REC closed several existing CCR units with natural soil liners and constructed several new CCR units with composite liner systems. One of the closed units was an area now referred to as North Section 16, an impoundment that received CCR including bottom ash, fly ash, and flue gas desulfurization material. North Section …

Transportation Logistics Panel, John Ward, Andrew Vollmer, Tracy Zea, Marci Jenks

World of Coal Ash Proceedings

As the industry shifts from freshly generated ash to harvested materials and advanced utilization, logistics is becoming one of the primary drivers of project success or failure. This moderated panel will explore how sourcing, transportation, and storage realities are changing — and what project teams most often underestimate when working with harvested coal ash. Panelists will discuss what breaks, what becomes more complex, and how logistics considerations are reshaping planning and development.

Abundances Of Elements In Global Coals, Shifeng Dai

World of Coal Ash Proceedings

The abundance of elements in coal is important not only because it provides a solid scientific and practical foundation for various geochemical comparisons, but also because it helps address broader questions in Earth Sciences. In this study, data on major and trace elements in global coals comprising hundreds of thousands of coal samples were compiled from peer-reviewed journal articles, books, various databases, dissertations, and technical reports. These data formed the basis for estimating element abundances in global coals presented in this study. All collected data were rigorously screened for reliability, and any records with questionable quality were excluded from the …

Optimization Of Remedial Strategies For Ccr Site Corrective Action Through Advanced Geochemical Modeling, Cole Mayer, Pj Nolan

World of Coal Ash Proceedings

The power industry is actively designing and implementing corrective measures for Coal Combustion Residuals (CCR). In many cases, these measures include active remedies such as pump and treat, in-situ injection, or reactive barriers, all of which demand a thorough understanding of the underlying geochemical system. Depending on the geochemical characteristics of an aquifer, different chemical reagents can achieve varying degrees of success or even be detrimental to the remediation of the site. Advanced geochemical modeling is an invaluable tool for developing a remedy that is optimized to the site-specific geological, hydrological, and geochemical environment. In the case study presented here, …

Application Of Stable Isotopes In An Alternative Source Demonstration, Alison O'Connor

World of Coal Ash Proceedings

Stable isotope analysis is commonly used in age dating, provenance studies and to differentiate between sources of groundwater. Multiple studies have shown that strontium and boron isotopic ratios can be successfully used in identifying CCR impacts to groundwater. This talk presents an applied case study using boron and strontium isotopes in conjunction with additional geochemical approaches in an alternative source demonstration. Boron and strontium isotopes were measured in both groundwater and CCR leachate over sampling events from 2019 to 2025. The data revealed that strontium and boron isotopic signatures in groundwater near the CCR unit differed significantly from both site-specific …

Alternative Cover Permitting And The Ccr Rule, Evan Andrews, Victor Damasceno

World of Coal Ash Proceedings

Federal rules (40 CFR Parts 9, 257 and 261) that regulate coal combustion residuals (CCR) created a significant demand associated with closure of coal ash management and storage facilities using liner systems. Timelines associated with these facility closures combined with substantial project scale and potential for future mining /reuse has driven the need for closure systems that perform beyond the prescriptive soil / geomembrane caps outlined in the federal regulations. As outlined in section 257.102 (d)(3)(i) of the CCR Rule, the standard cover system must include an infiltration layer of at least 18 inches of earthen material and an erosion …

Ccr Landfill Closure Challenges, Solutions And Innovation, Jay Mokotoff, Drew Browning, Steve Applegate

World of Coal Ash Proceedings

CCR landfills can present unique design and construction challenges for the industry when closing these units at the end of their life. In comparison to CCR surface impoundments, CCR landfills typically have greater flexibility under the CCR Rule for operations and beneficial use purposes and may not have defined closure dates which results in some of these closures extending further into the future. However, as coal burning plants continue to shudder, the closure of these landfills is rapidly approaching. This presentation will focus on the challenging site conditions, site specific considerations and potential solutions when designing and constructing the landfill …

Distinguishing Ccp From Nuclear Impacts In Groundwater, Lea Millet

World of Coal Ash Proceedings

As the energy transition from fossil fuels to other generation technologies continues, many companies worldwide are evaluating the feasibility of constructing nuclear power plants at sites previously used for coal-powered generation. Thermal power plant sites offer advantages for siting nuclear generation such as proximity to cooling water and grid connections; however existing impacts to groundwater from coal combustion product (CCP) management units may confound monitoring programs designed to detect impacts from nuclear operations. For example, boron and lithium may be present in waters associated with CCP management and nuclear power plant operations, and potassium that often has concentrations above background …

Engineering Granulometry To Optimize Performance Of Reclaimed Ash, Russell Hill

World of Coal Ash Proceedings

As utility production of fresh fly ash declines, the concrete industry is turning to reclaimed and beneficiated materials to maintain reliable SCM supply. This transition creates an opportunity not only to secure volumes but to engineer improved performance. The ReCinis™ beneficiation process enables this by providing controls that tune particle-size distribution (PSD), sphericity, packing behavior, surface area, and surface activation. Processing trials show that blends combining fine ground fractions with spherical, broad-graded hydrocyclone overflow (OF) materials can balance high reactivity with favorable rheology. Mechanochemical activation during grinding appears to increase reactivity beyond what surface-area metrics alone predict, likely through removal …

Sustainability And Waste Diversion At Tva Shawnee "Project Phoenix", Bryan Jacob, Shane Harris

World of Coal Ash Proceedings

An engineered turf closure system can serve as an ideal foundation for a solar energy system to be installed atop coal combustion residual (CCR) impoundments. This approach not only enables productive power generation during the post-closure period, it also preserves opportunities for recovery and beneficial use of CCR material in the future. “Project Phoenix” at TVA’s Shawnee Fossil Plant offers an illustrative example. This paper will cover the sustainability benefits of the companion ClosureTurf® and PowerCap® systems installed at that site as well as waste diversion activities undertaken during construction to recycle as much as practical and minimize waste destined …

Expert Perspectives On The U.S. Coal Combustion Products Market – Now, Then, And The Future, Mark Rokoff, David Cox, Walter Lemaire, John Ward

World of Coal Ash Proceedings

This panel discussion will explore the continued evolution of the U.S. coal combustion products market, with a focus on the impacts of dynamic regulatory and market forces. Invited expert panelists will share perspectives on developments over the past several years (building on discussions from WOCA 2022 and WOCA 2024), current conditions, and expected future trends—particularly those likely to shape the market between 2026 and 2030. The discussion will address the interrelated markets for engineering, construction, and beneficiation of ash from both operating and inactive plants. Panelists will offer perspectives relevant to the full coal ash industry, from owner/operator organizations to …

Demystifying Large Language Models: How Ai Is Transforming Data, Compliance, And Decision-Making In Coal Ash And Environmental Management, Scott Pfeiffer

World of Coal Ash Proceedings

The environmental and coal combustion residuals (CCR) industries generate vast amounts of information—from groundwater monitoring reports and RCRA documentation to closure plans and analytical data. Managing, interpreting, and communicating this information is a growing challenge for utilities, regulators, and consultants alike. Large Language Models (LLMs), such as OpenAI’s GPT architecture, represent a breakthrough in how organizations can interact with their technical data. These models use deep neural networks trained on billions of words to understand, summarize, and generate language with human-like accuracy. When securely adapted for enterprise use, LLMs can automate routine reporting, extract data from technical documents, generate regulatory …

Subsurface Delineation Of Coal Combustion Residuals Using Multiple Geophysical Methods, Eric Hageman, Adam Rak, Thomas Jordan, Kate Mckinley

World of Coal Ash Proceedings

Geophysical techniques provide alternative methods of Coal Combustion Residual (CCR) delineation and characterization to supplement more invasive boring programs used for beneficial reuse planning. A demonstration project was designed to characterize the electromagnetic and seismic stratigraphy of CCR material and test the effectiveness of three geophysical techniques: Electrical Resistivity Imaging (ERI), Transient Electromagnetic (TEM) induction, and Multi-channel Analysis of Surface Wave (MASW). The demonstration project was completed at a dry-stack CCR unit containing a variety of CCR ash, gypsum, and thin layers of drainage aggregate (limestone). During a single-day deployment, several geophysical survey tests were conducted in specific areas of …

Co-Electrospinning Polyacrylonitrile (Pan) / Polymer Of Intrinsic Microporosity-1 (Pim-1) For Electrochemical-Based Sensor For Pyridine Detection And Absorption, Samar A. Salim

Nanotechnology Research Centre

The electrospinning of the polymer of intrinsic microporosity-1 (PIM-1) poses challenges due to its limited solubility and tendency to form bead-like structures at high concentrations. This work details the synthesis and analysis of electrospun composite fibers made from polyacrylonitrile (PAN) and PIM-1 for electrochemical applications. The data analysis confirmed the successful incorporation of PIM-1 into the PAN matrix. The fiber characteristics were significantly influenced by PIM-1 loading (1–10%), resulting in fiber diameters ranging from 0.8 to 1.7 μm. A 10% concentration of PIM-1 results in the formation of macropores with diameters ranging from 0.5 to 1.7 μm. Optical analysis using …

Metal-Free Nitrogen-Enriched Graphitic Carbon Nitride Architectures For Advanced Supercapacitor Energy Storage: Design, Synthesis, And Electrochemical Performance Optimization, Loujain Gamal Mohamed

Theses and Dissertations

Abstract

This thesis addresses the urgent global requirement for efficient energy storage materials by developing and characterizing advanced graphitic carbon nitride (g-C3N4)-based electrode materials for supercapacitors. A facile, low-cost thermal polymerization method produces 2D nitrogen-rich GCN nanosheets exhibiting excellent electrochemical stability and wide voltage windows, enabling symmetric devices with 19.33 Wh/kg energy density and remarkable cycling stability over 21,000 cycles. To overcome intrinsic limitations of pristine GCN, a 3D/2D metal free composite with bio-derived carbon (Bio-Cx) is synthesized, delivering high capacitance, wide potential windows, and ultrahigh energy density of 53.72 Wh/kg in asymmetric configurations paired with mesoporous nitrogen-doped carbon (MPNDC). …

Feasibility Of Upcycling Spent Lithium-Ion Battery To Carbon Dioxide Capture Adsorbent, Chimezie Frank Onwudinjo

Master’s Theses

This study investigates the feasibility of repurposing spent lithium-ion battery (SLIB) to lithium orthosilicate (Li₄SiO₄), a high temperature carbon dioxide sorbent. Two synthesis pathways including conventional acid-leaching method (Scenario 1) and a pyrolysis-based route (Scenario 2) were explored. Additionally, techno-economic analysis (TEA) and lifecycle assessment (LCA) of the two processes were also performed. Different analytical characterization techniques were performed to understand the material properties of Li₄SiO₄ including surface area, crystallinity, morphology and thermal stability. CO₂ capture performance of the synthesized Li₄SiO₄ was tested in a thermogravimetric analyzer (TGA) using …

Nanostructured Cathode Catalysts For Aem Electrolysis: From Catalyst Design To Degradation And Hydrogen Dynamics, Yamini Kumaran

Electronic Theses & Dissertations (2024 - present)

Anion exchange membrane water electrolysis (AEMWE) presents a promising pathway toward cost-effective and sustainable hydrogen production by integrating the chemical robustness of alkaline systems with the compact, zero-gap design of proton exchange membrane electrolyzers. However, the widespread implementation of AEMWE is limited by the availability of highly active and durable platinum-group-metal (PGM)-free catalysts and by an incomplete understanding of their degradation behavior under realistic operating conditions.

This dissertation focuses on the development, characterization, and mechanistic investigation of nanostructured MoNi₄–MoO₂-based electrodes for efficient and stable hydrogen generation under alkaline and membrane-integrated environments. MoNi₄–MoO₂ nanorods …

Bio-Papcz: Corn Starch-Based Composite Bioplastic Reinforced With Pineapple Leaf Fiber (Palf), Zinc Oxide (Zno), And Polyvinyl Alcohol (Pva), Marvin C. Caya, Shervin Austin C. Huang, Jovar Khalel J. Maghari, Ruel M. Levida

Sinaya: A Philippine Journal for Senior High School Teachers and Students

Plastic pollution poses a serious global threat, as petroleum-based plastics persist for centuries, and their surging production of over 450 million tons overwhelms ecosystems (Ritchie et al., 2023). Using a quantitative experimental research design, the study examined the effects of varying concentrations of cornstarch-based bioplastic reinforced with pineapple leaf fiber (PALF), polyvinyl alcohol (PVA), and zinc oxide (ZnO) on the bioplastic’s tensile strength and soil degradability. Sample C2 (ZnO 3.0 %w/w; PVA 9.0 %w/w) demonstrated the optimal tensile properties with a tensile strength of 0.76 MPa and an elongation at break of 6.40%, which was attributed to the addition of …

The Science And Economics Of 3d-Printed Filament Recycling, Michael Domingo, Dane Freund, John Mcswiggin, Adam Meadows

Sustainability Conference

In recent years, 3D printing has grown rapidly, both in homes and commercially. This has led to increased demand for plastic filaments, many of which contribute to plastic waste. This project explores the potential of recycling household plastics into 3D printing filament, promoting sustainability and creating a circular economy. Materials like PLA, PETG, ABS, and polypropylene can be recycled or even composted. Existing research has shown that recycled filaments can maintain comparable tensile strength to their virgin counterparts, depending on the recycling process. Furthermore, implementing circular economy practices for plastics could save billions annually by mitigating pollution and reducing landfill …

Myceli-Yum: Elucidating Structure-Property Relationships For Polymer Degradation By Mycelial Digestion, Jordan Scott Ford

Master's Theses

Since the industrial entrance of polymer plastic materials, plastic has become ubiquitous in both everyday use and waste. Due to inefficiencies and knowledge gaps, current recycling methods are not able to account for the high scale of plastic waste, resulting in the bulk of this waste being landfilled, mishandled, and deposited in the environment. Mycelium, the microorganism responsible for fruiting mushroom bodies and mold growth, holds potential to reduce plastic waste and can potentially be utilized as a method of industrial recycling. Following a drug-design approach, the active site of mycelial enzymes responsible for natural biopolymer degradation have been assessed …

Refining Chlorosulfonation Methods For The Synthesis Of A Perfluoroalkyl Arylsulfonimide (Pfsi) Monomer, Ainsley P. Foster, Ben Varney, Hua Mei

SPARK Symposium Presentations

Proton-exchange membrane (PEM) fuel cells are sources of energy that are clean, quiet, and highly responsive to changes in power needs, making them promising for use in automobiles and other portable power devices. The electrolyte of a PEM cell–the layer responsible for conductivity–is a polymer membrane, commonly consisting of perfluoroalkyl sulfonic acid (PFSA) polymers. In place of the PFSA polymers, perfluoroalkyl arylsulfonimide (PFSI) polymers are expected to improve the efficiency of PEM fuel cells with better stability and proton conductivity. The trifluovinylether (TFVE) aryl perfluorosulfonamide monomer is a new PFSI monomer proposed to fulfill these benefits once polymerized. The previous …

Biobased Acrylate Composites With Enhanced Strength For Additive Manufacturing, Nicole Wagner, Joseph Mcwherter

Engineering Faculty Articles and Research

With the expanding use of polymers in additive manufacturing, sustainable resins for use in vat photopolymerization are required to reduce their environmental impact. One promising approach to achieve this is to incorporate biobased fillers that replace the acrylates in photopolymer resins as ‘green’ alternatives. In this study, photopolymer composites consisting of a methacrylate resin with varying calcium carbonate powder content between 0 and 50 wt.% were investigated. A digital light processing technique was used to fabricate tensile test specimens for mechanical testing. Good printability, dimensional accuracy, and good interlayer adhesion were observed for composite resin formulations that incorporated calcium carbonate …

Identifying The Effect Of Architecture Morphology On Wind Fields And Pm2.5 Dispersion At The Urban Block Scale Via A Combined Scheme, Bin Guo, Lu Li, Xiaowei Zhu, Zheng Wang, Miaoyi Chen, Lin Pei, Tengyue Guo

Mechanical and Materials Engineering Faculty Publications and Presentations

This study explores the potential of architecture morphology to mitigate PM2.5 pollution through enhanced urban ventilation. Despite the recognized influence of building designs on wind and air pollution distribution at the urban block scale, specific mechanisms remain poorly understood. To address this gap, we have developed an integrative approach combining in-situ observations, Geographic Information System (GIS), Remote Sensing (RS), Computational Fluid Dynamics (CFD), and statistical modeling. Here, CFD simulates the flow field and PM2.5 dispersion, using in-situ observations for turbulence model selection. GIS quantify architecture morphology parameters to establish accurate CFD boundary conditions, ensuring simulations reflect real-world conditions and precise …