Mechanical Engineering Commons^™

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 …

Sit-To-Stand: Smart Physical Therapy Device Design Project, Mollie Petersen, Evie Collier, Gracie Kniss, Lucas Sokolik, Jacob Zitek

Honors Program: Senior Projects (Public)

Mechanical engineering students in their last year are provided with the opportunity to form a small group and design a product. The specific project covered in this report is the creation of a smart attachment to a physical therapy device. A sit-to-stand piece of equipment is used to help patients recover or build the strength to move from a sitting to standing position after an injury or illness. Currently, there is not a way for physical therapists to collect numerical data while a patient is using the equipment. Much of their care plans are built off of personal perception and …

Analysis Of Approximations In Flash Thermal Diffusivity Measurements Using High‑Fidelity Simulations, Tage T. Burnett, Jakob G. Bates, Matthew R. Jones, Christopher R. Dillon, John Tencer

Faculty Publications

Thermal diffusivity is an important material property for understanding and characterizing transient behavior in many heat transfer applications. This study investigates the accuracy and approximations of inverse mathematical models for measuring thermal diffusivity of materials via the widely used Flash Method. High-fidelity simulations of the Flash Method in copper, silicon carbide, silicon, and glass were performed as numerical experiments and included physics such as in-depth absorption, radial conduction, and surface convection. Data from those numerical experiments were used to estimate material thermal diffusivity using seven traditional and new inverse models. Parker’s original model had relative errors 𝜖< 5% when the approximations it makes were enforced in numerical experiments. Newer models performed well even when experimental restrictions were relaxed. Models that include radial heat conduction were capable of accurately measuring thermal diffusivity (𝜖< 1%) when a Gaussian energy source was used. Models with radial conduction and in-depth material absorption of the laser source could calculate thermal diffusivity for semi-transparent materials such as silicon (𝜖< 1%) and even transparent materials like glass (𝜖< 10%). Convective losses from the material’s front surface had a negligible impact on measurements except for very low thermal diffusivity materials. Using temperatures from many locations of the test material’s surface increased resilience to noise, reducing the distribution of thermal diffusivity measurements by more than an order of magnitude. The models developed in this study could enable a more relaxed Flash Method experimental setup that maintains thermal diffusivity accuracy and extend the utility of the Flash Method to semitransparent materials.

Aerodynamic Performance Of Grid Fins As High Lift Devices, Luke Jeffrey Krick

Senior Honors Theses

Flaps are used in almost all aircraft to increase the amount of lift the wings can produce at low speeds. However, the flaps also increase the amount of drag experienced by the aircraft. The drag induced by the flaps causes energy loss and is unfavorable for aircraft effectiveness. In recent years, grid fins have become a popular choice for aircraft and armaments to control their orientation. First developed for launch escape towers, grid fins are made up of lines that cut the fin into many quadrants, leaving the fin with multiple rectangular shaped open areas. The aim of this study …

Engineering Design And Analysis Using Creo® Cad, Cae, And Manufacturing Applications, Swapnil Moon

Open and Affordable Textbooks

This textbook presents a structured approach to computer-aided design using Creo, integrating CAD, CAE, and CAM workflows within a unified engineering framework. The material emphasizes parametric modeling, design intent, and feature-based modeling as foundations for creating robust and adaptable engineering models. Through progressively structured tutorials, students develop skills in part modeling, assemblies, engineering drawings, mechanism design, simulation, and manufacturing. The text incorporates real-world engineering components and workflows, including structural and thermal analysis, motion simulation, and toolpath generation, reflecting modern engineering practice. Designed for upper-division undergraduate and graduate students, this open educational resource supports hands-on learning and prepares students for industry-relevant …

Introduction To Computer-Aided Design Using Solidworks® : A Structured Approach To Parametric Modeling And Design Intent, Swapnil Moon

Open and Affordable Textbooks

This textbook introduces computer-aided design (CAD) using SOLIDWORKS® through a structured, design-centered approach that emphasizes parametric modeling and engineering reasoning. Rather than focusing solely on software commands, the material develops foundational skills in design intent, constraint-based modeling, and feature relationships to create robust, adaptable models.

The content is organized progressively, beginning with basic sketching and feature creation and advancing to complex part modeling, assemblies, motion studies, and engineering drawings. Each chapter builds upon prior concepts, reinforcing systematic modeling practices and promoting the development of system-level thinking required in real-world engineering design workflows.

Designed for undergraduate students with little or no …

Aquaculture Ecosystem Modeling Aeration Efficiency Optimization Using Cfd, Gabriela Reyes Gomez

Electronic Theses and Dissertations

The Harbor Branch Oceanographic Institute (HBOI) is developing the Intelligent and Resource Efficient Pond Aquaculture (IREPA) project, which aims to improve aquaculture management through the integration of predictive models and automated technologies. This approach seeks to transition traditional practices toward data-driven systems capable of supporting informed decision-making for aeration management.

This study investigates the effectiveness of different aerator configurations on hydrodynamic circulation and dissolved oxygen (DO) distribution in aquaculture ponds using computational fluid dynamics (CFD). A model was developed in ANSYS Fluent, where the aerator was represented using a power-based formulation and implemented as a moving wall boundary condition. Dissolved …

Design Of Air-Entrained Concrete For Airport Pavements Through Local Aggregate Utilization: Performance Optimization And Economic Analysis, Li Wentao, Rizwan Qadir, Arslan Mushtaq, Hilal Khan, Kamran Jillani

Journal of Sustainable Construction Materials and Technologies

Airport pavement construction in developing countries faces critical challenges balancing international performance standards with economic constraints, while limited research exists on optimizing air-entrained concrete mixes using locally sourced materials for cost-effective solutions. This study investigated the development of economical air-entrained concrete mix designs for airport pavements utilizing Pakistani aggregates and systematic cement content optimization. Comprehensive experimental evaluation included material characterization through petrographic analysis, alkali-aggregate reactivity assessment via accelerated mortar bar testing, and mechanical property development across cement contents from 360-450 kg/m3. Air entrainment was achieved through controlled admixture dosing while maintaining target slump of 50mm. Results demonstrated that locally sourced …

Niu Fsae Brake Rotor Design & Flywheel-Based Test Stand Development, Cody J. Marko, Austin Coyne, Alexander Boyden

Honors Capstones

This project addresses the need for a reliable and validated brake rotor for the Northern Illinois University Formula SAE vehicle following a prior catastrophic rotor failure within the team. Brake rotors in high-performance applications are subjected to significant thermal and mechanical loads, and inadequate design can lead to failure, posing serious safety risks and limiting vehicle performance. To solve this issue, a new brake rotor was designed alongside a dedicated test stand to both improve braking performance and enable experimental validation. The rotor was evaluated using finite element analysis (FEA), including transient thermal and structural simulations, to predict maximum temperature, …

Portable Humidity Chamber, Calvin Wright, Ian Heilers, Sam Taylor

Honors Capstones

This engineering project, sponsored by Crandall Stats and Sensors, focuses on improving the ability to test product performance under controlled environmental conditions by designing a portable humidity chamber capable of maintaining a stable relative humidity between 20 and 80 percent with a tolerance of ±0.5 percent. Consistent humidity is crucial for evaluating how moisture influences material properties, product reliability, and long-term durability in real production environments. Because Crandall conducts testing across multiple facility locations, the chamber must also be lightweight, transportable, and easy for operators to use without specialized training. Developing such a system provides the company with a valuable …

The Expectation Of Pain: Effects On Threshold, Tolerance, And Perception, Emma Paulus

Mechanical Engineering Undergraduate Honors Theses

Brain activity in pain-related regions of the cortex is thought to be influenced by interactions between expectations and incoming sensory information. However, the subjective experience of pain based on expectation has not been thoroughly explored. By changing visual and auditory cues to set expectation levels, a relationship between unconscious expectation of pain and actual sensory pain experienced was characterized. With IRB approval, volunteers were randomly and blindly grouped into low and high pain expectancy groups. Each group completed a survey about initial pain expectations before the muscle stimulation tolerance test, followed by a survey about actual pain perception after the …

Multiscale Architecture Governs Stability In Suction-Actuated Variable Stiffness Catheters, Sheridan Lee

McKelvey School of Engineering Graduate Student Theses & Dissertations

Endovascular procedures require devices with widely varying mechanical properties: flexibility for navigating tortuous vessels and rigidity for stable therapeutic delivery. Suction-actuated variable stiffness sheaths address this challenge by incorporating axial wire string arrays that mechanically couple under suction to increase flexural rigidity. However, prototype devices achieve stiffening ratios below theoretical predictions, suggesting that interlayer mechanics and string positioning play a critical role. This study investigates whether interweaving polytetrafluoroethylene (PTFE) tape within the string array enhances flexural rigidity modulation and curvature stability. Prototype devices with varying wrap configurations were fabricated and evaluated using flexural testing, curvature stability testing, and mathematical modeling. …

Effect Of Environmental Conditions On Fracture Of Composite Materials And Thin Films, Victor Birman

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Environmental conditions, i.e., temperature and moisture, affect mechanical properties of materials, including composites. In this paper, we concentrate on one of the aspects of the effect of environment on fracture in a composite lamina. The paper demonstrates an analytical approach to account for the effect of the changes in environment on the strain energy release rate of composite materials and thin films. These analytically determined strain energy release rates should be compared to fracture toughness to predict the susceptibility of the material to fracture. Numerical examples are presented for several polymeric and metal matrix composites using available experimental data for …

A Federated Learning Framework For Data-Sovereign Predictive Maintenance In Distributed Smart Manufacturing, Md Sazol Ahmmed, Sriram Praneeth Isanaka, Frank Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Featured Application: The proposed federated learning framework can be applied in distributed smart manufacturing environments where multiple factories or production facilities collaboratively develop predictive maintenance models without sharing sensitive operational data. This approach is particularly useful for industrial networks involving geographically distributed plants, contract manufacturing partners, and multi-site production systems where data sovereignty and avoidance of raw data sharing are critical. Predictive maintenance enables early detection of machine failures and reduces unexpected production downtime. However, conventional approaches typically rely on centralized data collection and model training which introduce challenges related to data sovereignty, communication overhead and data ownership. To address …

Machine Vision For In Situ Measurement And Control Of Wire Stickout In Lwded Process, Braden Mclain, Remy Mathenia, Todd Sparks, Frank Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

This work presents a machine-vision–based measurement and control framework for laser wire directed energy deposition (LWDED) processes. A visible-light camera system is used to capture meltpool images, from which a novel vision algorithm extracts the wire–meltpool interface location. By utilizing a camera that is rigidly mounted to the deposition head, the vision algorithm provides a relative measurement of the distance between the nozzle tip and the workpiece, also referred to as wire stickout. A proportional-derivative (PD) control strategy is implemented using the measured stickout as feedback to adjust deposition feedrate. Results show that the control system successfully compensates for improper …

An Experimental Study Of The Morphology Of Dna-Carbon Nanotube Hybrid Structures In Direct Dna Sequencing, Avery P. Davis

Biomedical Engineering Undergraduate Honors Theses

Hybrid structures formed between single-stranded DNA (ssDNA) and single-walled carbon nanotubes (SWCNT) have emerged as promising components in future direct DNA sequencing technologies due to their unique morphological and electronic properties. The nanoscale configuration of these hybrids, including the DNA wrapping angle, pitch, and contour behavior, directly influences their potential for stable electronic readout. This thesis presents an experimental study of DNA-SWCNT hybrid morphology using a fixed, reproducible wrapping protocol designed to minimize environmental variability and isolate the influence of DNA nucleotide sequence on hybrid structure. As described in prior work, this protocol produces well-dispersed hybrids suitable for high-resolution imaging. …