Beneficial use structures

Abstract

Beneficial use structures are disclosed that include coal combustion residuals (CCR) mixed with water and a binder to form a structural material, and adapted to be compacted for use in the formation of the beneficial use structure. Various structures having beneficial uses are described, including compressed air storage facilities and a pumped hydroelectric facility, including such a facility adapted for use with a lock system of a waterway.

Claims

1. A beneficial use structure, comprising coal combustion residuals (CCR) mixed with water and a binder to form a structural material, and adapted to be compacted for use in formation of the beneficial use structure, wherein the beneficial use structure includes a pumped water storage reservoir, comprising: a. a base constructed of compacted CCR to increase the height of the storage facility to a predetermined amount above surrounding terrain and thereby provide for greater stored potential hydro energy; b. a water storage impoundment constructed on the base and constructed from a material selected from the group of materials consisting of at least one layer of roller-compacted concrete or strengthened CCR; c. drains positioned in a bottom of the impoundment; d. conduits connected for water flow from the drains; and e. at least one hydroelectric pump/generator connected to the conduits for receiving water outflow from the impoundment to generate electricity for use during peak use periods to supplement electricity generated by conventional electric utility generators and in low utilization periods to pump water into the impoundment through the drains.

2. A beneficial use structure according to claim 1, wherein the structural material is adapted for use as a load-bearing wall, and is comprised of between approximately 25 and 50 percent CCR, 25 and 50 percent water and 25 and 14 percent cement.

3. A beneficial use structure according to claim 1, wherein the structural material is adapted for use as a roller-compacted cement/CCR mixture, and is comprised of between approximately 50 and 75 percent CCR, 25 and 50 percent cement and additives.

4. A beneficial use structure according to claim 1, wherein the CCR is a material selected from the group of materials consisting of roller compacted CCR, poured-in-place concrete or a composite of roller compacted CCR and concrete.

5. A beneficial use structure, comprising coal combustion residuals (CCR) mixed with water and a binder to form a structural material, and adapted to be compacted for use in formation of the beneficial use structure, wherein the beneficial use structure is a pumped hydroelectric facility adapted for use with a lock system of a waterway, comprising: a. a base constructed of compacted CCR and positioned on a terrain for increasing the elevation of the hydroelectric facility about the lock system of the waterway; b. a water impoundment having raised walls constructed of a material selected from the group consisting of compacted concrete and compacted low leaching and low permeability strengthened CCR; c. a lock filling piping system that interconnects the water impoundment with the lock system of the waterway for increasing the fill rate of the lock system to permit an increased rate of transit of vessels through the lock system; d. intake pipes positioned upstream of the lock system for receiving water from the waterway; and e. a hydroelectric generator/pump facility for receiving water from the intake pipes and generating electricity from movement of the water from the intakes pipes through the hydroelectric generator/pump facility.

6. A beneficial use structure according to claim 5, and wherein the hydroelectric generator/pump facility is connected to impoundment fill piping for receiving water from the waterway and pumping the water into the impoundment for storage and use for increasing the fill rate of the lock system.

7. A beneficial use structure according to claim 5, wherein the structural material is adapted for use as a load-bearing wall, and is comprised of between approximately 25 and 50 percent CCR, 25 and 50 percent water and 25 and 14 percent cement.

8. A beneficial use structure according to claim 5, wherein the structural material is adapted for use as a roller-compacted cement/CCR mixture, and is comprised of between approximately 50 and 75 percent CCR, 25 and 50 percent cement and additives.

9. A beneficial use structure according to claim 5, wherein the CCR is a material selected from the group of materials consisting of roller compacted CCR, poured-in-place concrete or a composite of roller compacted CCR and concrete.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a plan view of a survival bunker with stepwell according to an embodiment of the present invention:

(2) FIG. 2 is a side elevation section of the survival bunker with stepwell taken along section lines A-A of FIG. 1;

(3) FIG. 3 is a plan view of a composting field constructed according to an embodiment of the invention;

(4) FIG. 4 is a side elevation section of the composting field taken along section lines A-A of FIG. 3;

(5) FIG. 5 is a plan view of a raised elevation water storage reservoir according to an embodiment of the invention;

(6) FIG. 6 is a side elevation section of the raised elevation water storage reservoir taken along section lines A-A of FIG. 5;

(7) FIG. 7 is a plan view of a horizontal and vertical compressed air storage system according to an embodiment of the invention;

(8) FIG. 8 is a vertical cross-section of a horizontal and vertical compressed air storage system reservoir according to an embodiment of the invention taken along lines A-A of FIG. 7;

(9) FIG. 9 is a plan view of a carbon sequestration/mineral carbonation facility according to an embodiment of the invention;

(10) FIG. 10 is a side elevation section of the carbon sequestration/mineral carbonation facility taken along lines B-B of FIG. 9;

(11) FIG. 10A is a fragmentary vertical cross-section showing details of the sequestration bed of the invention;

(12) FIG. 11 is a side elevation section of the carbon sequestration/mineral carbonation facility taken along lines A-A of FIG. 9;

(13) FIG. 12 is a plan view of a carbon capture facility according to an alternative embodiment of the invention;

(14) FIG. 13 is a side elevation section of the carbon capture facility taken along lines A-A of FIG. 12;

(15) FIG. 14 is a side elevation section of the carbon capture facility taken along lines B-B of FIG. 12;

(16) FIG. 15 is a side elevation section of a pumped hydroelectric storage system according to an embodiment of the invention; and

(17) FIG. 16 is a plan view of a pumped hydroelectric storage system according to an embodiment of the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

(18) Referring now to the drawings, a survival bunker 10 with stepwell according to one preferred embodiment of the invention is illustrated in FIGS. 1 and 2. This embodiment is only an example of a wide variety of structures that can be fabricated using the techniques disclosed in this application, and is not drawn to scale. Bunker 10 includes an interior volume 12 defined by sloped sidewalls 14 and a planar top 36 that together define a truncated pyramid structure, which may or may not include inherent blast-deflecting characteristics.

(19) The solid volume of the bunker 10 is formed of CCR-based materials according to the examples provided in this application. The bunker 10 is supported on a base 16, which will typically comprise the existing ground. The bunker 10 includes survival condominiums 18 and 20, which are comprised of a predetermined number of living areas. The condominiums 18 and 20 are reached by respective entrance/exit tunnels 22, 24 formed through the CCR material. Exits 26, 28 provide alternative emergency exits from the condominiums 18 and 20 if one or both of the entrance/exit tunnels 22, 24 are blocked or otherwise unavailable.

(20) Primary air intake and exhaust plenums 30, 32 maintain appropriate oxygen levels in the bunker 10 and vent carbon dioxide, combustion gases and other air contaminants. Fuel storage tanks 22 and 34 provide fuel to the enclosure 10 to operate all fuel-consuming equipment and are capable of storing and feeding multiple types of fuel, as required. The bunker 10 includes multi-fuel generators for providing electric current to all electrical equipment. In addition, external electric current can be supplied by suitable conduits and transmission equipment exterior to the bunker 10.

(21) The bunker 10 includes a water storage stepwell 34 that can be used to accumulate water from any source for use by the bunker occupants. The top surface 36 of the bunker 10 is sloped towards the stepwell 34 to promote drainage of water accumulating on the top surface 36 of the bunker 10. The stepwell 34 includes a vertical shaft from which water is drawn and the surrounding inclined subterranean passageways, chambers and steps, which provide access to the stepwell 34. Stepwells are known from antiquity in other contexts and are typically formed by a zig-zag array of narrow steps 38 along one side of the stepwell 34 that permit entry into the stepwell 34 and allow access to the entire stepwell 34 without the use of ladders or conventional, wide stair steps. See https://en.wikipedia.org/wiki/Stepwell#Details.

(22) The stepwell 34 may include a waterproof entrance/exit 40 from the condominium 20 into the stepwell 34. The stepwell 34 includes an overflow drain 42. In addition, the stepwell 34 may be used to generate electricity by allowing water to flow out of the bottom of the stepwell 34 through an outflow conduit 44 into a turbine generator 46 which generates electricity and then exits the generator 46 through a generator drain 48.

(23) Preferably, the bunker 10 is covered by an overburden of either soil or a synthetic material, which may have a camouflage appearance. The overall shape of the bunker 10 maybe contoured to correspond to surrounding topographical features. Of coarse, dimensions of the bunker 10 are variable within a wide range. The CCR constituents and relevant strength and density values for the load-bearing structures of FIGS. 1 and 2 are found in Table 1 of this application.

(24) Referring now to FIGS. 3 and 4, a composting field 50 constructed of strengthened CCR material 52 is shown. The CCR material 52 forms a volume within which are embedded a predetermined number of compost pits 54, which may be constructed of roller compacted CCR, poured-in-place concrete or a composite of roller compacted CCR and concrete. The compositing pits have solid sidewalls and bottom and are sized to receive a predetermined quantity of compostable material, which may be any suitable organic material that can be biodegraded. The size scale is widely variable.

(25) Each compost pit 54 has one or more drains 56 in the bottom that connect to drain conduits 58 that are controlled by valves (not shown) that permit controlled drainage as required to maintain proper moisture and temperature of the material being composted. Air pumps 60 force air under pressure to the compost pits through air conduits 62 that force air under pressure into the bottom of the compost pits 54 through vents 64 and convey the air to suitable biofilters. Preferably, the compost pits 54 are covered by respective airtight removable tops 66. See FIG. 4. Air passes through the compost pits 54 from the conduits 62 and exit the compost pits 54 though vents 68.

(26) The compost pits 54 are accessed, for example, by a ramp 70, FIG. 4, by which refuse-laden containers are moved into position to deposit material into the compost pits 54, and to remove composted material. The CCR constituents and relevant strength and density values for the load-bearing composting field 50 of FIGS. 3 and 4 are found in Table 1 of this application.

(27) Referring now to FIGS. 5 and 6, a raised elevation water storage reservoir 80 is shown. The reservoir 80 is formed by first constructing a base 82 of CCR formed to a suitable size with slopping sides according to civil engineering principles with an angle of repose, including margin of error appropriate to the engineering requirements. The CCR may contain additional constituents as required to enhance stability, resistance to environmental factors, and the like. See Table 1. The CCR material maybe covered with a suitable protective barrier, such as soil, vegetation, plastic, textiles or a combination of these or other materials.

(28) A water storage impoundment 84 is constructed on the base 82, having its own angle of repose which may be the same, or different than that of the base 82. The walls 85 of impoundment 84 walls are formed of roller-compacted concrete or strengthened CCR, or multiple layers of each of these materials. While the impoundment 84 maybe filled from the top, either by inflow from rivers, water supply conduits and/or rainfall, the preferable utility is achieved by utilizing the construction as a pump/storage system. As shown in FIG. 6, the impoundment 84 includes drains 86 and 88 that feed conduits 90 and 92, respectively. Variable flow valves, not shown, are provided to allow water to flow out of the impoundment through the drains 86 and 88 through conduits 90 and 92 that feed into hydroelectric pump/generator 94 and 96. Outflow from the impoundment generates electricity that can be used during peak use periods to supplement electricity generated by conventional electric utility generators, such as coal or gas-fired, nuclear or other hydroelectric generators. In low utilization periods, such as at night, excess electricity from these other conventional electric utility generators can be used to powers the pump/generators 94 and 96, which are reversed and pump water into the impoundment through the drains 86 and 88.

(29) Because of the status of CCR as a waste product that is easily shaped and compacted, it can be used to construct bases and similar structures having a wide range of sizes and shapes that can be conformed to size and space requirements of the surrounding land. The relevant strength and density values for the base 82 of FIGS. 5 and 6 are found in Table 1. The CCR constituents and relevant strength and density values for the load-bearing impoundment 84 of FIGS. 5 and 6 are found in Table 2.

(30) Referring to FIGS. 7 and 8, a compressed gas storage system 110 is shown. The storage system 110 is contained in a housing 112 that is constructed of CCR and a mixture of other materials that bind the CCR into a stable, airtight matrix. The materials may include organosilanes according to a formulation that fills the interstices between the CCR particles with material that is stable and does not permit the passage of a gas at or below a specified pressure. For purposes of illustration, the storage system 110 is shown with both horizontal storage containers 114 and vertical storage containers 116, but may be constructed with horizontal, vertical or sloped containers according to space requirements. The gas to be storage in its compressed state may be air, fuel, such as propane, natural gas, or any other gas suitable for storage in a compressed state. Compressors 118 and 120 compress the product to be stored in gaseous form supplied from a source, not shown, and deliver the gas to the horizontal and vertical storage containers 114 and 116 through feed pipes 122, 124, respectively. The feed pipes 122, 124 include valves, not shown, that permit gas to be delivered to specified containers, or all containers, as desired. The compressed gas maybe used for any purpose, including delivery to generators for production of electric power or to turbines connected to any work-producing apparatus.

(31) The CCR constituents and relevant strength and density values for the load-bearing structures of FIGS. 7 and 8 are found in Table 1 of this application.

(32) FIGS. 9, 10, 10A and 11 illustrate a carbon sequestration/mineral carbonation facility 140 constructed of a containment enclosure 142, including a base constructed of strengthened CCR in a mixture with other materials which may include other materials according to a formulation that fills the interstices between the CCR particles with material that is stable and does not permit leakage of the sequestered material from the facility 140. See Table 3. The containment enclosure 142 forms a base that provides stability to the facility and preferably includes walls tapered at an appropriate angle of repose. In the embodiment shown, three sequestration beds 144 are positioned within the enclosure 142 and secured behind airtight doors 146. Each sequestration bed 144 comprises a first filter section 148 of, for example, coarse gravel such as railroad-sized ballast, and a second filter section 150 of, for example, fine stone such as beach sand-sized aggregate.

(33) These filtration sections 148 and 150 provide a progressive filtration effect across a vastly large surface area, removing particulates and gas components of pressurized coal plant emissions that are injected into the containment enclosure 142 through supply conduits 152. The emissions flow from the second filtration section 150 and pass under pressure into sequestration sections 154 that are comprised of fly ash, sorbents and catalysts for enabling carbon-based gases such as carbon monoxide and carbon dioxide to be sequestered over a long period of time.

(34) Filtered gases are vented from the sequestration sections 154 through vents 156. When the sequestration beds 144 are exhausted and require removal and replacement, the doors 146 are removed and the contents of the sequestration beds removed and replaced. The strengthened CCR enables a containment enclosure 142 of indeterminate size to be inexpensively constructed utilizing a waste material to achieve a beneficial effect. The vertical height of the sequestration beds maybe varied as necessary to accommodate the overall height of the containment enclosure 142.

(35) Another facility 170 for capturing and sequestering carbon-based materials is shown in FIGS. 12, 13 and 14. As with the other embodiments, a containment enclosure 172 is provided that includes a base constructed of strengthened CCR in a mixture with other materials which may include according to a formulation that fills the interstices between the CCR particles with material that is stable and does not permit leakage of the sequestered material from the facility 170. See Table 1. The containment enclosure 172 includes a base that provides stability to the facility and preferably includes walls tapered at an appropriate angle of repose.

(36) The containment enclosure 172 is constructed of strengthened CCR rendered airtight with the addition of a mixture of other materials that bind the CCR into a stable, airtight matrix. The mixture may include materials according to a formulation that fills the interstices between the CCR particles with material that is stable and does not permit the passage of a gas at or below a specified pressure. See Table 1. The enclosure 172 includes spaced-apart arrays of structural components 174 formed of CCR reinforced with steel or other components. The interior volume of the enclosure 172 is filled with carbon capture materials 176, which may be aggregates of various sizes together with catalyst materials. Carbon-based emissions are conveyed to the enclosure 172 through conduits 178 that feed the emissions under pressure to the carbon capture materials 176 at spaced-apart intervals along its length. Filtered gases suitable for release into the environment are discharged through stacks 180. As shown in FIG. 12, the enclosure 172 is preferably only part of a larger facility. In contrast to the facility 140 of FIGS. 9-11, facility 170 is intended to permanently receive and contain the captured carbon-based materials. When the carbon capture materials 176 have exhausted their ability to sequester more carbon-based materials, the facility 170 is permanently abandoned after removing the stacks 180 and otherwise decommissioning the facility 170. Because of the low cost of the CCR material, abandonment of the facility 170 is cost-effective, and new CCR can be used to construct additional facilities 170 as needed.

(37) As is shown in FIG. 14, emissions conveyed under pressure from an emission-emitting source are passed by the conduits into the carbon capture materials 176 through a multitude of perforated feed pipes 182.

(38) Referring now to FIGS. 15 and 16, a pumped hydroelectric facility 190 is illustrated, and includes a base 192 constructed of strengthened CCR material that may include organosilanes, cement and/or lime according to a formulation that fills the interstices between the CCR particles with material that is stable and does not permit leakage of the sequestered material from the facility 190. The purpose of the base 192 is to raise a water impoundment 194 about the level of a lower water source, such as another reservoir or river, dammed or undammed. The impoundment 194 is formed by reinforced roller-compacted concrete walls 196. Table 2.

(39) Locks and dams located on the major navigable river waterways in the United States are widely known to be in desperate need of repair and or replacement. A large number of coal-fired power plants are located directly adjacent to or nearby these navigable waters. Many of the locks and darns in the United States were built in the 1930s or before, and the original design life of most locks and dams when they were constructed was 50 years. The current and historical lack of infrastructure funding to repair and/or replace these locks and dams, and lack of maintenance and repair causes delays in river traffic in location such as the Ohio River near Pittsburgh, Pa. due to repairs taking place on its locks and dams. Unless these problems are solved, situations of this type will become progressively worse. There is a demand for repair and replacement of existing locks and dams on the nation's river systems, to increase capacity, timeliness and efficiency of cargo traffic that can be solved in large measure by using CCR as a means of cost-effectively maintaining and repairing riverine structures.

(40) As shown in FIGS. 15 and 16, a river lock 198 is shown positioned in a river 200 and is used for passage of vessels in the ordinary manner. In accordance with an embodiment of the invention, a piping system 202 that enables rapid filling of the lock 198 interconnects the impoundment 194 with the lock 198, which includes a run of the river intake/penstock water intake piping structure 204 and a downstream outflow piping structure 206.

(41) As is best shown in FIG. 16, a hydroelectric generator/pump facility 208 that receives water from the intake piping structure 204, generates electricity from movement of the water, and discharges the water back into the river downstream of the facility 208. Bypass outflow pipes 210; permit water to be discharged from the impoundment 194 downstream into the river. This enables the level in the impoundment to be controlled by direct discharge into the river.

(42) When a vessel passes through a lock on, for example, the Mississippi River south of Illinois, it takes approximately 1 hour and 30 minutes to raise the vessel once the lock gates are closed when it is traveling from the downstream side of the lock to the upstream side. With a vessel on the Ohio River, it takes approximately 45 minutes once the lock gates are closed to raise the vessel when traveling from the downstream side of the lock and dam to the upstream side.

(43) FIGS. 15 and 16 demonstrate the use of a CCR such as the base 192 static structure for the rapid filling of river locks to decrease the time it takes a vessel to transit a lock such as lock 198. Water from the impoundment 194 flows into the lock 198 either as the full water supply or together with river water to fill the lock as required. This results in a much more rapid fill rate. Another benefit is the ability for the lock to function during times of low river water when the lock might otherwise be unusable due to lower water flow. Vessels using locks that fill with the traditional method experience higher costs than those using the rapid filling method described due to the longer time it will to navigate the lock. The business model for this new rapid fill system is based on the ability to use very inexpensive CCR as a principal part of construction.

(44) A key ancillary feature is the ability of the impoundment 194 to supply water to power the hydroelectric generator 208 with an intake structure to create the energy to pump water from the river to the water storage facility. As shown in the drawings, water from the impoundment 194 can be discharged through the piping system 202 that interconnects through valves, not shown, with the run of the river intake/penstock water intake piping structure 204 to feed the hydroelectric generator 208 and thereby produce electricity. During periods of low electricity usage, water from upstream of the lock 198, can be taken from the river by the run of the river intake/penstock water intake piping structure 204 and delivered to the generator 208. This water can be used to either generate electricity for the electric grid, or used to power a pump that pumps water from the river through a conduit 212 up into the impoundment 194 for use during peak electricity demand periods.

(45) Thus, energy from off-site renewable sources such as wind and/or solar, the hydroelectric system described above, or conventional coal, or natural gas electrical power sources can be used to pump water into the impoundment for storage until needed for production of power at times as required during peak demand.

(46) The CCR constituents and relevant strength and density values for the load-bearing structures of FIGS. 15 and 16 are found in Tables 2 of this application.

(47) The more flowable mixes should have less cracking and lower permeability. Less compressive strength, lower cement content of a mix in general makes a more ductile mix that has less potential for cracking. It will allow the CCR mix to act like a liner and a structural component.

(48) Having these different types of mix designs, brackets, and expands the range of uses and provides flexibility in the design. The CCR mix that would be used on a specific project will be verified by leachability, compressive strength and durability testing during the design phase of each project.

(49) TABLE-US-00001 TABLE 1 Load Bearing Wall CCR Specialty Mix Designs Target Fly Sand Compressive Water Cement Fly Ash Ash to or Fine Course Water- Mix Design Strength Density Content Content Content Cement Aggregate Aggregate Cement/Fly Application (psi) (lb/ft3) (lb/yd3) (lb/yd3) (lb/yd3) Percent (lb/yd3) (lb/yd3) Ash Ratio Load Bearing 3,500 144.1 166 135 290 68.2% 2100 1200 0.39 Bottom Ash Aggr Load Bearing 4,000 147.0 170 135 135 50.0% 1230 2300 0.63 Standard Mix Load Bearing 1,200 118.9 300 100 300 75.0% 2500 10 0.75 Flowable Mix

(50) TABLE-US-00002 TABLE 2 Encapsulated RCC Dam CCR Specialty Mix Designs Bottom Target FGD or Fly Ash Ash, Sand Percentage Compressive Water Cement Fly Ash to or Fine Course of Catalyst Water- Mix Design Strength Density Content Content Content Cement Aggregate Aggregate or Cement/Fly Application (psi) (lb/ft3) (lb/yd3) (lb/yd3) (lb/yd3) Percent (lb/yd3) (lb/yd3) Additives Ash Ratio USBR Upper 4,000 147.0 166 134 291 68.5% 1,148 2,231 3.0% 0.39 Stillwater Dam USBR Upper 4,000 148.4 150 159 349 68.7% 1,171 2,178 3.0% 0.30 Stillwater Dam RCC Dam 3,500 144.1 166 135 290 68.2% 2,100 1,200 3.0% 0.39 High Fly Ash Mix RCC Dam 4,000 147.0 170 135 135 50.0% 1,230 2,300 3.0% 0.63 Standard Mix Load Bearing 1,200 118.9 300 100 300 75.0% 2,500 10 3.0% 0.75 Flowable Mix

(51) TABLE-US-00003 TABLE 3 Encapsulated Mine Reclamation and Carbon Sequestration-CCR Specialty Mix Designs FGD Bottom Target or Fly Fly Sand Water- Compressive Water Cement Ash Ash to or Fine Course Percentage Cement/ Mix Design Strength Density Content Content Content Cement Aggregate Aggregate of Catalst Fly Ash Application (psi) (lb/ft3) (lb/yd3) (lb/yd3) (lb/yd3) Percent (lb/yd3) (lb/yd3) or Additive Ratio PA-OSM Field Less than 500 psi 153.0 800 282 1900 87.1% 1,148 0 3.0% 0.37 Office-1980 to 1997 PA-OSM Field Less than 1,000 psi 129.5 458 340 1375 80.2% 1,323 0 3.0% 0.27 Higher Strength Mix Mine Reclamation 3,000 144.5 166 135 300 69.0% 2,100 1,200 3.0% 0.38 Aggregate Mix Mine Reclamation 1,200 129.6 300 100 400 80.0% 2,500 200 3.0% 0.6 Carbon Capture Note: 1) PA OSM. To be Verified from other sources and 2) Proprietary additives developed by Dr. S. Chen provide encapsulation of carbon and metals.

(52) A number of structures utilizing CCR as a structural component with other components are described above. Various details of the invention maybe changed without departing from its scope. Furthermore, the foregoing description of the preferred embodiments of the invention and the best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation.