CCR Impoundment Structure for Pumped Storage and Contaminant Encapsulation

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Solution Overview

Problem

Coal combustion residuals (CCR) accumulate in vast quantities, posing environmental risks and regulatory challenges, and existing disposal methods are costly and inefficient, failing to meet the criteria for beneficial use as defined by the Federal CCR Rule.

Innovation Solution

Construct impoundments using consolidated and compacted CCR, applying engineering measures such as encapsulation with bio-geopolymers to create structures that store water, generate hydroelectric power, and encapsulate contaminants, meeting the criteria for beneficial use by providing functional benefits, conserving resources, and ensuring environmental safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If CCR is stored in traditional landfills or impoundments, then disposal capacity is provided, but environmental risks increase and regulatory compliance becomes difficult

Engineering Contradiction:

ImproveCCR disposal capacityVSAvoidenvironmental risks

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The patent transforms CCR from a harmful waste material into a beneficial structural material by using it as fill and construction aggregate in dam and impoundment projects. This conversion eliminates the need for traditional disposal while creating useful infrastructure, directly addressing the contradiction between disposal capacity and environmental risk.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent applies engineering measures including encapsulation with geomembranes and chemical stabilization with cementitious materials to change the physical and chemical parameters of CCR. These parameter changes reduce leachability and improve structural properties, enabling CCR to serve both disposal and environmental safety requirements simultaneously.

Inventive Principle:

Principle #35Parameter changes

2Loss of substance

If CCR is used in beneficial applications, then resource conservation is achieved, but meeting regulatory standards for environmental releases becomes challenging

Engineering Contradiction:

Improveresource conservationVSAvoidenvironmental releases

Core Design Contradiction:

Loss of substanceVSObject-affected harmful factors

Solution Approach 1:

The patent introduces intermediary materials including geomembrane liners and cementitious encapsulation materials between CCR and the environment. These intermediaries act as barriers that prevent direct contact between CCR and groundwater or soil, thereby enabling resource conservation while maintaining environmental safety standards.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent creates composite material systems by combining CCR with cement, lime, and other stabilizing materials. This composite approach enhances the environmental performance of CCR by reducing leachability while maintaining its utility as a construction material, thus satisfying both resource conservation and environmental release requirements.

Inventive Principle:

Principle #40Composite materials

3Object-affected harmful factors

If engineering measures are applied to CCR structures, then environmental safety is improved, but construction complexity and cost increase

Engineering Contradiction:

Improveenvironmental safetyVSAvoidconstruction complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent divides the CCR structure into distinct functional zones including lined and unlined portions, encapsulated and unencapsulated areas. This segmentation allows different engineering measures to be applied where most needed while leaving other areas simpler, thereby improving environmental safety without uniformly increasing construction complexity across the entire structure.

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method effectively transforms CCR into structural materials for impoundments and hydroelectric facilities, reducing environmental risks and regulatory non-compliance, while conserving resources and ensuring long-term stability and safety.

Implementation Method 1

applying engineering measures to the impoundment. The encapsulation may include a bio-geopolymer

Methodology Applied

Scientific EffectEncapsulation:

Implementation Method 2

The encapsulation may include a bio-geopolymer

Methodology Applied

Scientific EffectGeopolymer formation:

Implementation Method 3

consolidating and compacting at least a portion of coal combustion residual (CCR) of a CCR installation

Methodology Applied

Scientific EffectCompaction: Compression

Implementation Method 4

constructing an impoundment for water storage at least partially on top of the CCR installation

Methodology Applied

Scientific EffectHydroelectric power generation: Water Turbine

Data Source

PatentUS20260022527A1CCR beneficial use structure for a pumped storage facility using in-SITU coal combustion residuals with engineering measures

Publication Date: 2026.01.22 GO TEAM CCR LLC

AI summary

Beneficial use structures are disclosed that include coal combustion residuals (“CCR”) mixed with liquids and other materials 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 a pumped hydroelectric facility. A method of constructing an impoundment includes: consolidating and compacting at least a portion of coal combustion residual (CCR) of a CCR installation; constructing an impoundment for water storage at least partially on top of the CCR installation; and applying engineering measures to the impoundment. An impoundment for water storage includes a berm and a barrier and applied engineering measures. The impoundment is constructed using at least a portion of coal combustion residual (CCR) of a pre-existing CCR installation.