Processed CCR Mixes for Hardened Structure Enclosures
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Solution Overview
Problem
The accumulation of coal combustion residuals (CCR) poses environmental and economic challenges due to storage costs and regulatory concerns, necessitating a beneficial use that meets EPA standards for disposal and conservation of natural resources.
Innovation Solution
Processing CCR to create fortified and strengthened mix designs for constructing hardened structures on military bases, incorporating materials like lime, cement, and synthetic gypsum, which provide enhanced strength and workability, and are resistant to concussive forces, electromagnetic pulses, and severe weather conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If CCR is stored in landfills or impoundments, then disposal is achieved, but storage costs increase and environmental risk increases
Solution Approach 1:
The patent converts the harmful waste material CCR into a beneficial construction aggregate by processing it through drying, screening, and mixing operations. The processed CCR is then used as a substitute for traditional aggregates in concrete and asphalt applications, transforming the disposal problem into a resource utilization solution that eliminates storage costs and environmental risks associated with landfilling.
Solution Approach 2:
The patent applies parameter changes by modifying the physical and chemical properties of CCR through processing. Moisture content is reduced through drying, particle size distribution is adjusted through screening and grinding, and material composition is optimized through mixing with supplementary materials. These parameter changes transform CCR from an unsuitable waste product into a viable construction aggregate meeting specific performance criteria.
2Reliability
If CCR is used in construction applications, then beneficial use is achieved, but material processing complexity increases
Solution Approach 1:
The patent segments the CCR processing system into distinct operational modules: drying section, screening section, grinding section, and mixing section. Each module performs a specific function and can be independently controlled and optimized. This segmentation reduces overall system complexity by allowing each component to be designed and operated separately rather than as a monolithic complex system.
Solution Approach 2:
The processed CCR aggregate serves multiple functions: it can be used in concrete production, asphalt production, backfill applications, and other construction uses. This multi-functionality allows a single processing facility to serve diverse construction needs, reducing the number of specialized processing lines required and thereby reducing overall system complexity.
3Quantity of substance
If CCR is transported to distant disposal sites, then disposal capacity is achieved, but transportation cost increases
Solution Approach 1:
The patent enables CCR storage facilities to serve themselves by processing their own waste material into usable construction aggregate. The processed CCR can then be used for backfill at the storage facility, construction projects at the facility location, or sold to nearby contractors. This self-service approach eliminates the need to transport CCR to distant landfills and reduces transportation costs by utilizing the material locally.
Solution Approach 2:
The patent applies preliminary action by processing CCR into a usable aggregate form before it would otherwise require disposal. By preparing the material in advance through drying, screening, and mixing operations, the CCR becomes a valuable resource that can be immediately utilized in construction applications, eliminating the need for future transportation to disposal sites.
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 use of CCR in constructing hardened structures addresses storage and disposal issues while providing cost-effective, environmentally friendly solutions that meet regulatory standards, offering increased protection and design flexibility for military and civilian applications.
Implementation Method 1
incorporating materials like lime, cement, and synthetic gypsum, which provide enhanced strength and workability
Implementation Method 2
resistant to concussive forces, electromagnetic pulses, and severe weather conditions
Implementation Method 3
resistant to concussive forces, electromagnetic pulses, and severe weather conditions
Data Source
AI summary
A process of fabricating a static structure including an interior volume that includes the steps of mixing coal combustible residual (CCR) with structural reinforcing materials to form a construction material and utilizing the construction material to fabricate exterior enclosure-forming components of the static structure. The enclosure-forming components are sufficiently reinforced, enhanced and/or thick to provide protection against exterior forces directed against the structure.