Note: The scenarios described are hypothetical and are intended to illustrate how BTL's geomembrane products can be applied in coal ash management operations.
Scenario 1: Coal Ash Pond Lining Retrofit with BTL’s ArmorPro Geomembranes
Background
A power plant in Virginia faced stringent new environmental regulations that required it to upgrade its operating coal ash ponds. These rigorous new regulations were intended to prevent groundwater contamination. The facility’s existing ponds were unlined, allowing contaminated leachate to seep into the groundwater, posing serious environmental and health risks.
Challenge
The facility needed a robust solution to quickly bring the coal ash ponds into compliance without disrupting its day-to-day operations. The solution required careful project planning and execution to ensure the retrofit could be completed efficiently and effectively without taking the ponds out of service. This requirement presented a significant challenge given the continuous production of ash.
Solution
The operational coal ash ponds were retrofitted with BTL’s XR-5 geomembranes, chosen for their high durability and excellent chemical resistance. XR-5 was particularly suited for its quick installation capabilities and minimal maintenance requirements.
The installation process included:
Phased Installation
The retrofit was conducted in phases to minimize disruption. Only portions of the ponds were taken offline at any one time, allowing the rest of the system to continue operating normally.
Site Preparation
The sections of the ponds being retrofitted were isolated and temporarily drained. The pond beds were then prepared—graded and compacted—to ensure a smooth and stable substrate, supporting the new liner without compromising its integrity.
Geomembrane Installation
XR-5 geomembranes were deployed across the prepared sections. Advanced welding techniques were used to join the geomembrane sections, with particular attention to seam integrity to ensure robust, leak-proof seams that could withstand the physical stress from continuous operation. Installation teams worked efficiently to minimize downtime associated with the exposed areas.
Protection and Inspection
A geotextile protective layer was placed over the geomembrane to prevent damage from the ash as the ponds were refilled. Upon completion of the installation in each phase, thorough inspections and leak detection tests were performed to confirm the integrity of the geomembranes before reintroducing coal ash.
Outcome
The retrofit significantly enhanced the ponds’ containment capabilities. The ArmorPro XR-5 geomembrane provided a reliable barrier against leachate escape, reducing the risk of groundwater contamination and bringing the facility into regulatory compliance without disrupting the plant’s operations. The successful phased approach allowed the facility to maintain continuous operation.
Scenario 2: Successful Emergency Containment Inspires Widespread Upgrades with BTL Geomembranes
Background
A coal-fired power plant in Indiana recently initiated a pilot project to upgrade the secondary containment systems at one of its liquid coal ash storage facilities. This upgrade involved replacing the old geomembrane liners with new, advanced RPE geomembranes designed for enhanced chemical resistance and durability.
Secondary Containment Upgrade
The pilot project upgraded the secondary containment area surrounding older storage tanks with new, advanced RPE geomembranes. This upgrade included reinforcing the containment berms and laying new geomembranes around the tank base, enhancing the overall spill containment capacity.
During the geomembrane installation, the plant implemented a new state-of-the-art leak detection system around the tank perimeter. This system would provide early warnings in the event of a breach, enabling rapid response to prevent environmental damage.
Incident and Response
Not long after the upgrade, one of the primary storage tanks, holding a substantial volume of coal ash slurry, experienced a structural failure, resulting in a breach. This incident posed a severe risk of environmental contamination, potentially leading to significant ecological and regulatory consequences.
Immediate Containment
When the tank breached, the newly installed secondary containment system featuring BTL’s RPE geomembrane was immediately tested. The liner easily contained the escaping slurry, preventing it from reaching the surrounding environment, and suffered no damage during response or cleanup activities.
Rapid Cleanup
The containment system also facilitated a quick and efficient cleanup process. Emergency crews recovered the spilled material and repaired the breach without environmental contamination or significant operational disruption.
System Review and Assessment
Following the incident, the incident was thoroughly reviewed and documented, providing valuable data on the performance of the secondary containment system. The effectiveness of BTL’s RPE geomembrane in containing the spill was immediately apparent, preventing significant environmental contamination, reputational damage, and potential regulatory penalties.
Outcome
Encouraged by the geomembrane’s success during and after the incident, the power plant conducted a thorough evaluation of other existing ash containment areas. Motivated by the geomembrane’s reliability and effectiveness, the power company implemented a company-wide upgrade, replacing older systems with BTL’s advanced geomembrane technology, thus standardizing high safety and environmental compliance across all its facilities.
