Note: The scenarios described are hypothetical and are intended to illustrate how BTL's geomembrane products can be applied in coal extraction and processing operations.
Scenario 1: Managing Process Water with BTL’s RPE Geomembranes
Background
A coal processing facility in the Powder River Basin of Wyoming faced challenges in managing large volumes of process water from coal washing and preparation. The process water contained fine coal particles and other impurities that needed complete containment to prevent environmental contamination.
Challenge
The facility was required to upgrade its process water management system to prevent seepage into the local groundwater, which would lead to significant environmental penalties. The solution needed to be highly effective, cost-efficient, and durable to withstand the abrasive nature of the coal fines.
Solution
The facility chose BTL’s RPE geomembranes for their new process water containment ponds. BTL’s RPE products were selected for their superior strength and durability, chemical resistance, and flexibility, making them ideal for the rigorous demands of coal processing environments. The geomembranes were installed with a dual-layer system, where RPE served as the primary liner accompanied by a protective geotextile layer to enhance puncture resistance and reduce wear.
Installation involved laying and seaming the geomembrane panels together using heat welding to ensure high-quality, leak-proof joints. The flexibility of the RPE geomembrane created a smooth installation process, fitting snugly to the contours of the existing pond structures without requiring extensive site modifications.
Outcome
The new RPE-lined ponds provided robust containment of the process water, preventing leakage and protecting the local water table from contamination. The enhanced durability and chemical resistance of the RPE geomembranes significantly extended the lifespan of the containment system, reducing maintenance costs and downtime for the facility. Moreover, the system’s efficiency in managing process water allowed the facility to implement water recycling measures, significantly reducing water usage and environmental footprint.
The finished project met and exceeded environmental compliance standards, earning the facility recognition for its commitment to sustainable mining practices. The success of BTL’s geomembranes in this application has led to their consideration for other similar projects across the industry.
Scenario 2: Acid Mine Drainage Containment with BTL’s ArmorPro Geomembranes.
Background
A coal mine in the Appalachian Mountains was facing significant environmental challenges due to acid mine drainage (AMD), which threatened water quality and local ecosystems. AMD, resulting from the exposure of sulfide minerals to air and water, creates highly acidic water that can carry harmful metals.
Challenge
The mine required a robust solution to contain and treat the AMD effectively. The solution needed to offer exceptional resistance to both chemical corrosion and physical wear to ensure longevity and reliability under acidic and abrasive conditions.
Solution
The mine opted for BTL’s ArmorPro XR-5 geomembranes to line its AMD treatment ponds. XR-5 is particularly suited for such applications due to its superior chemical resistance and durability. It is constructed from an ethylene interpolymer alloy, providing excellent protection against a wide range of chemicals and environmental stressors.
The installation process included:
Site Preparation
The site was carefully prepared to ensure the pond bed was smooth and free from objects that could puncture the geomembrane.
Geomembrane Installation
BTL’s XR-5 geomembranes were carefully deployed, with particular attention to seam integrity, to prevent any possible leaks. The remaining seams were secured on-site using advanced welding techniques to ensure a solid, leak-proof bond.
Protective Overlays
A protective layer of geotextile was placed over the geomembrane to help shield it from any potential damage from overlying materials or debris. This additional protection ensured the liner would continue to perform over the long term.
System Integration
To effectively manage AMD, a drainage system was integrated into the lining system to collect and convey acidic liquids to treatment systems adjacent to the ponds. The treatment systems process the collected AMD by adjusting pH levels and removing harmful metals before the water is recycled into the mining process or released into the environment.
This setup ensured that the AMD was effectively managed, treated, and disposed of or reused in a way that minimized environmental impact. Positioning the treatment facilities adjacent to or in close proximity to the containment ponds optimized the logistics and efficiency of the treatment process.
Outcome
The geomembrane-lined containment ponds effectively captured the AMD, preventing further contamination of local waterways. The integrated treatment systems neutralized the acidic water, allowing the mine to meet environmental regulations and significantly reduce the ecological impact of its operations. The system’s success helped improve community relations and ensured compliance with EPA standards.
Scenario 3: Upgrading Coal Stockpile Covers with BTL’s AquaArmor Geomembranes
Background
A coal-fired power plant in Illinois was required to implement stringent measures to control dust emissions and manage runoff from its coal stockpiles.
Challenge
The previous cover systems were inadequate in controlling dust and runoff and suffered from rapid degradation due to prolonged exposure to UV radiation. The plant needed a durable and effective solution against environmental factors, including resistance to UV degradation.
Solution
The facility decided to upgrade its coal stockpile covers using BTL’s RPE geomembranes. These geomembranes were selected for their superior durability, flexibility, and UV and chemical resistance, prolonging their lifespan and maintaining their integrity in the site’s demanding conditions.
The installation process included:
Site Preparation
Before installation, the surface areas around the coal stockpiles were cleared to ensure a debris-free surface, minimizing risks of punctures or tears during deployment and over the stockpile’s operational lifetime.
Custom Fitting and Deployment
Each RPE geomembrane was tailored to the dimensions and shapes of the coal stockpiles to ensure full coverage. RPE’s flexibility ensured an easy and effective fit by adapting to the stockpiles’ uneven surfaces.
Secure Anchoring
The geomembranes were anchored using a weighted edge system to keep them in place under high wind conditions. This method ensured the covers remained secure and provided continuous protection against environmental factors.
Outcome
The BTL’s RPE geomembranes provided robust, long-lasting coverage for the coal stockpiles, significantly reducing dust emissions and preventing rainwater from contacting the coal and creating contaminated runoff. RPE’s high resistance to UV exposure ensured the covers functioned for an extended period, reducing maintenance frequency and the cost of frequent replacement. This upgrade helped the plant meet stringent environmental standards and improved its operational efficiencies by minimizing the environmental impact of coal storage.
