Market Assessment and Demonstration of Lignite FBC Ash Flowable Fill Applications
Montana-Dakota Utilities (MDU) and Western Research Institute (WRI) have been developing flowable fill materials formulated using ash from the Montana-Dakota Utilities R. M. Heskett Station in Mandan, North Dakota. MDU and WRI have partnered with the U.S. Department of Energy (DOE) and the North Dakota Industrial Commission (NDIC) to further the development of these materials for lignite-fired fluidized-bed combustion (FBC) facilities. The MDU controlled density fill (CDF) appears to be a viable engineering material and environmentally safe. WRI is pursuing the commercialization of the technology under the trademark Ready-Fill{trademark}. The project objectives were to: (1) assess the market in the Bismarck-Mandan area; (2) evaluate the geotechnical properties and environmental compatibility; and (3) construct and monitor demonstrations of the various grades of flowable fill products in full-scale demonstrations. The scope of initial phase of work entailed the following: Task I--Assess Market for MDU Flowable Fill Products; Task II--Assess Geotechnical and Environmental Properties of MDU Flowable Fill Products; and Task III--Demonstrate and Monitor MDU Flowable Fill Products in Field-Scale Demonstrations. The results of these testing and demonstration activities proved the following: (1) The market assessment indicated that a market exists in the Bismarck-Mandan area for structural construction applications, such as sub-bases for residential and commercial businesses, and excavatable fill applications, such as gas line and utility trench filling. (2) The cost of the MDU flowable fill product must be lower than the current $35-$45/cubic yard price if it is to become a common construction material. Formulations using MDU ash and lower-cost sand alternatives offer that opportunity. An estimated market of 10,000 cubic yards of MDU flowable fill products could be realized if prices could be made competitive. (3) The geotechnical properties of the MDU ash-based flowable fill can be modified to meet the needs of a range of applications from structural fill applications to excavatable applications, such as utility trench fill. (4) Environmental assessments using standard testing indicate that the environmental properties of the fill materials are compatible with numerous construction applications and do not pose a threat to either adjacent groundwater or soils. (5) WRI developed an Environmental Field Simulator (EFS) method for assessing the impact of flowable fill materials on adjacent soils and found that the zone of impact is less than a couple of inches, thereby posing no threat to adjacent soils. (6) Field-scale demonstrations of the MDU flowable fill were constructed and were successful for structural, as well as excavatable applications. Monitoring has demonstrated the geotechnical performance, environmental performance, and compatibility with common embed materials with the MDU flowable fill products. Technical and economic issues were identified that may hinder the commercial acceptance of MDU flowable fill materials, including: (1) the ability to produce a consistent product; (2) the ability to provide a product year round (cold weather retards strength development); and (3) the ability to evaluate and produce commercial quantities of MDU flowable fill using inexpensive materials.
- Research Organization:
- Western Research Institute
- Sponsoring Organization:
- USDOE
- DOE Contract Number:
- FC26-98FT40323
- OSTI ID:
- 910129
- Country of Publication:
- United States
- Language:
- English
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