PBCo and MERG Announce Completion of a Groundbreaking Beneficial Use Project at the R. Paul Smith WV Ash Landfill

The Paul Blum Company (PBCo LLC) and Maryland Environmental Restoration Group (MERG) are pleased to announce the completion of their project to reclaim and restore the CCP landfills and sedimentation ponds of the R. Paul Smith Power Plant Landfill in Berkeley County, West Virginia. Over the course of the 12 – year project, the team, which also included the civil construction contractor, C. William Hetzer, Inc., excavated and reclaimed all of the 3.2 million tons of fly and bottom ash (CCP) from 80 acres of R. Paul Smith Power Plant impoundments. PBCo and MERG contracted with 5 local trucking companies for the delivery of the reclaimed ash for beneficial reuse at two nearby portland cement manufacturers.

R. Paul Smith landfill and ponds circa 2009
R. Paul Smith landfill and ponds circa 2009

To the best of our knowledge, this is the first ever 100% beneficial use of a coal fired power producer’s coal ash impoundment and landfill anywhere in North America and marks a significant milestone in the drive for sustainability from both the cement industry and the nearby communities they serve.

An early morning line up of trucks loading ash

For the landfill owners, the project resulted in a complete restoration of a more than one half century old ash landfill. By completely removing all of the ash and restoring the natural vegetation, PBCo and MERG significantly reduced the potential ground water contamination and associated monitoring, as well as eliminating any storm water runoff into the Potomac River. Furthermore, the restoration of the site reversed what was a significant real estate liability into a real estate asset, on which other power producing renewable structures, such as solar farms, can be built. With all the ash removed and the site certified clean, the owner will likely request a release of its WV landfill permit.

To the nearby portland cement producers the beneficial reuse project offered a long term, uninterrupted and less expensive supply of feedstock. A truly sustainable alternative to mining shale or importing bauxite. All of the 3.2 million tons of ash were used to make cement, nothing R. Paul Smith landfill and ponds circa 2009 An early morning line up of trucks loading ash other than a handful of 50-year-old truck tires found buried in the 150 ft. high ash piles had to be sent for disposal. Replacing shale with fly ash in the manufacture of portland cement reduces the heat and fuel required, saving production costs as well as significantly reducing CO2 emissions from the plant and eliminating emissions from the alternative mining operations.

The neighboring communities have realized benefits too. Reclaiming the enormous mountains of ash completely removed a potential contamination of the Potomac River, local water supplies and air quality. Restoring the land to a green field status positively impacted residential real estate, local contractors and business as well many trucking companies.

During the twelve year project, from ground breaking to certified clean, the PBCo-MERG team did not receive a single complaint from neighbors about the truck traffic, fugitive dust or noise.

Restoration complete, 80 acres Berkely, WV
Restoration complete, 80 acres Berkely, WV

Restoration complete, 80 acres Berkely, WV Prior to 2009, there had been little consideration for harvesting CCP’s from landfills and impoundments. The success of the R. Paul Smith beneficial reuse project demonstrates that there is a sustainable economic alternative to the diminishing supply of dry fly ash for the cement industry where all stakeholders benefit. With the market demand for CCP cement feedstock ever increasing in the wake of closures of coal-fired plants across the U.S., the PBCo-MERG team is excited about the growing prospects for CCP beneficial reuse.

About PBCo LLC

To date, Paul Blum Company has supplied and delivered over 40 million tons of raw and cementious minerals to the U.S. and Canadian cement-making industry. PBCo is known for sourcing and qualifying beneficial sustainable alternatives proven to increase portland cement quality and production while reducing costs.

About MERG

MERG has been a trusted vendor to the U.S. power industry for over 20 years. MERG was established in 2002 through a grant from the PPRP (Power Plant Research Program), division of The Maryland Department of Natural resources. MERG’s history of accomplishments include CCP research and contract procurement of major producers of fly ash and synthetic gypsum for use in the production of Portland cement.

About C.W. Hetzer

C. William Hetzer, Inc. is a Hagerstown, Maryland-based contractor. Our operating radius ranges from 35 to 50-miles from Hagerstown, with much of our activity falling within the Cumberland and Shenandoah Valleys (from Winchester to Chambersburg). As a company focused on directhire construction, we self-perform the great majority of our contracting volume.