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DESIGN AND OPERATIONAL ISSUES RELATED TO THE CO-DISPOSAL OF SLUDGES AND BIOSOLIDS IN CLASS I LANDFILLS Introduction Biosolids are

a byproduct of wastewater treatment and contain organic and inorganic materials removed from the wastewater. These residuals are concentrated by various methods to semi-solid form. Likewise, sludge is generated during water treatment and contains solid materials removed from water as well as chemicals added during the treatment process. The final residual water content depends on the type of treatment provided and varies from a slurry to a dry state. Disposal of water treatment facility sludge and wastewater treatment facility biosolids represents significant challenges to facility operators. Various strategies are employed for the treatment and disposal of these residuals, including treatment options such as anaerobic digestion, composting, incineration, thermal drying with incineration, thermophillic aerobic digestion, and lime stabilization. Final disposal primarily involves land application or disposal to landfills. Approximately 5.1 million tons/year of biosolids were produced in the US in 1999, of which approximately 26% was placed in landfills (www.biosolids.policy.net, 2001). As can be seen in Figure 1, approximately 17% of the 270,000 tons of biosolids generated in Florida were placed in landfills. The majority of biosolids in the US are applied to the land. However, this practice often violates the permissible loading of metals, exceeds allowable levels of pathogens, and is frequently cited for operational problems related to improper monitoring and record maintenance (U.S. EPA, 1998).

Incineration 9% Landfilling 18%

Surface Disposal 1%

Land Application 72%

Figure 1. Distribution of Florida Biosolids Management Practices

The application of sludges and biosolids to the land is regulated at the federal level under the Clean Water Act (40 CFR Part 503) and at the state level in Chapter 62-640, FAC. These regulations establish pollutant limits and treatment requirements for pathogen control. The disposal of sludges in landfills is addressed under 40 CFR Part 258, however, the US EPA has delegated regulation of municipal solid waste landfills to the states. Landfill owners, however, can be potentially liable for cleanup costs related to the disposal of hazardous wastes although the US EPA has issued policy suggesting that they do not intend to pursue liability against municipalities legally placing sludges in landfills. In Florida, Chapter 62-701, FAC regulates solid waste management facilities and prohibits the disposal of liquid wastes in landfills, defined as a material containing free liquids as determined by the Paint Filter Liquids Test. The introduction of sludges to Florida landfills is controlled by the state through the landfill permit. Researchers have suggested co-disposal of residuals and MSW since the early 1980s. Studies suggest that such co-disposal results in enhanced stabilization of the combined waste, increased gas production, and improved quality of leachate with respect to leaching of metals. Co-disposal may have particular benefits to the operation of bioreactor landfills as a source of moisture. In laboratory and pilot studies, biosolids addition has had mixed impact on MSW degradation (Barlaz et al, 1990). ten Brummeler et al (1991), however, found that composted sludge had a positive effect on the start up of MSW digestion, preventing souring experienced in reactors with leachate recirculation alone. Studies by Leuschner (1989), Pohland (1992) and NYSERDA (1987) all showed positive effects of addition of sludge on methane generation onset and rates. Stegmann and Spendlin (1989) indicated that sludge addition does not enhance gas production. Leckie (1987) found that the addition of septic tank pumpings stimulated acid fermentation and suppressed methane generation. Hill (1989) showed co-disposal of controlled waste and sewage sludge in West Yorkshire U.K. to be a promising disposal option in terms of stabilization of waste, gas production and leachate quality. The effect measured may be due to buffering or moisture addition more than microbial seeding. Blakey (1989) conducted laboratory and pilot-scale experiments in the U.K. to study the codisposal of domestic solid waste and sewage sludge. He reported that the leachate chemical oxygen demand was reduced by 50% during the study as compared to domestic waste alone. He also reported an early increase in gas production rates during co-disposal, with increased methane content. Studies have also shown a reduction in the leaching of metals attributed to the presence of sulfides in biosolids (Cossu and Serra, 1989). Beker (1989) concluded that the addition of biosolids to MSW at low percentages (less than 10%) has no effect on landfill environmental impact. At higher percentages, he reported an expected positive impact on the biological processes within a landfill. Cossu et. al. (1989) studied the co-disposal of coal fly-ash and biosolids in landfills. The high moisture content of the biosolids reduced dust evolution in the landfill, whereas ash helped to solidify the semi-liquid biosolids. Batch elution tests for release of metals, using actual landfill leachate as the liquid phase, showed that ash absorbed the majority of the heavy metals. An alternative approach to co-disposal of residuals is to use this material as daily or final landfill cover. When dewatered to a solids content above 50%, sludges become soil-like in

characteristics and meet the objectives of cover, namely, providing a physical barrier, odorous emission control, erosion resistance, and vegetative growth support (Griffen et al., 1998). While researchers largely agree that the addition of residuals to MSW landfills has no affect on leachate quality, areas of concern remain regarding operational impact and landfill stability. If the residuals are too wet, compaction equipment may slip and/or bog down and material will lodge in compactor wheels (de Bekker et al, 1989). Cossu and Serra (1989) offered a possible solution to this problem of mixing sludges with combustion ash to lower moisture content of the sludge. The physical nature of dewatered wastewater sludge placed in a landfill is of critical importance. The primary issues of interest in the geotechnical aspects of landfilling sludge are handling and placement, compaction, shear strength and slope stability. Since such landfills can reach large heights, the moisture characteristics and the associated geotechnical stability need to be taken into account. In general, lower limits are set for the total solids content but there are no established geotechnical criteria for the moisture content and shear strength for the sludge with the exception of Germany (German Federal Government, 1993). A state-of-the-art summary of the physical aspects of sludge in landfills is presented in van den Berg et al. (1991). More recently, Koenig et al. (1996) have presented a study to evaluate the geotechnical properties such as vane shear strength, consolidation characteristics and hydraulic properties of municipal wastewater treatment plant biosolids in Hong Kong. This study found that the vane shear strength of dewatered sludge was related to the total solid content in a manner consistent with the critical state soil mechanics theory. Although the consolidation behavior was seen to follow the conventional consolidation theory for soils, the compressibility properties were substantially higher than soils. The permeability of the landfilled sludge was related to the applied stress using a logarithmic relationship. De Bekker and Van den Berg (1993) provided a summary of the mechanical and rheological properties of sludge with regards to the stability and bearing capacity of a landfill in Holland. They pointed out some of the physical characteristics of sewage sludge codisposal with regards to water content and shear strength. A large quantity of water is brought in along with the sludge, which impacts the soil mechanics and hydrological conditions of the landfills. By dumping sludge with a dry matter content of 5% together with domestic waste, the weight of the landfill is more than doubled. Thus, the applicable guidelines in Holland impose lower limits on the dry matter content of sewage sludge to be dumped, namely greater than about 35% d.m. This requires the sludge to be dewatered mechanically after conditioning with lime and iron chloride or with polymers. For sewage sludge conditioned with polymers and dewatered with a sieve band press, the weight ratio of domestic waste and sludge is about 4:1. With smaller ratios, the sludge can no longer be properly processed within and among the domestic waste and bearing capacity is reduced. In addition, the mechanical properties such as cohesion and shear resistance are of importance in determining the stability of the dry matter content. Geotechnical properties of biosolids are affected by the generating source and treatment of residuals (stabilization, thickening, conditioning, and dewatering). Otte-Witte (1989) found that the presence of industrial sources had definite impact on shear strength of the material as

measured by the vane apparatus. For example, the addition of highly organic wastes had a positive influence on strength, while the addition of wastes with inorganic nature such as galvanic and chemical industry, had a negative influence. Benoit et al. (1999) studied the geotechnical properties of a mixture of wastewater treatment plant biosolids with MSW incinerator bottom ash. Mixtures ranging from 10:1 to 5:1 (ash:sludge by volume) were studied and geotechnical properties such as particle size, water content, specific gravity, density, shear strength and compressibility were evaluated. Standard Proctor tests as well as field compaction tests, were performed and the relationship between dry density and water content was established. For stability evaluations, direct shear tests were conducted and strength changes with several parameters were measured. Field settlement studies showed that the settlement occurred very rapidly and the stability of the landfill improved with time. The results from the geotechnical investigation were used to get a co-disposal concept in practice at a full-scale facility in New Hampshire. Objectives Because of concerns related to alternative disposal practices, the placement of sludges and biosolids in landfills is expected to increase. Landfilling of residuals is not without challenges related to landfill operations (including waste compaction, odors, and landfill stability) and, potentially adverse impact on leachate and gas quality and quantity. The objective of the proposed research, therefore, is to provide an assessment of the practicality of residuals landfilling in Florida. The ultimate goal of this project is to develop guidance on operational procedures necessary to safely landfill water and wastewater residuals. Methods The approach proposed for conducting this research includes the following tasks: Task 1. Literature review: The technical literature will be searched for information regarding co-disposal of sludges and biosolids with municipal solid waste in landfills. Sources such as an annual literature review conducted by the Water Environment Federation (e.g. Krogman et al, 1997 and 1999) will be explored. Pertinent literature will be gathered and summarized with particular emphasis on Florida experiences. Task 2. Landfill Surveys: A survey instrument will be developed and distributed to small, medium, and large-sized landfills throughout the US currently receiving residuals to assess the issues and challenges related to landfilling of sludges and biosolids. The survey will seek information regarding the condition of the residuals, the ratio of residuals to solid waste, operational problems encountered, perceived impact on leachate and gas quality, techniques used to mix residuals with waste, techniques used to minimize impact, etc. The written survey will be followed by telephone interviews in some cases.

Task 3. Evaluation of Florida Leachate Quality Data: Florida Class I landfill leachate quality data will be obtained from the Florida Department of Environmental Protection (FDEP). These data are routinely submitted to FDEP as part of permit conditions. Leachate quality from landfills accepting residuals will be statistically compared with leachates from landfills that do not accept residuals to identify any potential quality issues. This comparison will be performed using the Microsoft Excel Analysis ToolPak, KURV+, and SYSTAT. Task 4. Geotechnical Investigations: In order to assess the stability of the soil-waste-sludge mixture, the shear strength of the compacted mixture needs to be determined. This will be obtained using a direct shear test in the laboratory. A series of direct shear tests for various ratios of the mixture and different confining stresses will be carried out on samples at the natural and optimal moisture contents. Slope stability analyses on different landfill configurations will be carried out using the Method of Slices, Bishops Method and Spencers Method. Commercially available computer programs for slope-stability analyses will be used to accomplish this task. Critical sections of a landfill with different profiles based on cross-sectional areas and slopes will be selected for modeling. Potential failure surfaces and related factor of safety against slope failure will be studied. The mechanical properties of different landfill components to be used in the slope stability analysis will be obtained from literature. Finally, laboratory compaction tests (Proctor tests) will be conducted to determine the maximum dry density and optimum moisture content characteristics of the sludge-waste mixture. Results from the laboratory compaction tests will be useful in establishing the field placement procedures in the next phase of this research. Task 5. Full-Scale Study Design: During the first year of this investigation, locations for a full-scale evaluation of residuals codisposal with Municipal Solid Waste (MSW) in a Class I landfill will be identified. Once an appropriate site is selected, a preliminary operational plan will be developed identifying the source of biosolids or sludges, the expected quantity, a schedule for application to the landfill, operational considerations for placing the material, and a plan for evaluating any impact on operations or gas/leachate quality. Deliverables Deliverables include quarterly reports, an annual report, minutes of TAG meetings, a project web site, and papers for presentation and publication.

Timeline/Milestones Table 1. Project Gantt Chart Task


Literature Search Landfill Surveys Evaluation of Florida Leachate Quality Data Geotechnical Investigations Full-Scale Study Design TAG Group Meetings Quarterly Progress Reports Final Report

1 X

2 X

3 X X X

4 X X

5 X X X

Month 6 7 X X X X X X X

8 X X

9 X X X

10

11

12

X X X

X X

X X X

Expected Technical Results The research will provide design and operational guidance related to residuals co-disposal with MSW in lined landfills. The research will provide information regarding the environmental and operating impacts of residual landfill disposal and will help operators make decisions regarding accepting these materials. Anticipated Benefits The design and operational guidance related to residuals co-disposal with MSW can make codisposal more efficient and safer. Related Work Dr. Reinhart has performed a study of Florida leachate quality and characteristics (funded by the FCSWHWM). Both Dr. Townsend and Dr. Reinhart are involved with the NRRL bioreactor demonstration project a possible candidate for follow up work. Dr. Reinhart was the director of Research and Development for the City of Atlantas Bureau of Pollution Control during which time she participated in many biosolids investigations. Dr. Chopra has used modeling techniques such as the finite element and the boundary element methods for analyzing the strength and stability of soils. He has applied these techniques to determine the response of shallow and deep foundations in soils undergoing consolidation and shear flow under static and dynamic (earthquake) loads. Possible Follow-up A more comprehensive follow-up study during Year 2 of the project will be required to develop the guidance procedures for co-disposal. The study will focus on odor impacts, leachate and gas 6

quality, and waste placement. A field geotechnical investigation would be conducted in conjunction with these studies. Vane shear test and cone penetrometer (CPT) tests will be conducted on a mixture of solid waste-sludge-soil with varying amounts of total solid contents (TSC). Field compaction tests will be conducted in this second phase to determine the placement procedures for obtaining the optimum field compacted density with a workable mixture. These tests will provide an insight into the behavior of the mixture with regard to the optimum moisture content and the required shear strength.

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