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Engineering Design and Operations Report Ciba

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Engineering Design and Operations Report Ciba 236639 1 ENGINEERING DESIGN & OPERATIONS REPORT CIBA-GEIGY, TOMS RIVER PLANT INDUSTRIAL WASTE LANDFILL CELL 3 inCORPORHTED consultants in environmental management CIB 013 ENGINEERING DESIGN & OPERATIONS REPORT CIBA-GEIGY, TOMS RIVER PLANT INDUSTRIAL WASTE LANDFILL CELL 3 Prepared for: Ciba-Geigy Corporation Rt. 37 W Toms River, New Jersey Prepared by: AWARE Incorporated 80 Airport Road West Milford, New Jersey 07480 June 1987 ENGINEERING REPORT Page No. 1.0 INTRODUCTION 1-1 2.0 GENERAL INFORMATION 2-1 2.1 Site History and Description- 2-1 2.1.1 Location 2-1 2.1.2 Site Layout 2-1 2.1.3 Site History 2-2 2.2 Environmental Setting 2-3 2.2.1 Land Use and Zoning 2-3 2.2.2 Climate and Meteorology 2-3 2.2.3 Surface Waters 2-4 2.2.4 Site Drainage 2-5 2.3 Existing Industrial Landfill Facility Description 2-5 2.4 Waste Types and Volumes 2-7 2.4.1 Waste Types 2-7 2.4.2 Waste Volumes 2-7 2.5 Easements and Utilities 2-8 2.6 Geology, Hydrogeology, Soils and Geotechnical Aspects of the Facility 2-8 2.7 Permit Requirements 2-9 3.0 LANDFILL DESIGN 3-1 3.1 Excavation Plan 3-1 3.2 Run-on/Run-off Controls 3-1 3.3 Foundation Design 3-3 3.3.1 General 3-3 3.3.2 Stability Analysis 3-4 3.3.3 Settlement Characteristics 3-5 3.3.4 Ultimate Bearing Capacity 3-6 3.4 Landfill Liner System 3-6 3.4.1 Secondary Geocomposite Liner System 3-7 3.4.1.1 Secondary Clay layer 3-7 3.4.1.2 Secondary Geomembrane Liner 3-11 3.4.2 Secondary Leachate Detection System 3-13 3.4.3 Primary Geocomposite Liner System 3-17 3.4.3.1 Primary Clay Layer 3-18 3.4.3.2 Primary Geomembrane Liner 3-19 3.4.4 Primary Leachate Collection System 3-23 3.5 Leachate Generation 3-29 3.5.1 Characterization 3-29 3.5.2 Generation Rates 3-30 3.6 Leachate Disposal 3-37 3.6.1 Leachate Collection Piping 3-38 3.6.2 Leachate Pump Station 3-44 3.6.3 Leachate Force Main 3-44 3.6.4 Leachate Treatment and Disposal 3-52 3.7 Gas Generation and Control 3-52 3.8 Groundwater Monitoring Program 3-53 3.8.1 Sampling and Analysis 3-54 3.9 Closure 3-59 CIB 013 0358 ENGINEERING REPORT (continued) Page No. 5.0 LANDFILL OPERATIONS 5-1 5.1 Hours of Operation 5-1 5.2 Personnel and Facilities 5-1 5.3 Record Keeping 5-1 5.4 Landfill Equipment 5-1 5.5 Access Control 5-1 5.6 Work Area Control 5-3 5.7 Waste Handling 5-3 5.8 Filling Sequence for the Landfill Facility 5-3 5.8.1 Filling to Intermediate Operations Grade 5-3 5.8.2 Filling to Intermediate Closure Grade 5-4 5.8.3 Filling to Final Closure Grade 5-5 5.9 Contingency Plans 5-5 5.9.1 Fire Control 5-5 5.9.2 Dust Control 5-6 5.9.3 Odor Control 5-6 5.9.4 Severe Weather Conditions 5-6 5.9.4.1 Freezing 5-6 5.9.4.2 Heavy Rain 5-7 5.9.4.3 Snowfall 5-7 5.9.4.4 Electric Storms 5-7 5.9.4.5 Extremely Windy Conditions 5-7 5.10 Equipment Breakdown 5-8 CIB 013 0 ENGINEERING REPORT (continued) Page No. 5.0 LANDFILL OPERATIONS 5-1 5.1 Hours of Operation 5-1 5.2 Personnel and Facilities 5-1 5.3 Record Keeping 5-1 5.4 Landfill Equipment 5-1 5.5 Access Control 5-1 5.6 Work Area Control 5-3 5.7 Waste Handling 5-3 5.8 Filling Sequence for the Landfill Facility 5-3 5.8.1 Filling to Intermediate Operations Grade 5-3 5.8.2 Filling to Intermediate Closure Grade 5-4 5.8.3 Filling to Final Closure Grade 5-5 5.9 Contingency Plans 5-5 5.9.1 Fire Control 5-5 5.9.2 Dust Control 5-6 5.9.3 Odor Control 5-6 5.9.4 Severe Weather Conditions 5-6 5.9.4.1 Freezing 5-6 5.9.4.2 Heavy Rain 5-7 5.9.4.3 Snowfall 5-7 5.9.4.4 Electric Storms 5-7 5.9.4.5 Extremely Windy Conditions 5-7 5.10 Equipment Breakdown 5-8 013 0360 LIST OF TABLES AND FIGURES Page No. TABLES 2- 1 List of Required Permits 2-10 3- 1 Wedge Analysis Summary 3-21 3-2 Transmissivity Comparison 3-28 3-3 Operational Stage Leachate Generation Rates 3-32 3-4 post Closure Stage Leachate Generation Rates 3-32 3-5 Rainfall Summary Table 3-34 3-6 Hydraulic Analysis of Collector Pipes 3-41 3- 7 Groundwater, Leachate and Leak Detection Sampling/ Analytical Parameters 3-56 4- 1 Cell No. 3 Materials of Construction 4-2 5- 1 Landfill Equipment 5-2 FIGURES 3-1 Rainfall Summary Table 3-26 3-2 Primary Collection Layer Thickness Graph 3-35 APPENDICES APPENDIX TITLE A Cell No. 3 Permit Drawings B Hydrogeologic/Geotechnical Report C Landfill Closure and Post Closure Plan D Cell No. 3 Construction Specifications E Supporting Landfill Design Calculations F Geotechnical Characterization of Candidate Soils for Landfill Liner; Clay Compatibility Investigation Phase II, Interim Report G Cell No. 3 Construction Quality Assurance/ Quality Control (QA/QC) Plan H Chemical Compatibility Testing of Polyethylene Membranes I Cell No. 3 Construction Drawings Industrial Waste Landfill Area Leachate Pipeline Outside Landfill Area 1.0 INTRODUCTION Ciba-Geigy operates an approved and fully licensed Industrial Waste Landfill (New Jersey Department of Environmental Protection (NJDEP) Facility Nos. 1507C and 1507D), at its plant located in Toms River, New Jersey. This Engineering Design Report, the accompanying drawings provided in Appendix A - Cell No. 3 Permit Drawings, Industrial Waste Landfill, and the supporting documentation provided in Appendices B through I describe the methods, materials and procedures which will be used to construct and operate Cell No. 3 and close Cell Nos. 1 thru 7, and must be submitted and approved before NJDEP will issue a new Engineering Design Approval. This Engineering Report describes the landfill design, construction and operational procedures along with a closure and post-closure plan. This report documents the proposed engineering design developed in response to the submission requirements of 7:26-2.10, and the scope of applicable disposal regulations for sanitary landfills specifically: 7:26-2A.5 engineering design submittal requirements for sanitary landfills 7:26-2A.6 sanitary landfill environmental performance standards 7:26-2A.7 sanitary landfill engineering design, standards and construction requirements 7:26-2A.8 sanitary landfill operational and maintenance requirements 7:26-2A.9 closure, post closure care of sanitary landfills Pertinent documents accompanying this submittal are provided in Appendix A, Drawings Nos. 6505-100P through 180P of the Cell No. 3 Permit Drawings, Industrial Waste Landfill, NJDEP Facility No. 1907D, Toms River, New Jersey, and other support documentation provided in Appendices B through I. 1-1 2.0 GENERAL INFORMATION 2.1 Site History and Description In this section the location, physical features, and a brief history of the Toms River Plant site are presented. 2.1.1 Location The Ciba-Geigy Corporation Toms River Plant is located in Dover Township, Ocean County, New Jersey (Appendix A, Drawing Nos. 6505-100P and 101P). The site encompasses approximately 1,300 acres and is situated about one mile west of the Garden State Parkway. The center of the site is situated at approximately N 39° 59' 10" latitude and W 74° 14' 20" longitude. The site is bounded by the Toms River on the northeast, by Cardinal Drive on the east, by Route 37 and residential/commercial development to the south and west, and by Pine Lake Park, a residential development, to the north. Winding River Park, an outdoor recreational area, borders the Toms River to the east and southeast of the site. The central business district of Toms River is located approximately three miles to the southeast of the site; an industrial park adjoins the site on the west. A residential area, including two senior citizen developments, is located about one mile south of the site. 2.1.2 Site Layout The approximate limits of the Toms River Plant property are provided in Appendix A, Drawing No. 6505-101P. Approximately three-hundred-twenty (320) acres of the 1,300-acre site are developed; the remainder is largely wooded pineland. The developed area includes the manufacturing or process area of the facility, a wastewater treatment plant with a capacity of 7.5 million 2-1 gallons per day (MGD), and a lined reservoir for emergency storage of wastewater. The bulk of the developed area is located nearly in the center of the property; the surrounding woodland thus serves as a buffer between the active portion of the facility and the surrounding land uses. The site ranges in elevation from a maximum of about 70 feet above mean sea level in the extreme western area to less than 20 feet above mean sea level adjacent to the Toms River. The site slopes gently to the northeast, east, and southeast, before dropping off sharply towards the river in the north­ eastern section. Except for the wooded area in the northwest and the non-contiguous area east of Oak Ridge Parkway, the entire property is fenced.
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