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File: 18G (6 35A ~~~D.B. /4t cc- 0V. DESIGN DOCUMENT SOIL COMPOSTING DESIGN FOR REMEDIATION OF HYDROCARBON-CONTAMINATED SOIL FIELSON AIR FORCE BASE, ALASKA DRAFT FINAL February 1993 United States Air Force Environmental Restoration Program
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File: 18G(6 35A ~~~D.B.

/4t cc- 0V.

DESIGN DOCUMENT

SOIL COMPOSTING DESIGN FORREMEDIATION OFHYDROCARBON-CONTAMINATED SOILFIELSON AIR FORCE BASE, ALASKA

DRAFT FINAL

February 1993

United States Air ForceEnvironmental Restoration Program

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a ~~~EAFB Soil Composting Design Document 1/29/93, Draft Rev. IS

WSoiI Composting Design for 1993 Elelson Soll Compostin Demonstration

OVERVIEW

The design for conmposting hydrocarbon-contaminated soil at Eielson Air Force Base (EAFB)in Fairbanks, Alaska is based on the need for controlling leachate and air emissions; providinga simple, easily installed system; and providing a cost effective treatment system. This designwill have four major components: the compost pile, the blower system, the leachate collectionsystem, and the leachate redistribution system. The demonstration is planned for 500 cubicyards of contaminated soil. Figure 1 shows a compost pile and the pertinent dimensions. (Notethat the figure is not to scale and that a slope of 40' from horizontal was assumed based on thesoil being a sandy gravel.) Figure 2 shows the conceptual design of a composting system withall major components represented. (T7he figures for this Design Document are collected andpresented in Appendix A.)

The compost plot consists of a shallow excavation confined by earthen berms with a 20-30 milhigh density polyethylene (HIDPE) liner placed in the excavation and held in place by soil piledon the outside of the berns. The excavation will be 14 feet wide, 86 feet long and 1A foot deep,

I - ~~sloping at 1 inch per 14 feet to 1 foot depth at the end of the plot where the collection basin islocated. Material excavated from the plot will be used to construct the 1-foot-high berm on theO ~~perimeter of the excavation. A sump area will be adjacent to the main plot area to collectleachate for its removal to storage tanks. The sump area also will be surrounded by theperimeter berm. Prior to installing the liner, sharp objects will be removed from the plot. Theliner is 22 feet wide and will be manually rolled out along the length of the plot. No seamingwill be necessary. The liner will be manually fitted to conform with the plot contour and its-outside edges secured with soil along the entire perimeter using a backhoe. The entrance gapto the sump area will be filled manually with a gravel berm. Each compost pile will be roughly5 to 6 feet high and will contain about 150 cubic yards of contaminated soil.

A blower system is required for aeration of the compost pile to enhance microbial activity andcontaminant destruction. PVC piping will be installed lengthwise in the compost pile at a heighxtof about 0.5 foot above the pit bottom and will have alternating 5-foot-long sections of slottedpipe (well screen) and 3-foot-long sections of solid pipe. Thbe design uses one line of pipingper pile placed in the center of the pile near the bottom. Volatile organics stripped during thisprocess will be adsorbed in a granular activated carbon (GAO system. The blower will becycled to aerate the compost pile without overly drying the pile or dissipating heat. Detaileddesign work is needed to determine the size of the blower and to determine the blower dutycycle (see below).

A passive aeration system also may be employed. This system consists of a series of slottedpipe sections placed through the width of the pile at 3-foot intervals along the length of the pile. ~~and at alternating heights. These pipe sections provide an air passage to the center section of

1

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the pile. The driving forces for oxygen transport into the pile are diffusion, thermal gradients,and natural advection (wind) only. No control of VOC emissions is possible with this system.

The leachate collection system wil consist of a sunken sump area for each plot, a portablecentrifugal pump to remove leachate, storage tanks, and associated piping and flexible tubing.The sump area at each plot wil provide a holding area to collect leachate from excess rainfalland a basin from which leachate can be removed and pumped to the storage tanks. Leachate inexcess of the capacity of the sump area wil collect in the lower layers of the compost pile. Thecapacity of the liner plot and sump area combined is in excess of a 10-inch rainfall. A portablecentrifugal pump will be used to transfer the leachate from the collection basin to the storagetanks as required. The pump will have a screened inlet placed in the bottom of the sump areato retrieve the leachate. Electricity for the pump will be provided through an exterior outlet neareach sump area.

The leachate redistribution system will consist of a pump and associated piping. The leachatewill be redistributed onto compost piles via a portable soaker hose system installed on top of thepile. Clean water wil be distributed with a portable sprinkler system.

The proposed layout of the soil composting demonstration area is shown in Figure 3. This areawas calculated for rernediating 500 cubic yards of contaminated soil. Space was allotted forstorage of the contaminated soil, sludge, and nutrients. A mixing area is also necessary for abackhoedfront end loader to mix sludge, nutrients, and soil. The remaining free -area will be. ~~used for staging equipment and miscellaneous other needs.

This design is for a soil composting system to be used as a technology demonstration as part ofthe EAFIB Installation Restoration Technology Demonstration Program. Two primary tasks areassociated with implementing this design: 1) the site will be prepared and lined plots for thccompost piles constructed, and 2) the contaminated soil will be mixed with the appropniateamendments, piled on the compost plot liners, and the designated equipment installed andimplemented as an operable system. The construction and installation for all portions ofconstruction will meet specific requirements including operational testing.

Preparation of the demonstration site will involve the basic tasks of installing appropriate sitecontrol (e.g., a fence), preparing soil and sludge storage areas, and excavating and installing theliner and associated equipment to construct four compost plots (Figure 3). Construction of thecompost piles will require the basic tasks of mixing the soil with the appropriate amendments(e.g., sludge and/or nutrients) and layering the mixed soil with the necessary process equipmentinto apile on top of the liner. A backhoe can be used to mix the soil. To pile the soil, anadditional backhoe can be used, however, an excavator (track-mounted, large backhoe) wouldbe more efficient at transferring the soil from the mixing area and placing it in the pile.Construction will proceed using the following steps. First, the soil wil be mixed using thebackhoe with the necessary amendments on the soil mixing pad located between two compostpiles at one end (Figure 3). Mixing will proceed by combining the constituents on the pad and

* ~~successively lifting and dropping the pile with the front-end loader portion of the backhoe.

2

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EAPS Soil Composting Design Document 1/29/93 * Draft Rev. IS

Mixed soil will be piled at the end of the mixing pad that is accessible to the excavator. Theexcavator will pick up the soil and transfer it to the compost pile according to the specificlayering protocol. In this procedure, the excavator will only need to move up and back betweenthe two compost piles and swivel to drop the soil in the desired location.

Procedures for operation of the blower system, the leachate collection system, and the leachateredistribution system are addressed in detail in section 6.0 of the Project Work Plan. Thefollowing discussion is an overview of the how these subsystems will operate.

The blower system will operate on a duty cycle. The timing of the cycle will be based onoxygen consumption rates and compost pile temperatures. Once the correct time period forblower operation is calculated, automatic timers will be used to control the system. The dutycycle for the blower will be reevaluated in the middle of the treatment period since the microbialpopulation (and hence the oxygen consumption rate) will change with time. Emissions from thecompost piles will be monitored at both the inlet and the outlet of the GAC canister for volatileorganic compounds (VOCs) to ensure that organics are adsorbed onto the GJAC.

The leachate collection system will operate manually. The portable pump will be used toremove leachate from the sump area when the water level reaches a specific location. Thestorage tank liquid levels will be monitored as part of periodic inspection protocols and will havea high-level alarm.

Leachate will be redistributed onto the soil composting piles to help maintain a suitable soilmoisture content in the compost piles and to minimize potential secondary waste (i.e. leachate).The governing factors for leachate redistribution will be soil moisture and liquid level in thestorage tanks.

1.0 SYSTEM COMPONENT

This section describes the primary components of the composting system. For each componentor subsystem, the appropriate design calculations (referenced to the calculation numbers) aieshown in Appendix B. Design decisions and assumptions are also included as necessary.

~J Compost Pile Aeraion

For the two forced-aeration compost piles, soil gas will be controlled to maintain between 20%and 5 % oxygen content to support hydrocarbon degradation. Aeration will occur via a batch-fill-and-draw process. Because the soil gas will be replenished on a regular cycle, the exhaustedgas will remove heat and the incoming gas will need to be heated (with heat generated in thebiodegradation reactions) to the ambient compost pile temperature. Thus, the aeration cycle will

also be controlled by the need to maintain the pile temperature between 25 and 45 C.

3

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BAFB Soil Composting Design Document 1/29/93, Draft Rev. IS

Two passive aeration piles will be constructed for demonstration. The mechanisms of aerationin these systems are diffusion, thermal gradients, and natural advection (wind). No control ofVOC emissions is possible with this system. These piles will, however, be plumbed forconnection to forced aeration in the demonstration as a contingency if contaminant degradationis not adequate.

1. 1.1I Aeration System Components - Forced Air

The aeration system will consist of an inlet manifold and a blower. Also included will be aknockout drum to remove entrained water; ports to measure vacuum, oxygen, flow, and VOCs;and a GAC canister to remove VOCs from the effluent air.

1.1.1.1 The air manifold will consist of PVC pipe with 5-foot-long sections of well screenas the inlets. The pressure drop in the pipe will be smaller than the pressure drop in the soilso that the pipe will act as a manifold.

1.1.1.2 A sealed centrifugal blower will be used to pull 1-2 cfm/cu.yd. of soil throughthe compost pile based on data from the pilot-scale study (CH2M Hill, 1992). The blower willbe capable of operating at up to 48 inches of total water pressure. The blower will also havea solenoid-operated drain to remove water when the blower is not operating.. ~~1.1.1.3 The knockout drum will collect water entrained in the exhaust air and willfunction by decreasing the velocity and cooling of the air stream. A sump pump will be usedto withdraw the collected water periodically.

1.1.1.4 An air heater will be installed at the outlet of the blower to decrease the relativehumidity of the exhausted air. Decreasing the relative humidity of the exhausted air dramaticallyimproves the efficiency of the GAC.

1.1.1.5 The GAG canister will be installed to remove VOCs from the exhaust air. Thesize of the canister is determined by assuming an approximate concentration of TNHcontamination (mg/kg), of which 5 % will volatilize, and an approximate concentration of BTEXcontamination (mg/kg), of which 50% will volatilize and calculating the kg of volatilecontaminants that must be retained on the GAG. Sizing of the canister is then directly calculatedusing the manufacturer's suggested loading rate (kg of contamin~ant/kg of GAG) for air with 50%relative humidity. Potentially, GAG canisters may not be required if initial concentrations ofvolatile contaminants are low and direct air emissions are within limits acceptable to appropriateregulations.

4

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* ~~~EAFB Soil Composting Design Document 1/29/93, Draft Rev. #8

1. 1. 2 Aeration System Calculations - Forced Air

1.1.2.1 Pressure dropsThe pressure drop across the soil will be assumed to be 2 inches of water at a flow rate of 1.5cfm/cu.yd. of soil based on data from the pilot-scale study performed by CH2M Hill (1992).The pressure drop across the well screens is estimated to be negligible. The calculated pressuredrop from the end of the pipe to the knockout drum is 0.5 inch of water for a 4-inch diameterpipe at 200 cfm air flow. Thus, the diameter of the manifold pipe should be 4 inches to assurethat it performs as a manifold and does not preferentially pull air from any section of thecompost pile.c~ Calculation #1

1.1.2.2 Blower cycle/oxygen consumptionThe blower will be operated in a cyclic manner to insure that the compost piles are well aeratedand so that heat transfer (causing cooling of the piles) is controlled. Aeration is required forbiological growth (and hence degradation of the contaminants). The duration of the on/off cycleshall be determined by the following method:

Part 1*Turn the0 2 meter on* Connect the 02 meter to the chart recorder* Calibrate the 02 meter and adjust the chart recorder

Part 2*Insert the0 2 meter into the samnpling port* Start the blower* On the chart recorder paper, note the time when the blower was turned on* Monitor the 02 meter reading* Turn off the blower when the amount of oxygen is roughly 21 %* Note the time when the oxygen concentration is 21 %, this is time zero

Part 3* Wait for 15 minutes* Start the blower* On the chart recorder paper, note the time when the blower was turned on* Monitor the 02 meter reading* Note the lowest percentage of oxygen, and the time elapsed from time zero* Turn off the blower when the amount of oxygen is roughly 21 %* Stop the blower

Part 4* Wait for 30 minutes

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EAFB Soil Compostlng Design Document 1/29/93, Draft Rev. IS

* Start the blower* On the chart recorder paper, note the time when the blower was turned on* Monitor the 02 meter reading* Note the lowest percentage of oxygen, and the time elapsed from time zero* Turn off the blower when the amount of oxygen is roughly 21 %* Stop the blower

Part 5* Wait for 60 minutes* Start the blower* On the chart recorder paper, note the time when the blower was turned on* Monitor the 02 meter reading* Note the lowest percentage of oxygen, and the time elapsed from time zero* Turn off the blower when the amount of oxygen is roughly 21 %* Stop the blower

Part 6* Wait for 90 minutes* Start the blower* On the chart recorder paper, note the time when the blower was turned on* Monitor the 02 meter reading* Note the lowest percentage of oxygen, and the time elapsed from time zero* Turn off the blower when the amount of oxygen is roughly 21 %* Stop the blower

Part 7.~* Wait for 120 minutes* Start the blower* On the chart recorder paper, note the time when the blower was turned on* Monitor the 02 meter reading* Note the lowest percentage of oxygen, and the time elapsed from time zero* Turn off the blower when the amount of oxygen is roughly 21 %* Stop the blower

Part 8* * ~~~~Wait for 240 minutes

* Start the blower* On the chart recorder paper, note the time when the blower was turned on* Monitor the 02 meter reading* Note the lowest percentage of oxygen, and the time elapsed from time zero* Turn off the blower when the amount of oxygen is roughly 21 %* Stop the blower

6

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BAFB Soil Composting Design Document 1/29/93, Draft Rev. IS

Part 9 (See Figure 4 for an example calculation)* Graph the lowest oxygen concentrations (from Parts 3-7) versus time (x axis)* Curve fit the points which are above 5 % to a linear curve fit (below 5 %, bacterial

activity falls off nonlinearly)IlTe slope of the curve fit will be the oxygen consumption rate, k02 (% 02 usedper minute)

* We want the oxygen concentration to remain above 5%* Use the equation: 21 %- (kO tdp) = 5% to solve for¼td* td,, is the time required for the oxygen concentration in the pile to drop to 5%* Determine the time to reoxygenate the compost pile, t,.., from the equation:

t,= {(V*,- e) I FbIOWJ{S]F} where the variables are as defined in Figure 4.

Now the cycle is approximately defined. The blower can be operated for t,.. minutesafter a static period of t&, minutes. Or the blower can be operated for an equivalent amountin different proportions to account for a heat balance.

1.1.2.3 Heat loss due to air exchange and ambient conditionsThe heat energy required to warm the replenished soil gas from l0'C to 45YC based on a heatcapacity of I U/~kg-K is 2000 kU for each compost pile using an estimated 175,000 kg of soilper pile. T1he heat removed by flushing the soil is assumed to be approximately equal to the heatneeded to warm the air. Thus, each time the air is replenished, 4000 kU of heat are required.Heat also will be consumed by vaporizing water to humiddify the air as its temperature increases.This will require approximately 6000 UJ. Thus, the blower cycle will influence the heat loadby approximately 10,000 K(1/hr. Additional heat losses will occur due to convection andradiation from the pile to the atmosphere. Using an average ambient temperature of 10C andquiescent conditions, approximately 255,000 U/hr will be lost from a 45 C pile. Incomparison, the heat generated by the biological reactions will be approximately 1,800,000 kU/hrduring vigorous degradation (150 g VSS/hr) and 180,000 Id/hr during slow degradation (15 gVSS/hr) based on a heat production of 12000 kJ/g VSS destroyed during degradation (CH2MHill, 1992). To lower the compost pile temperature a longer blower cycle, increased timebetween blower cycles (to deplete pile oxygen content and slow degradation rates), or wat&raddition to the pile will be implemented. Conversely, to maintain pile temperature, optimaldegradation rates will be maintained with a minimal blower cycle, adequate oxygen content, andif necessary, a cover for the pile to limit convective/radiative heat losses. For cold weatheroperation, additional design and operational parameters may be altered as described in section2.11 of this document.b* Calculation 12

1.1.2.4 Quantity of water trapped in knockout drumAssuming that the air will be 100% humid at 45C in the compost pile, and will leave theknockout drum at 100% humidity at 20'C, the water collected in the knockout drum for each. ~~pile will be270oml/min at a200 cfm air flow rate. A 55-gallon drum will be used as the

7

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a ~~EAFB Soil Composting Design Document 1129/93, Draft Rev. IS

W ~~knockout drum. A barrel pump will be used with an automatic level switch to remove

condensate from the knockout drum to the storage tanks.> Calculation #3

1.1.2.5 GAC canisterThe GAC canister will be sized to remove 15 kg of VOCs from the exhaust air per 150 cu.yd.of contaminated soil. T1his is based on the assumption that the soil contamination will containapproximately 1500 mg/kg of TPH contamdination, of which 5% will volatilize, and 10 mg/kgof BTEX contamination, of which 50% will volatilize. Manufacturer recommended maximumloadings for hydrocarbons in air (50% humidity, 70'F) is about 0. 195 kg of benzene/kg of GACand 0. 155 kg of n-hexane/kg of GAC. T1hus, based on the estimated 15 kg of VOCs volatilizedfrom each pile, the GAC requirement is 773 lb for all four piles (or 4-200 lb canisters).> Calculation #4

Nutrient Reouiremients

Nitrogen is required for efficient microbial activity at a ratio of between 18:1 and 30:1,carbon:nitrogen (Golueke & Diaz, 1990). Phosphorus is also required for efficient microbialactivity at about 300:1 ratio, carbon:phosphorus. Nutrients can be added as fertilizer during theinitial mixing and construction of the compost pile or as aqueous fertilizer during periodic

* ~~wetting of the compost pile to maintain soil moisture. Nutrients may also be supplied usingdried, digested sludge from a waste water treatment facility (see Sludge Amendment section).The required nitrogen and phosphorus for soil containing -1500 mgk of hydrocarboncontaminant are about 40 mg/(kg of soil) and 4 mg/(kg of soil), respectively. The amount ofnutrients added, however, should be increased by a factor of 1.2 to account for inefficient useof the nutrients. From estimates, about 8 lb of nitrogen and 0.8 lb of phosphorus are requiredper compost pile. In the technology demonstration, nutrients will be provided using lawnfertilizer in two of the compost piles and using digested waste water treatment sludge for theother two compost piles. Additionally, organic matter will be amended to the non-sludge pilesin the form of horse feed, straw, or manure at the same weight ratio of VSS contained in thesludge.> Calculation #5

LI Si Mitr

The optimal soil moisture for efficient aerobic microbial activity is 100% of field capacity.Field capacity is defined when all of the soil macropores are drained, but no micropore dryinghas occurred. Hence, at 100% of field capacity, there is sufficient water for microbial activityyet the soil macropores are open for efficient oxygen transport. The soil moisture for sandysoils should be maintained above 50% of field capacity to support microbial activity. Soilmoisture is adjusted at the time of construction as needed and is then controlled by periodic

* ~~watering during the treatment period. To increase the soil moisture by 25% of field capacity,

8

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HAVE Soil Composting Design Document 1/29/93, Draft Rev. IS

15 gallonslcu.yd. of soil must be added (based on an estimated 15 % by weight moisture contentfor 100% field capacity). Soil moisture can be decreased using pile aeration, although this willonly remove about 1 gallon every 14 minutes of blower operation.b- Calculation #6

£4 SludgetAmendmen1

The addition of dried, digested waste water treatment sludge to the contaminated soil mayenhance contaminant destruction rates by providing a source of organic matter, nitrogen,phosphorus, microorganisms, and water to the soil. The rate of bioremediation is linked to allof these parameters because they affect the amount of microbial activity in the soil. A dried,digested sludge with at least 15% solids content should be used so that it can be adequatelymixed with the soil and does not severely impact the soil porosity or moisture content. Amixture of 6:1 soil-to-sludge r-atio as calculated below is sufficient for the nutrient amendmentfor most applications. The sludge will also act to increase the compost pile temperature due tothe increased organic matter and should be factored into heat balance calculations. For thetechnology demonstration, sludge will be amended to two of the four compost piles. The othertwo piles will receive nutrients from lawn fertilizer, and organic matter from wood chips, so thatthe effectiveness of sludge as a nutrient and organic material source, and its effect on compostpile temperature, can be determined.. ~~The sludge that will be applied to the contaminated soil in this project is anaerobically-digested,dried sludge either from the EAFB wastewater treatment facility drying beds or from stockpiles.The sludge is estimated to have approximately 25% total solids content. The nitrogen andphosphorus content in this type of sludge is typically about 4% and 2.5% of the total solids,respectively (Metcalf and Eddy, 1979). Using an acceptable carbon-to.-nitrogen ratio of 30: 1,8 kg of nitrogen is required per pile to degrade 1500 ppm TPH. A sludge mixture ratio of 15-20 cu. yd. of sludge to 130 cu. yd. of soil was chosen based on mixing effectiveness. Assumingthat 80% of the nitrogen in the sludge is available for use in degradation, and that 4% of thetotal solids is nitrogen, only 1.5 - 2.0 cu. yd. of sludge with a 25% solids content is actuallyrequired as a nutrient source. From related treatability test results, the sludge should providea readily available source of nitrogen and phosphorus. In fact, land application of sludge as afertilizer for agricultural purposes is a well established means of municipal sludge disposal(Metcalf and Eddy, 1979).tb Calculation #7

L5 System Control and Monitoring

1.5. Forced Aeration

System control will be implemented using the blower cycle, by watering the pile (with water or

* ~~collected leachate), and by covering the pile with plastic sheeting. T1hese actions will be used

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EAFB Soil Composting Design Document 1/29/93. Draft Rev. IS

* ~~to control the primary composting variables of temperature and soil moisture. In addition,nutrients may be added with water as necessary. Nutrient addition will not be used as a primarycontrol, however, due to the long lag time for sample analysis.

The primary process monitoring parameters will be soil temperature, oxygen content in theexhausted air, pH, air flow rate, blower vacuum and pressure, and soil moisture. Thleseparameters will be monitored and the appropriate controls enacted to maintain conditions foreffective contaminant destruction. Nutrient content of the soil also will be measured periodicallyso that appropriate adjustments can be implemented. Contaminant destruction Wil be monitoredby measuring the concentration of VOCs in the exhausted air, soil TPH and BTEXconcentrations, and leachate TPH and BTEX concentrations with discrete samples.

1.5.2 Passive Aeration

Only water addition and plastic cover will be used for process control of the passive aerationsystem. The primary process monitoring parameters wil be soil temperature, pH, and soilmoisture. Contaminant destruction will be monitored by measuring TPH and BTEXconcentrations in the soil and leachate with discrete samples

a ~~A 22-foot wide, 20-30 mil thick H-DPE liner is used to contain leachate from the compost pile.W ~~A long, narrow, windrow design is used so that the compost pile can be constructed without

driving on the liner and so that there are no seams imthe liner. The liner is placed in ashallowexcavation confined by earthen berms. Leachate is then collected in a sump area for laterredistribution to the compost pile when it is required to increase the soil moisture content.

LiCompost Pile Construction Reouirements

Construction of the compost piles will require the basic tasks of mixing the soil with theappropriate amendments (e.g., sludge and/or nutrients) and layering the mixed soil with thenecessary process equipment into apile on top of the liner. A backhoe can be used to mix thesoil. To pile the soil, an additional backhoe can be used, however, an excavator (track-mounted,large backhoe) would be more efficient at transferring the soil from the mixing area and placingit in the pile. Construction will proceed using the following steps. First, the soil will be mixedusing the backhoe with the necessary amendments on the soil mixing pa located between twocompost piles at one end (Figure 3). Mixing will proceed by combining the constituents on thepad and successively lifting and dropping the pile with the front-end loader portion of thebackhoe. Mixed soil will be piled at the end of the mixinlgpad that is accessible to theexcavator. The excavator will pick up the soil and transfer it to the compost pile according tothe specific layering protocol. In this procedure, the excavator will only need to move up andback between the two compost piles and swivel to drop the soil in the desired location.

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EAFB Soil Compoeting Design Document 1/29/93, Draft Rev. #8

2.0 COMPONENT DESCRIPTION AND SPECIFICATIONS

This section describes the details of each component and lists the component specifications.

To complete the general construction and soil-moving portions of this project, the followingtypes of equipment and supplies will be required:

- backhoe- front-end-loader- excavator- fertilizer, lawn, 5% N, 4% P, 5% K- source of organics- wood chips

* ~~~~- sludge- fencing- safety equipment (first aid, fire extinguishers, eye wash, stretcher, blanket, etc.)-general construction equipment (shovels, rakes, plumbing equipment, locks, silicon seal,

etc.)-sign, 3 ft by 4 ft

2M1Liner SystmThe liner system consists of a shallow excavation confined by earthen berms with a 20-30 milHDPE liner placed in the excavation and held in place by soil piled on the outside of the berms.The excavation (Figure 5) will be 13 feet wide, 86 feet long and 'I2 feet deep, sloping at 1 inchesper 15 feet to 1 foot deep at the end of the plot where the collection basin is located. Mateiaexcavated from the plot will be used to construct the 1-foot-high berm on the perimeter of theexcavation. A sump area will be excavated as shown in Figures 6and 7and will also besurrounded by the perimeter berm. A shallow trenlch sloping toward the sump entrance will beinstalled manually and the elevation of the sump area adjusted so that it is the lowest point jnthe plot. Prior to installing the liner, sharp objects will be removed from the plot. The lineris 22 feet wide and will be manually rolled out along the length of the plot. No seaming wilbe necessary. The liner will be manually fitted to conform with the plot contour and its outsideedges secured with soil along the entire perimeter using a backhoe. The entrance gap to thesump area will be filled manually with a gravel berm.

* ~~Equipment List:-Liner, HDPE, 20-30 mil, 22.5-ft wide, cut to length - suggested vendor: Glundle Lining

Systems, Inc.* ~~~~-Liner patch material - suggested vendor: Gundle Lining Systems, Inc.

-Liner patch tape - suggested vendor: Gundle Lining Systems, Inc.-Pea gravel

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. BA~~EAF Soil Composting Design Document 1/29/93, Draft Rev. 18

'I ~ ~ 2, Sump Pumpn System for Leachate Removoyal

The sump pump system consists of a portable centrifugal pump and piping/flexible tubing to theleachate storage tanks. The pump will deliver at least 10 gal/min at a working head of 30 ft ofwater. The intake to the pump will be a flexible tube with an intake screen to exclude largesolids. Solids will be periodically removed from the sump basin with a plastic hand shovel.T1he pump will be plugged into an exterior outlet for power and will pump the leachate throughflexible tubing and 'A -inch-diameter hose to the leachate storage tanks. Installation of the sumpsystem is described in the Liner System section. T'he sump system piping will be plumbed usingglued PVC fittings and standard hose connections according to Figure 8. The discharge of thesump pump tubing will be portable so that leachate can be deposited in either storage tank.

Equipment List:-Pump, centrifugal, self-priming, explosion proof, 120 VAC, portable, >4 gpm @ 15

ft of water head-INet filter for pump, 100 mesh-Pea gravel-3/4 inch hose

2.3 Leachate Storage and Redistribution System

Ile ~The leachate storage system will consist of two 1500 gallon LLDPE free-standing tanks.Leachate from all compost piles will be routed to these tanks via the sump pump plumbing(Figure 8). The tanks will be capped except for a small air vent. Liquid level will be monitoredwith a sight glass and a level switch will be used as a high-level alarm. At the appropriatetimes, leachate will be redistributed to the compost piles. The redistribution system will beplumbed with switching valves and will use a 40 gal/min centrifugal pump at a working headof15 feet of water. 7e inlet of the pump will be 6inches above the bottom of the tanks toallow for solids deposition. A sample valve will be included in the inlet of the pump forperiodic measurement of TPH and BTE in the leachate. Redistribution piping will be 1-inch-diameter PVC piping with glued joints to plumb from the pump to the edge of the compost pile(Figure 9). Flexible hose and small sprinkler heads will be used to distribute clean water on thesoil or clean water amended with nutrients. A soaker hose will be used when contaminatedleachate is redistributed on piles.

Equipment List:-Pump, centrifugal, explosion proof, 120 VAC, > 24 gpm @ 50 ft of water head-Garden hose-Garden hose fittings for manifold-Sprinkler heads, 4 gpm, 360', 15 ft radius - suggested brand: Toro-Soaker hose-Piping

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EAFB Soil Composting Design Document 1t29/93, Draft Rev. IS

-Pipe fittings-Tanks, LLDPE, leachate storage, 1500 gallon (2)-Shut-off valves

LABlowerLSyte

The blower will be a 200 cfm scaled centrifugal blower capable of operating at a static pressureof 48 inches of water column. Inlet and compost pile manifold plumbing will be 4-inch-diameterPVC pipe with glued fittings (Figure 10). A knockout drum will be placed as shown in Figure10 and will consist of a 55-gallon drum with modifications as shown in Figure I11, including alevel switch to control a sump pump to remove water as necessary. Alternatively, the knockoutdrum may be purchase commercially as long as it meets the specifications (200 cfm, 10" WCpressure drop or less). Removed water will be pumped through 'A -in-diamieter flexible tubingto the storage tanks. Effluent from the blower will pass through a heated section of pipe, four200-lb CIAC canisters in parallel, and then will be released to the atmosphere in an 8-foot-highstand pipe. The heater will consist of a steel pipe section with external band heaters to provideapproximately 4 kW of heat. The heater control will contain a thermocouple to monitor the pipewall temperature and will maintain this temperature below 150'C, which is 50'C below the

ignition temperature for typical VOC components. The heater is required to reduce the relativehumidity to below 60%. Instrument ports will have threaded caps and will be configured asshown in Figures 12 and 13. The blower system will be mounted on a concrete pad and bolted

down (manufacturer will provide dimensions with the blower).

Equipment List:-Blower, centrifugal, 200 cfm @ 48 in of water pressure/vacuum, explosion proof, gas-

sealed - required vendor: Baxter Air Engineering-GAC canister, 100 cfm, 200 lb, sealed-regenerable unit (must include regeneration

costs) (4) - suggested vendor: Calgon Corp. (Ventsorb canisters)-Knockout drum, 55 gallon drum (per Figure 1 1) or commercially built, 200 cf~m, 10'

WC or less-Heater, band (for piping), external, 4 kW - required vendor: Weilman-steel pipe (for heater section, 6 inch diameter-pipe insulation (for heater section)-PVC piping, 2 and 4 inch diameter, schedule 80-PVC pipe fittings, 2 and 4 inch diameter, as specified-PVC pipe well screen, continuous slot, 4 inch diameter, 5 foot length - suggested

vendor- Brain ard Kilman-Solenoid valves, air, 2 inch diameter, see specifications-Pump, barrel, > 4 gpm @ 15 ft of water head, explosion proof, level-switch-activated-Level switch, barrel, high low pump activation/shut off-PVC tubing

* ~~~-Hose

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. H~~~AFB Soil Composting Design Document 1029/93, Draft Rev. IS

2t1S oilStorg§Area

Excavated soil will be transported to the area defined on Figure 3 for storage prior toconstruction of the compost pile. The storage area will be lined with overlapped, but unsealed,sheets of 6-mil-thick visqueen (100' x 40'). However, all soil will be covered with 6-milvisqueen plastic (100' x 40') sheets with the edges secured by concrete blocks to preventleaching. After the final load of soil, 3-4 inches of soil will be scrapped from all areas in thestorage area where contaminated soil was placed and added to the last load on the compost pile.At the end of compost pile construction, the storage area will be regraded with clean fill.

Equipment list:-Visqueen, 6-mil, 100 ft by 40 ft sheets, clear-Concrete blocks

26 Sludge Storage Are

Sludge will be transported from the wastewater treatment facility in a dump truck and stored inthe areas defined in Figure 3. The storage area will be lined with overlapped, but unsealed,

F ~~~sheets of 6-mil-thick visqueen (100' x 40'). However, all sludge will be covered with 6-milvisqueen plastic (100' x 40') sheets with the edges secured by concrete blocks.

* a ~Equipment List:W -V~~~~isqueen, 6-mil, 100 ft by 40 ft sheets, clear

-Concrete blocks

2±2 MixingPad

The mixing pad will consist of a leveled section of ground and will not be lined. During the lastset of soil transfers to the compost pile each day, 3-4 inches of soil will be scrapped from allareas in the mixing pad where contamirnated soil was placed and added to the last load onlthecompost pile. At the end of compost pile construction, the pa will be regraded with clean fill.

Equipment List:-Visqueen, 6-mil, 100 ft by 40 ft sheets, clear-Concrete blocks

ElectricalSe i

Electrical service (3o, 208 VAC, 100-125 amp) will be provided to the site through a futseddisconnect/load center. A separate panel will contain circuit breakers and switches for devicesrequiring Io, 120 VAC service. These devices include the sump pumps, the leachate

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' ~~~BAFB Soil Composting Design Document 1129/93, Drmft Rev. 1S

redistribution pump, blower control circuits, and outlets in the test equipment shed and for thesump areas. The 120 VAC, 10 service will be provided using one phase to neutral from the 208VAC service. Additionally, the 3o service will drive the blower motor using a motor startercircuit and the air heater. The blower control system will consist of a programmable timer,solenoids, heater relay, and motor starter to control blower operation. T'he electrical schematicis illustrated in Figure 15. Electrical cabinets will be attached to a free-standing mounting panelwith the lowest cabinet 30 inches from ground surface. The main disconnect will be separatefrom the electrical cabinets. One cabinet will house the motor disconnect, motor starter andheater contact. Another cabinet will house the circuit breakers and fused switches for the 120VAC components. Another cabinet will house the controller such that cycle parameters can beadjusted without electrical hazard to the operator. Cabinets will meet EAFB specifications forexplosion-proof and outdoor operation. Cabinet layout is shown on Figure 15 and is locatedadjacent to the blower pad (Figure 3). All devices will be hard-wired using appropriate conduitmaterial. Outlet enclosures at the sump area for use with the portable centrifugal pump will befree standing, exterior outlets located 24 inches above ground surface with a fused on/off switch.These outlets will be hard-wired with conduit back to the 120 VAC electrical component cabinet.

2.9 Test Equipment

Equipment will be configured as shown in Figure 15. The wiring diagram is also illustrated inFigure 15. An 8-ft by 6-ft shed will be used to house equipment and store small supplies.

O ~~Equipment List:-Scale, +/- 0.001 g-Oven, drying, 120'C, double wall, 120 VAC-Gloves, chemical resistant-Oxygen monitor (existing)-Photo Ionization Detector, rented, including calibration kit and carrying case - vendor:

Hacoo-Pressure gauge, Magnehelic, 0-50 in of water-Thermocouple switchbox, 10 input, type T (4)-Thermocouple wire, type T, 1000 ft, 24 ga, PVC coated-Thermocouple, type T, steel-sheathed, grounded, 1/8 inch diameter, 6 inch long-Thermometer, type T, 2 input, one output-Pitot tube and manometer air velocity kit

2A9 Sampnling Eouipment

-Cooler-Ladder-Flags, marking-Plywood, 4 ft by 3 ft

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MEAF Soil Composting Design Document 1/29/93, Draft Rev. IS

-Sample jars, various-Auger, soil sampling, hand, rented - suggested vendor: Sheilds

* 2J1 £g~Cnfingenckie

Pile cover: If conditions warrant covering the pile, 100' by 40' sheets of 6-mil visqueen willbe used. The plastic will be separated from the sail by 4-6 inch flexible plastic tubing (e.g.,plastic tiling tubing) placed across the width of the pile every 6 feet for the length of the pile.Plastic sheeting will be secured with concrete blocks placed every 6 feet along the plot berm.To allow airflow into the soil, vertical 2-foot-long slits will be cut and bordered with duct tapebetween each tube. When operating with a covered pile, a soaker hose will be permanentlyinstalled for leachate or clean water distribution.

Insulation: If conditions warrant insulating the pile, a 6-inch layer of wood chips will be placedon the pile and covered with plastic sheeting as described above except that no plastic tubing willbe used.

Pile Heating: If conditions warrant heating the pile, the blowers may be reversed to blow airinto the piles. Instead of GAC canisters and a knockout drum, the blowers would push airthrough an air heater before the air enters the pile. Increasing the air temperature to near 300C

* ~~would be optimal. Note that forcing heated air into the compost pile would occur only afterenough drawn-air operation to draw off VOCs and collect them in GAC canisters. Forced airoperation means that there is no control of emissions from the compost pile, so VOCs must becollected prior to forced air operation. Forced air operation of the blower (into the pile) wouldrequire replumbing the blower into the air manifold with the solenoid valves. The knockoutdrum would be circumvented and the blower inlet would be re fitted with an air filter.

Air Short Circuiting: If the air manifold is not adequately puffing air from the far end of thecompost pile as determined by the vacuum measurement at the end of the manifold, a sheet of6-mil visqueen will be used to cover aportion of the front end of the pile. Thiswill force airto be pulled through the far end of the pile. The operation will then be cycled regularly betweenpuffing air through the front and back of the pile.

Contaminated Soil Spills During Construction: Contaminated soil that is spill duringconstruction will be scraped up from the ground and returned to the contaminated sail storagearea at the end of each day or as appropriate.

Soil bulking: If the soil is not porous enough or if the soil has a high percolation rate, woodchips may be mixed with the soil. Wood chips provide bulking to increase the porosity of themedia. Wood chips also hold moisture well and would help increase the water retentionproperties of the media.

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BAFB Soil Composting Design Document 1/29193, Draft Rev. IS

Liner repair: Should the compost pile liner be torn during insiallation or construction, the sitesupervisor shall first determ-ine whether or not the liner can be repaired. If the tear inunrepairable, the liner shall be replaced. If the tear is repairable, the tear will be patched. Apatch of extra liner will be cut to cover the tear and have one foot extra distance from the tearon all sides. The liner surface around the tear shall be cleaned of any dirt or substances whichwould prevent a good seal. Liner repair tape shall be placed all around the tear at a distanceof 4 inches from the tear on all sides. Liner repair tape shall also be attached to the bottom sideof the patch at the outer edge of the patch. The patch shall be placed over the tear and presseddown around the edges and where the repair tape was placed. Note that care shall be takenwhen walking on the liner to make a repair in order to prevent further tears.

Surplus clean soil: If there should be surplus clean soil as a result of excavation activities, thesoil shall be stockpiled. This would be soil that was excavated to form the compost plot pits(not remnediated soil). The best location for stockpiling would be the lower left corner on Figure3.

Air manifold flooding: If the air manifold in the compost pile (with alternating slotted and solid4 inch PVC pipe) should flood due to excess buildup of water in the liner, blower operationswill be halted until the leachate can be removed from the liner containment area (via the sumppump).. ~~~Soil pH adjustment: If the initial pH of the contamninated soil or of the contaminated soil/sludgemixture is lower than pH 6, a proper amount of lime will be mixed with the soil to bring thepH up to 7.

Entrainment of Soil by Wind: To control particulate problems, should there be high windconditions, the piles will either be planted with grass, covered with plastic as described in thepile cover contingency, or the surface of the piles will be kept wet by sprinkling.

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EAfB Soil Composting Design Document 1/29/93, Draft Rev. #8. ~3.0 CONSTRUCTION DESCRIPTION/CONTRACT OUTLINE

For a description of the project scope, refer to the introduction section of the design document.

32 Detailed Tasks and Schedule

The composting system to remnediate 500 cubic yards of soil requires about an acre, using thedesign presented in Section 4 of the Work Plan. The layout shown in Figure 3 was selectedbecause of the small area required and for efficient operations and logistics.

3.2.)1 Requirements of the excavation contractorThe following is a general list of activities that will be performed in constructing the

composting system. This list is broken into two construction phases: phase 1 - site preparation,compost plot construction, and subsystem construction, and phase 2 - compost pile construction.Further details are provided as part of the soil composting document entitled "Project WorkPlan: Demonstration of Soil Composting for Remediation of Hydrocarbon-Contaminated Soil."

b~ Construction Phase I - Site preparation, compost plot area construction, & subsystemconstruction

Site preparation will consist of installing an 8-foot-high, chain-link perimeter fence toenclose the area shown in Figure 3 and described in the design document. Sitepreparation will also include removing vegetation as necessary and grading the site asnecessary.

Compost plot construction will be implemented using the folowing basic tasks:

* Fence and compost plot construction may begini on 5/31/93 but no later than6/4/93 (depending on weather). The fence must be completed within the firstthree days of construction to insure access control to the site.

* Soil and sludge storage areas will be graded and prepared to specifications. Theareas shall be nominally flat. No large or sharp protrusions will be allowed.

* Four rectangular compost plots will be excavated according to specifications inFigure 3. Depth should be sloped starting at ½h foot deep and going to 1 footbelow grade. The compost plots should be graded slightly (I inch of drop per 15feet length) in the direction downward towards the leachate collection system(Figure 5). There shall not be any areas in the compost plot itself where watercan pool; all water must drain to the sump area basin.

* Sump pits shall be dug to a depth of 21 inches below grade at the appropriate

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EAFB So0 Composting Design Document 1/29/93, Draft Rev. IS

corner (see Figure 3) of the compost plots. The sump pit area shall be 6 feetlong in the long direction of the compost plot area and 5 feet wide in the widthdirection (Figure 6). These sump pits shall be sloped such that the pit is thelowest point of the compost plot area.

*An earthen berm shall be erected around each compost plot area. The bermsshall be roughly 1 foot high (from grade) and shall enclose each compost plotarea as well as the associated sump pit (see Figure 6). The berms shall have thedimensions given in Figure 16. If this is not possible with the existing soil, thesoil shall be compacted or fill dirt shall be used to get the values in Figure 16.

* T'he collection trench at the end of the plot will be manually installed. Thiscollection trench will be 13 feet long (along the width of the plot), 1 foot wide,and shall slope down to the corner where the sump area will be located. Theslope will be 1 inch per 1½/ feet down to a depth of 1½' feet below grade. Thetransition from the longitudinal plot slope to the perpendicular trench slope shallbe smooth so that the liner will have support beneath it (see Figure 5).

* After the construction equipment has completed the pit excavation and bermconstruction, the elevation of the sump area will be manually adjusted asnecessary to meet the requirements of Figure 7.

* The plot excavation will then be inspected for unevenness and jagged materialsand these conditions will be corrected as necessary. Satisfactory completion ofthis final procedure will be determined by the site supervisor.

0 ~~~~Next, the leachate recovery system will be installed.

* Ther liner shall be manually rolled out over each compost plot area along thelength of the plot. Liner shall be positioned such that the edges fall over theoutside of the surrounding earthen berm (Figure 5 detail).

* 'The liner shall be manually fitted to conform with the plot contour. There shallbe support underneath the liner (especially at corners) so that a heavy load willnot stress and tear the liner.

* Extra soil (removed from the compost plot areas) shall be placed over the outeredge of the liners to secure the liners in position (Figure 5 detail).

* T'he entrance gap to the sump pit area shall be manually filled with a 1.5 foothigh gravel berm as shown in Figure 6.

Concurrent with the above activities, the following subsystems will be assembled so thatthey can be easily installed at the specified time.

* The test shed shall be moved into place.* The 4 inch diameter PVC piping (2½/ or 3 foot lengths) and slotted PVC piping

(5 foot lengths) shall be assembled in alternating sections (see Figure 17).* The slotted piping for the passive aeration piles will be assembled.

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EAFB Soil Composting Design Document 1)29/93, Draft Rev. IS

*The blower system (blower & GAC) shall be assembled according to Figure 10.* Piping/bose for leachate collection shall be assembled (i.e. the piping from the

portable sump pump to the storage tanks).* The sump pump liquid output shall be connected to the appropriate piping/hose.* The leachate redistribution piping shall be assembled.* The hole for the knockout drum shall be dug. The hole shall be approximately

40 inches deep. See Figure 10 for knockout drum placement.* The air manifold shall be assemble per Figure 10.* The GAC manifold shall be assembled per Figure 10.* The knockout drum shall be connected to the blower system per Figure 10.* The blower shall be connected to the GAC manifold and GAC canisters.* The heater shall be installed and connected to the power supply.* The storage tanks shall be put into position.* The leachate collection piping shall be connected to the portable pump and the

storage tanks per Figure S.* Sump pump electrical service shall be connected per Figure 15.* The leachate redistribution pump system shall be installed and electricity

connected per Figures 8 and 15.* Electrical systems will be installed using the conduit, wiring, control system, and

electrical box layouts specified in Figure 15 (detail).* Text equipment connection will be the responsibility of PNL. However, electrical

service to the test equipment shed will be the responsibility of the contractor andwill be completed per Figure 15.

All construction of compost plot areas, installation of liner systems, andassembly/installation of subsystems shall be completed and ready for compost pileconstruction by 6118/93

t~ Phase 2 - Compost pile construction

When the contaminated soil becomes available for construction of the compost piles, thefollowing basic tasks will be implemented to finalize the compost system construction.Soil delivery is planned for 6/21/93. The soil delivery date is referred to as day 0 forreference to the dates given below.

For all piles:*The contaminated soil will be mixed with the necessary amendments (sludge,

water, and nutrients) on the soil mixing pa located between two compost piles(Figure 3) using the front-end loader of a standard backhoe. Mixing will proceedby combining the constituents on the pa and successively lifting and dropping thepile with the front-end loader. The appropriate number of repetitions of thisprocess will be determined by the site supervisor. During mixing, any large

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EAFB Soil Composting Design Document 1/29/93, Draft Rev. IS

debris (e.g. cobbles, metal, etc.) shall be removed to prevent undue stress to theliner when the soil is piled into compost piles. The mixture for piles 1 and 2(Figure 3) will consist of 6 parts soil (i.e., 6 front-end-loader loads) plus one partsludge (this is a 7:1 mixture). Water will also be added to the mlixture for piles1 and 2, as directed by the site supervisor. The mixture for piles 3 and 4 willconsist of 6 parts soil plus x lbs of horse feed, straw, or manure mixed with lawnfertilizer. The lawn fertilizer (5 weight % nitrogen) will be added in the ratio of20 pounds of fertilizer per 6 cubic yards of soil. Water will be added as directedby the site supervisor. Mixed soil will be piled at the end of the mixing pa thatis accessible to the excavator. The excavator will pick up the soil and transferit to the compost pile according to the specific layering protocol. In thisprocedure, the excavator will only need to move up and back between the twocompost piles and swivel to drop the soil in the desired location. Soil and sludgestock piles will be covered with secured sheets of 6-mil-thick visqueen except forportions that are in use for the mixing process. During all off shifts, the soil andthe sludge piles will be completely covered and the cover shall be secured againstwind and rain.The first lift of soil shall be put in place using the excavator. Care will be takento preserve the integrity of the liner (no driving on the liner, no contact betweenearthmoving equipment and the liner, no dropping of soil from greater than 1 footabove the liner surface). The contractor is responsible for satisfactory repair orreplacement of the liner if it is damaged. All damage to the liner will beinspected by the site supervisor who will determine the appropniate correctiveaction. All repairs or replacements must be approved and documented by the sitesupervisor. The first lift shtall be spread out over the entire compost plot areainside the earthen berms to a height even with the grade. The first layer shall beroughly smoothed out using the excavator or a backhoe, as necessary, so that thetop of the soil layer is acceptably even and flat as determined by the sitesupervisor.

For piles 2 and 3:* Once the first layer has been leveled for piles 2 and 3, a trench shall be installed

into which the air manifold and pea gravel will be placed. The trench will runalong the longitudinal center of the compost pile and will be 1 foot wide. Thetrench will be angled at the same slope as the bottom of the compost plot pit (1inch drop per 15 ft of longitudinal distance).

* Pea gravel shall be laid down in the trench according to Figure 17. The peagravel shall be laid down at a width of 1 foot and a depth of 4 inches.

* The assembled PVC piping shall be laid down and nestled into the gravel. Oneend of the assembled piping shall extend out the end of the compost plot area.

* Thermocouples shall be placed by PNL personnel at the appropriate areasaccording to Figure 18.

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HAVE Soil Composting Design Document 1/29/93, Draft Rev. IS

*More contaminated soil and sludge shall be mixed as per the previous instructionsand carefully placed near the PVC piping. Care shall be taken to not disturb thePVC piping and to not destroy or disturb the thermocouples. The PVC pipingneeds to stay with the outlet end at the proper angle (it will be perpendicular tothe grade when viewed from the end of the pile).

*Pea gravel shall be placed all around the slotted PVC piping by hand shovel andcontaminated soil shall be used to hold the pea gravel (and piping) in place. SeeFigure 17 for an example of pea gravel placement.

* Contaminated soil/sludge mixture application will then resume using the excavatorin a second layer, taking care as the PVC pipe is packed. The second layer shall

-, ~~~~~~be piled across the width of the compost plot area as far as possible. The secondlayer shall be piled to a height of roughly 3 feet from the original grade (surface)with a side slope of 300-400 and the maximum possible width at the top of thislayer. The top of the pile shall be smoothed out for placement of thethermocouples according to Figure 18 (for the thermocouples at 3 feet abovegrade)

* Thermocouples shall be placed by PNL personnel at the smoothed out areas at aheight of 3 feet from grade (specified in Figure 18).

* T'he contaminated soil/sludge mixture application shall continue for a third layeruntil a height of roughly 5½A feet (from the original grade) is attained. The pileshall be smoothed out to a roughly flat area on top. The pile should be roughly5½h feet high above the original grade when the top is smoothed out flat.

I . *~~~~~ Narrow trenches shall be dug by hand trowel at the specified places according toFigure 18. Thermocouples shall be placed in the bottom of these trenches byPNa personnel and then the thermocouples and wire shall be covered with soil.

For piles 1 and 4:* The construction of piles 1 and 4 will be the same as for piles 2 and 3 (ite., the

air manifold, thermocouples, and soil layering will be the same) except for thefollowing additions.

* After the air manifold has been installed, soil will be layered onto the pile untilit is level with the berm. A set of slotted air piping will then be installed acrossthe narrow section of the pile at 6-foot intervals (Figure 14).

* Soil will be layered to the next designated thermocouple position (3 feet abovegrade) and a set of slotted air piping installed at 6-foot intervals so that the pipingis located at alternating positions with the lower set of piping (Figure 14).Thermocouple placement will proceed as described for piles 2 and 3.

* The compost pile will then be completed as described for piles 2 and 3.

For all piles:*Construction shall proceed such that piles 1 and 2 are built concurrently and piles

3 and 4 are built concurrently. The pile construction shall proceed such that the

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EAFB Soil Composting Design Document 1/29/93. Draft Rev. 08

first two piles are finished by the 6' day. The remaining two piles shall befinished by the 12' day. Final subsystem connections and installation will takeplace on the last two days so the whale system is ready to operate by the end ofthe I1' shift on the 14' day.

Once construction of the composting piles is complete (or as soon as it is practical), thefollowing systems will be installed:

The ends of the PVC pipe which protrude from compost piles 2 and 3 shall beconnected to the air manifold and the knockout drum per Figure 10.

* Vacuum gauges and air flow meters shall be installed in piles 2 and 3 per Figure19.

* Soaker hoses, sprinklers and leachate redistribution piping shall be connected tothe leachate redistribution pump and installed on the top of all composting piles.

All systems will be installed and ready for operational testing of the composting systemby day 14 (this would be 7/5/93 based on the expected soil delivery date).

The compost system will be tested for correct performance and to set operationalparameters when construction is complete. Following testing, compost operation willcommence per instructions outlined in the operational procedures and test plan sectionsof the Work Plan (sections 6.0 and 7.0, respectively).

5.1.2 Schedule of constructionA proposed schedule of events has been developed to facilitate construction.

Figures 20A and 20B show the relationships among construction events.

* ~~~~~~~~~~~~23

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APPENDIXK A

FIGURES

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. ~~~Work Plan Figure N Design Document Figure NBrief Description

1 Overview of QM gas station

2 1 Compost pile dimensions

3 2 Conceptual design of compostsystem

4 3 Layout of demonstration site

5 5 Compost plot pit specifications

6 6 Sump pit area

7 16 Berm dimensions

8 7 Sump area elevation

9 17 Air piping in compost pile

10 10 Air piping & blowerIGAC system-

11 8 Leachate collection schematic

12 15 Electrical diagram

13 18 Thermocouple locations

14 14 Passive aeration design schematic

15 19 Air schematic

16 20 PERT chart

17 4 Blower cycle example

18 _____________Sampling locations

19 Leachate sampling port

20 12 VOC sampling ports

21 13 Oxygen sampling port

22 _ _ _ _ _ _ Health & safety

9 Leachate redistribution schematic

11 Knockout drum specifications

A- I

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* a ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~r

'I I~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~44M

0

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4a

100~4~~~

A-2

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EAFB Soil Composting Wott Plan 1/29893. Rev. 01O

ho~~~~~~~~~~~- 0

la Na U

0

4, 01~~~~~~0

3E4

CL

S ~~~~~E0

0 E~.0U0 ~~~ -O 0

cm 0 0~~43 I. cm

* 01 ii' I~~~r:04) r~~.

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U S~~AFR Soil Coampodng Work Mma I/903. Rev. #10

237 ft

27 ft 26f

20 ft~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~I86 ft~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~I

L~~o 90ft 27 ftt

* It I I~~~omos Pilt#

ComostP11 1145 cu. yd. 20otl4 Acu. muyd. io

27ft It~2 f

It ~~~~~~~~~~~~~~~~~~~~~~oI 0f

Compost Pile #3 i

145~~~~~~~~~~~~50 u d cu.y

27 ft C27Trachotn Mixing Area~~~~~~I

0N

47 ft Staging Area~~~~~~~~~~~~~4 f '

Gate~~~~~~~~~~~~~~~~~~~~~~~~~~~I

Figure 3 Layoutof the Sil Compsting Deonstraton Site.Surnp aeas and erms ar

It&~~~~~etie inFgre n 1,rsectey

It It~~~~~~~~~~-

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I . ~~~~~~~~~~~~~~y -(koz)(x) + b

15 30 80 90 120

elapsed time (mini)

Note that the curve fit is only linear between approximately 21 and S % oxygen.Below about 5% oxygen. bacteria become less active.

Example: ~~~~~~~~~~y = X oxygen

Let koa = .25 %/min. (from graphed data) x= elapsed timeb =y intercept

Calculate lko2 = slope = rate of oxygen consumptiontdrog = time for oxygen to drop to 5%

21% -1(koa)(tdrop)] 5% F blower flow rateV = compost pile volume

=>21 - 5=16= (o.25)(tdfrop) e = porosity of the compost piletrnxy = time to reoxygenate the pile

t~~op - 64 minutes ~SF = safety factor - 1.5

Let P= 200 CFlV = 150 cubic yards = 4050 cubic feet

a 0.5

Calculate

tmazy (V)(e) / F

=(4050)(0.5)/(200)

=10.125 minutes

Figure 4. Example calculation for determination of length of blower

cycle.

A-5

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slope I in. drop per 15 ft, length

¶ . ~~~~~~~smooth transition alongthis edge of the trench

slope = I in. drop per transitioneslop

edge of compostecionvie o

Figure 5. Compost plot pit specifications (slopes).

A-6

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EAFB Soil Composdng Work Plan 1/29d93, Rev. 1110

6f ~~Pea gravel berm

St 90pe > ~~Pea gravel berm:

Dimensions are from ie 2ftabout 3 ft widethe inside of the soilberm 1

Sump Area (lowest point of compost plot area)

jDetail of Sump Area

S~~~~~~~~~Br

Overview of a compost pile and the location of the leachate coflection tank.

Figure 6. Detail of sump area.

A-7

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12"

grade - {-!~~~~~~~ar end of plot pit ----- 6------------------------- 6

sump pit isthe lowest pointof the sumparea. See Figure6 also.

Figure 7. Sump area elevation.

A-8

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- - lb

IIII I

II

ii

---------.- jI II t-

(--I tilt - C-1

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1 2

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From leachate redistribution pump

Tee with valve

Soaker hose ~~~~~~~Sprinkler head

4- - ~~~~Sprinkler piping

Compost pile

Top of compost pile

Figure 9. Leachate redistribution on a compost pile. The leachate/water will

be redistributed on the top of the pile by either sprinklers orthrough a soaker hose.

A-10

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compost pile B in. nominal height

5 ft nominal height suppor posts (20 ft spacing)

From pile ~~ storage tnki av

From pile 14 ~ ~ ~ .. ip

higerth Fige urlet1.Arppn n boe/A ytm

Sunke

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fittings to connect to 4" PVCschedue so pipe

0Om thick stool plate. No.nee10, mLaxTMNO.m

fiiga~~~~~ackdelddmt li

hole for lovel switchoe fr brre

(small hung hole)~(lrgebug bI6

Section view oid hsemle

wihholes u for bloere swita.1 d

hole for ~ ~ ~ ~ ~ adth anlpun

Figure 11. a Knockoutdanseiictosuiga 5glo rm

A-fl

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Manifold to GAC~GC cnnite

cannisters 4- ~~~~~~~~~~~Screw cap with3/6" UA. tygon silicon sealant0 ~~~~~~~~~~~~~~~~~tubig to attach around tygontoPID probe tubeextention

Section of Te shown

Figure 12. Volatile Organic Compound sampling port locations anddetails.

A- 13

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Compost pile

-4 2.75- 1<--32Pagravel

3/18" 14. tygon * ~Screw cap 'with3/16" i~~d. tygon silicon sealant

tubing to attach aroundtyo

Figure 13. Oxygen sampling port location and detail.

A- 1

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. ~~Top view section of a compost pile

F-I--

I.~~~~~~~~~~~~~T

Front view section of a compost pileeihs r

c=PO~~~~~~~~~~t Poenmna o h

bottom of the

exd stend

Endse a"renmtaed ~7

frlong p~m 13

Note: There will be 12 pipes in the bottom layer and 11. pipes in the top layer, evenly

spaced (as indicated) along the length of the compost Pile. Pipes in the bottom

layer will have at least 13 ft of slotted pipe and pipes in the top layer will have

at least 7 ft of slotted pipe.

Figure 14. Compost pile with passive aeration. Pipe locations are shown.

Not to scale.A-15

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Fl ____________________________________________________________________

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20 ft -

6 It ~2 It nominal 6I

.5 to 1Itt

Figure 16. Dimensions for the compost pile bermns.

A- 17

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Top view section -M 2.5 ft solid PVC pipe sectionsmm 3 ft solid PVC pipe sectionsI.~~~ ~~~~~~~~~r-- 5 ft slotted PVC pipe sections

IM 1 ft wide. 4" layer of pea gravel under pipe

snso solid PVC pipe ____

2' for outer piles (#1 & #4)Toofbr1.5' for inner piles (#2 & g3)

5,

Side view section Cmotpl

To knockout drum

-12.75' 1k 3.25' *---I

Pea gae

Front view sectionCompost pile

0.51 Pipe is sloped sameas the bottom surface

Figure 17. Compost pile with forced aeration. Pipe locatins are shown.

Not to scale.

A-18

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13 ft

+ 6 below compost pilesurface

12 ft

+ 3 ft, above grade +

12 ft

+ even with grade + o

12* ft

+ ~~~~~31ft, above grade +

12 ft

'C~~~~~~~~~~~~~

+ 4" 6'*below compost pile+

T ~~~surface

12 It,

* even with grade +

13 It,

t ~~~~~~~~+ = location ofthermocouple head

Compost pile

Figure 18. Thermocouple locations. Not to scale.A- 19

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F: I * * I I.1

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II3

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vt

0.4

IL~~~~~~~~~~~~~~~~~~~~~~~~~~~~

A-g

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APPENDIXK B

i ~~~~CALCULATIONS

,0

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OpBanfelle CALCULATION WORKSHEETPae o

Pacific Nonthwnl Labcratori, ag

Pno gz)t In corAPC's qi'k -£ 6

&

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4. 15,1130S 3.Sioo Tlq

7, 2. 4 , soo0T

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9 2 .t-c/3 C0a5or n 30beJ)

roe Prood~~~Dae Releeby Ot

- --- ,.-..-.- - ~ ~ ~ ~ ~ ~ ~~~~ ------ -d~¶S

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FC) Baflelle CALCULATION WORKSHEET a.NPacific Northwnt Laborator"e I PageIp

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r

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COBanelleCACLTOWRKHE

ILL * Ir. LI'a

;ts

.33-

r z ,o j- 3 ;-tt

3~~-38. aA o"

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.? = 0o3 (ic-;..'tkf P&.ri-o~fD 9 rj)

Tu~~~~.IW..J L 0 5 5 ~~~~~~~~~~~too

Z: L: D-- 4o (C> 60 -r&20C

ki .35 (4)4I. 6,O +4 .5 4

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A;.. ?r ssL CIE 1).-. ? A-S s. 95:i C.rtpo'

Prepared by: at Revie d by.

0 To~~~~~~~~~~~~~~ so.,%- ---- - - 4IIl(i

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(Baueue ~~~CALCULATION WORKSHEET

Pacific NorthwnIt Laboratoriet ao' ~

7.~~~1A *tT.1

A U~~~~~

Title Pmlect~~~~~~~~~~~~~~~2,- -4b

ProlmedSPbya Reviewedby. D-MoW'

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c NO.

(~Balelle CALCULATION WORKSHEET

Pacilic Northwest tabo,110r1p " l o -

r~t tucn 44S'$l4 -te ro'.='~e ur-

C s 106400 *~~ci O M

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CA1

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Tite P Ero50

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(Baneue CALCULATION WORKSHEETPaifaic Nottfhwel Laboratour IPOf

Pr C- '-it? ~~~~~~ 1o09so k:5

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(s IQ +Ra ?e x"cA a

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Pmpwd by; 4,S7M5(tfl~~~Pmp

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ODBaltele CALCULATION WORKSHEETPacific Noflhwei i tboIat-rif ~Par_____

i-t -+~-4 2 %V~ o~r~ JQ (~

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U ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~Cak. No. 2#") Balieile CALCULATION WORKSHEET

Pacific Northwell Ljboratcril Pag

[2 ~~~~~. IQ'~~~0c: To BP3 k

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kt &0263 K.7 B /t333,c I

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()BalteIe CALCULATION WORKSHEET cac o

Pacilic Northwest taboiltotin

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( Baffelle ~~CALCULATION WORKSHEETPacific Northm,"t Laboratories PK~~~~~~~~~~~~~~ -L-,P-of~~a

iW jss/r<

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OBattele CALCULATION WORKSHEETca. 4 3Pacific Northw.It Labonalori"P"o

Co.icpi*e C 4($ 40t-e 04 V;Lgcec C P

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lb. ~~~~~~~~~~~~~~~~~~~Pmjedkin ock~~t LA~O.44c Cn.~.~St:AEA aiD 5P3) ~' 1

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ceoc.N.0.1)'Baneue ~CALCULATION WORKSHEET

Pacific Northwust Laboatrs iPa

.16 it'6k T sg I/ac ?" ?1

MTN 41 (cl."k) = 11-3.36 lb TMUX4Ql&1.

q i(.6 3,.H k3j ~ 5? lb !TEV( Vdc 4,4. 1

AC C- cci,.5+-et5 At -+ F 5 o7oInCJ+

Agse rrHC 0 T^ T' VOC10O ~p 3TEC-. L/oc

represent TP H4 ia.s '

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0 BalenlePae tP~c'lc oflw~stL~beatfl~ENGINEERING WORKSHEET

red By: ~ ~ ~ ~ ~ Oto: Poject: ~~~p ~C'- S rv~~~~~t~~ 7• C1~ P

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"O~~aneue ~CALCULATION WORKSHEETCaeNOOw uu~ 1~ Pagei otw~ aomorI-J ot

too '. 9,1d& ,oo7S%~C0 -4'1 Cc&coCox-y c Cr(CePCb

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Banew Page ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~of

Pacl~cNoq~,w; Lb~r~oteiENGINEERING WORKSHEETad By:I" zcs3 Project: ~ ~ Ss - 4

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* Q'C.Battelue CALCULATION WORKSHEET Pap ot..2LOf

PaCifiC NWthwesl Laboniond$

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JBaIuene CALCULATION WORKSHEETpae__oPacific Noethwes Laboratonl /Pa

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Bjaieiie CALCULATION WORKSHEET Pag C

Pacifi Northwveut LaboratoriesPag

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