A closed landfill operator faced significant safety concerns due to multiple shallow slope failures along an exterior slope near a main access roadway. EARTHRES was engaged to perform a detailed investigation and develop an economical remediation plan. The comprehensive approach taken by EARTHRES resulted in a six-step progressive remediation recommendation process, ensuring long-term slope stability and safety while managing costs effectively. 

The Challenge

The primary challenge faced by the client was ensuring slope stability in the absence of comprehensive historical data. Given the age and closed status of the landfill, records of waste placement, leachate collection and detection system details, liner system details, capping system details, and phased development plans were limited.

Additionally, the shallow slope failures near a main access roadway heightened the need for a thorough investigation and an effective remediation plan. 

Key challenges included: 

The need for an economical solution that could adapt to the evolving conditions of the slope. 

Limited historical data on the landfill’s construction and operational history. 

Multiple shallow slope failures, posing safety risks and operational challenges. 

The Results

The solution provided by EARTHRES resulted in significant safety improvements and operational efficiencies for the client. Key outcomes included: 

• Improved Safety: The progressive remediation plan ensured that slope stability was continuously monitored and addressed, reducing the risk of further slope failures and enhancing personnel safety. 
• Cost-Effective Landfill Solutions: The six-step remediation process allowed the client to implement remedial efforts as needed, optimizing costs and resources over time. 
• Enhanced Understanding of Slope Conditions: The sensitivity analyses and iterative modeling provided a detailed understanding of the factors contributing to slope failures, enabling more effective long-term management. 

The collaboration between the landfill operator and EARTHRES resulted in a robust and economical solution to address the slope failures at the closed landfill site. EARTHRES’s expertise and methodical approach ensured that the remediation efforts were effective, safe, and cost-efficient. 

Looking ahead, the client can continue to rely on EARTHRES for ongoing monitoring and additional support as needed. The partnership exemplifies how engineering expertise and a tailored approach can address complex environmental challenges effectively. 

Click the link to learn more about our Geotechnical Engineering Services.

The post Overcoming Slope Failures at a Closed Landfill Site with EARTHRES appeared first on EARTHRES | A Division of RESPEC.

Practical. Innovative. Hands-On.

Project Background

When our client, a leading mining company, struggled with underutilization of their sand plant, they sought out EARTHRES for a solution. The plant, operating at only 36% capacity, relied on haul trucks and loaders, causing inefficiencies. EARTHRES conducted a thorough assessment and designed a reclaim and conveyor system to streamline the feeding process, boosting operational efficiency and eliminating the need for heavy equipment. The result was a dramatic increase in production, reduced fuel consumption, and faster return on investment, delivering significant long-term benefits for the client.

The Challenge

While on a site visit for a primary crusher renovation project, our engineering team noticed the inefficiency of the sand plant operation. 

The mining company fed the sand plant from a surge pile using one (1) 980-loader and two (2) 40-ton haul trucks. As the sand plant was designed to operate with a steady feed rate of 700 TPH, feeding the sand plant with only the trucks yielded a drastically under-utilized production rate of 250 TPH or 36% of capacity.

The Results

Implementation of the new Reclaim and Conveyor Circuit as designed along with comprehensive support from EARTHRES brought significant benefits to the client: 

• Increased Production Rate: The production rate increased from an actual 250 TPH to a design potential of 800 TPH. Actual operations have been running at 650 TPH on average.
• Return on Investment: In the design phase, an ROI Analysis showed full payback in 6 months; however, once installed and operating, the actual payback time was only 4 months!
• Reduced Fuel Usage: In eliminating the vehicular use to feed the sand plant, the vehicle miles traveled, emissions, over 100,000 gal/yr of fuel were no longer needed to transfer sand from the surge pile to the feeder.
• Reduced Power Usage:  The total power usage for the Sand Plant Operation was reduced by 1,046 HP.
• Reduced Carbon Footprint: Greenhouse gas (GHG) emissions were reduced by over 1,055 TPY. 

EARTHRES’ Mining Engineering Consulting services provided thorough analysis, strategic planning, and expert execution to overcome significant operational challenges. By implementing the process solution and providing ongoing support, they enabled their client to achieve greater efficiency and productivity from their operations. 

EARTHRES continues to collaborate with this client to find innovative solutions to further optimize their processes and achieve new levels of operational excellence. 

Click the links to learn more about our Mining Process Plant Design and our Mining Operations & Maintenance Support Services.

The post Innovative Solutions for Material Handling in Mining Operations appeared first on EARTHRES | A Division of RESPEC.

When our client, a key player in the mining industry, faced excessive downtime and operational inefficiencies with their primary gyratory crusher, they turned to EARTHRES for a solution. Their existing primary gyratory crusher was causing unforeseen challenges that threatened to disrupt their operations. EARTHRES conducted a thorough analysis, specified a new primary Gyratory crusher, and provided comprehensive support. The result was significantly reduced downtime, increased efficiency, and a more stable operation.

The Results

The implementation of the new crusher, along with comprehensive support from EARTHRES, brought significant benefits to the client:

• Reduced Downtime:

The new crusher’s design and installation minimized unscheduled downtime, allowing for continuous operations.

• Enhanced Efficiency:

Replacing an 800 hp crusher with a 500 hp crusher not only increased efficiency but also contributed to operational stability.

• Improved Safety and Maintenance with 360° access to all levels of the Crusher

The original design had no provision for maintenance access below the crusher except through a manhole into a confined space.

Enhancing access to the crusher through the use of a removable rolling platform and new fixed platforms facilitated efficient and safer maintenance while reducing repair times and costs.

• Increased Production Rate:

The average production rate increased from 1200 TPH to 2000 TPH, demonstrating a marked improvement in throughput.

• Operational Cost Savings:

Operational improvements eliminated the need for a 2nd shift, significantly reducing annual operating costs.

• Return on Investment:

The project achieved ROI in only 2 years, which is half of the normal ROI for a project of this nature.

• Operational Stability:

The upgraded drive arrangement and structural reinforcements minimized failures and the need for outside contractor intervention.

EARTHRES’ Mining Engineering Consulting services provided thorough analysis, strategic planning, and expert execution to overcome significant operational challenges. By implementing the process solution and providing ongoing support, they enabled their client to achieve greater efficiency and stability in their operations.

EARTHRES continues to collaborate with this client to find innovative solutions to further optimize their processes and achieve new levels of operational excellence. 

Click the links to learn more about our Mining Process Plant Design and our Mining Operations & Maintenance Support Services? 

The post Solving Crushing Challenges with Practical Solutions appeared first on EARTHRES | A Division of RESPEC.

The Project: Air Re-Entrainment Analysis

Confidential

 

The Challenge

Growth and Demand Requires More Emergency Power

 

EARTHRES was contracted by a Medical Care Facility to conduct an air re-entrainment analysis for their facility. In order for the Facility’s emergency power system to keep up with growth and demand, the Client proposed to install two (2) identical emergency generators in a new building with room for a third generator to be installed at a later date.

An analysis was needed to evaluate the placement of air intakes and exhausts associated with the proposed generator plant and whether generator plant exhaust air may contribute to re-entrainment into fresh air intakes.

 

Impact to Sensitive Patient Populations

 

While this analysis was not required to demonstrate environmental and/or regulatory compliance, the Client wanted to address public or patient concerns considering the sensitive population associated with the Facility.

 

The Solution

Use Site-Specific Data with a Complete and Powerful, State-of-the Science AERMOD Air Dispersion Modeling Assessment

 

EARTHRES performed air dispersion modeling using the U.S. EPA AERMOD Model (via Lakes Environmental AERMOD View software) for the proposed generator installation project.  This highly specific model requires site-specific parameters to be identified and entered into the model including the following:

• • source information (source type, stack dimensions, emission rates, etc.),

• • building information (dimensions and stack locations),

• • building downwash (aerodynamic turbulence induced by adjacent / nearby buildings),

• • local meteorological data, and

• • sensitive receptor information (locations of nearby schools, etc.).

 

Comparison with Standards and Thresholds

 

EARTHRES compared the AERMOD Model results (emission rates, concentrations, and associated plume geometry) to the National Ambient Air Quality Standards (NAAQS), Pennsylvania Ambient Air Quality Standards (PAAQS), and human olfactory detectable odor thresholds.  Based on the AERMOD Model emission concentrations and proposed plant design, the re-entrainment of generator exhaust air from the proposed project into fresh air intakes had the potential to cause slight-to-moderate impacts to sensitive populations.

 

 

Design to Control the Outcome and Keep the Patients Safe

 

Based on the results, EARTHRES recommended installing a control device (selective catalytic reduction (SCR), or other control device(s)), implementing operational controls (limit testing and maintenance to certain non-peak hours), and/or considering other plant design modifications (increased stack height, placement of fresh air intakes upwind of the maximum concentrations observed, etc.) in order to reduce actual air quality impacts to sensitive populations.

In order to reduce potential emissions and/or nuisance odors, the Facility has since proposed adding oxidation catalysts to the emergency generators, as recommended by EARTHRES.

 

The Results

Prevented detrimental effects to sensitive patient populations by reducing emissions and nuisance odors.

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NAVFAC, MCRC Floyd Bennett Field, Brooklyn NY

The Challenge

EarthRes Group Inc. provided coastal revetment design services for Marine Corps Reserve Center (MCRC) Floyd Bennett Field. The facility shoreline along the northern edge of Jamaica Bay was comprised of steel sheet piling which was severely corroded. Significant erosion and destabilization of the fill material located behind the sheet pile wall occurred due to wave action and scouring through wall breaches and corrosion holes.

The Solution

TN & Associates contracted with EarthRes Group, Inc. to prepare the geotechnical investigation and sheet pile structural evaluation, gather the required oceanographic/meteorological data, and to perform the design calculations for rock revetment construction. EarthRes prepared construction drawings depicting existing conditions, proposed grading, cross-sections and stormwater management controls; prepared design calculations for stormwater management controls; completed revetment slope stability and construction geotextile evaluations; prepared civil discipline technical specifications; and provided assistance with the New York State Department of Conservation Joint Application for Permit.

EarthRes also provided construction support including assessment of potential armor rock sources, field QA/QC methods, and review of constructed components for conformance with the design.

Before

After

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Burlington Township, New Jersey

The Challenge

Our client needed EARTHRES to prepare a renewal of an existing DPCC DCR spill plan. This Discharge Prevention Control and Countermeasure and Discharge clean up and removal plan was required due to the greater than the 20,000-gallon storage capacity of hazardous materials as well as multiple oil storage locations.

The Solution

Hazmat Inventory

EARTHRES Group, Inc., performed a site visit, reviewed existing facility records and conducted a hazardous materials (HAZMAT) inventory of the facility.  During this process, they documented secondary containment structures, spill kit locations, and direction of flow in the event of a discharge.

Spill Plan Development

Based on this information, EARTHRES prepared site figures in Autodesk AutoCAD^®, inspection logs, training logs, spill response forms, and an updated Discharge Prevention Control and Countermeasure and Discharge Cleanup and Removal (DPPC DCR) Plan.  The submittal was certified by an EARTHRES licensed Professional Engineer and provided to the New Jersey Department of Environmental Protection (NJ DEP) for compliance with the State’s required renewal every three years.

The Results

Our client’s facility is now in compliance with NJ DEP regulations for having updated DPCC and DCR plans.

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Confidential

The Challenge

Prepare an air quality plan approval application for a 10-mw cogeneration project allowing for their facility to maintain their current synthetic minor (non-major) source status for air emissions.  A  tight deadline needed to be met in order to keep within construction timelines.

The Solution

Why Cogeneration

EARTHRES prepared the air quality plan approval application and the air quality testing oversight, including pre-test protocol and post-test final report for the 10-MW cogeneration project.  This project consisted of natural gas-fired turbines, waste heat recovery boilers, and an emergency generator.  Cogeneration (also known as combined heat and power, CHP) is the use of a heat engine or a power station to simultaneously generate both electricity and useful heat. CHP is one of the most common forms of energy recycling and with electric deregulation it provides long-term benefits and significant cost reduction to facilities.  The permit approach allowed the facility to maintain their current synthetic minor (non-major) source status for air emissions.  This was achieved by calculating the current heating boiler emissions that would be offset by the new cogeneration plant waste heat that is then used to heat buildings.

Air Quality Plan Approval Application

The air quality project included preparing potential and projected actual emission calculations from the proposed cogeneration plant based on operating schedule and loads.  Regulatory requirements were evaluated and summarized for the project, including Pennsylvania’s Best Available Technology (BAT), and Federal New Source Performance Standards (NSPS) for turbines and for boilers.  A pre-application meeting with the Pennsylvania Department of Environmental Protection (PADEP) Southcentral Regional Office was held in order to qualify the project for the PADEP’s Expedited Review Timeframe.  Through this program, the air quality plan approval was issued in less than three months, allowing the facility to continue with construction and plant startup.

Stack Testing

Once the plant became operational, EARTHRES coordinated the stack testing of the turbines to meet the requirements of the plan approval application.  This included protocol preparation, liaison with the PA DEP, and field data collection during the stack testing and contractor oversight.  In addition, we worked with the mechanical engineering firm that designed the cogen to prepare the financial estimates for selling power back to the grid.  The plant will supply all electricity for the hospital’s main campus and partial power to the hospital affiliates as well as supply power back to the electric grid depending on demand.  According to the Client, the project will result in potential savings of $1.25 to $1.5 million a year in their electric bill resulting in a short-term payback on the project.

The Results

Supply most of the hospital’s power needs and allow for provision back to the power grid. This project has a potential savings of up to $1.5 million per year.

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Pine Grove, Schuylkill County, Pennsylvania

The Challenge

EARTHRES was contracted by our client to perform an RCRA facility investigation and remediation related to potential sources of chlorinated solvents in response to US EPA Consent Order.  The project would require EARTHRES to perform an RCRA facility investigation, corrective measures study and associated US EPA-approved investigations in support of soil and groundwater remediation of chlorinated volatile organic compounds (VOCs) including Perchloroethylene (PCE) and Trichloroethylene (TCE).  Soil Vapor Extraction (SVE) and groundwater pilot studies would have to be completed, and a full-scale SVE system installed. 

Also, during the course of completing the project, EARTHRES would perform SVE system operation, monitoring, performance evaluation, reporting and closure; a process waste lagoon investigation, remediation, reporting and closure; as well as optimization and modification of a groundwater pump and treat system.

The Solution

EARTHRES prepared and submitted a detailed RCRA Soil Sampling Workplan to the US EPA and upon approval commenced with quarterly groundwater monitoring and reporting. EARTHRES field personnel directed the soil investigation activities utilizing track-mounted Geoprobe technology and field screening activities to conduct soil sampling and delineation of suspected chlorinated solvents. Soil sampling laboratory results indicated the presence of PCE and related daughter products beneath the area of a historical dry cleaning machine within the production building. EARTHRES prepared and submitted a detailed soil investigation report presenting the soil investigation results to the US EPA for review. As directed by the US EPA, EARTHRES prepared a Corrective Measures Study Workplan (CMS) for the facility in regard to the identified PCE and related compounds.

As part of this work plan, EARTHRES performed a Corrective Measure Alternatives Analysis to determine feasible remedial options. EARTHRES identified in-situ SVE as the most cost-effective, technologically reliable remediation technique for the identified impacts. Subsequently, EARTHRES performed additional soil delineation and installed vacuum extraction points for the SVE pilot testing program. Based on the physical and laboratory data collected during the pilot test, EARTHRES concluded the SVE system would be effective in removing VOCs from the soils beneath the former dry cleaner area. The US EPA approved the use of the SVE system and the CMS Workplan.

SVE System Design, Installation and Monitoring

After the EARTHRES designed and oversaw installation of the SVE system, EARTHRES commenced with monitoring the SVE which included a collection of vacuum readings on the extraction well and observation wells, air velocity measurements on the effluent of the system, and air samples from the system effluent vapor. EARTHRES regularly reported system performance to the US EPA during the SVE system operational period. The reports included an assessment of system operation efficiency and calculations of the mass of solvents removed by the system. The SVE system was shown to be successful in remediating the VOC- impacted soils. A closure work plan was developed and approved by US EPA and investigation of the remediated area was completed. US EPA approval of the closure was obtained and removal of the SVE system was completed.

Groundwater Pump and Treat System Optimization

Due to ongoing RCRA groundwater issues, EARTHRES completed a groundwater pump and treat system optimization and capture zone analysis for both the deep fractured bedrock and shallow groundwater systems. Work included conversion from the interim pump and treat system carbon units to an innovative air stripping system approved by the US EPA. Current groundwater sampling and an Annual Certification of Compliance are completed in accordance with the 2016 US EPA Final Remedy.

The Results

Based upon the successful completion of the project by EARTHRES, the client has fulfilled the requirements of US EPA Consent Order and are maintaining compliance with the requirements specified by the Final Remedy and Environmental Covenant, allowing our client to focus on business operations.

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Lehigh & Northampton Counties, Pennsylvania

The Challenge

EARTHRES, in prime partnership with two other firms, secured a contract for environmental services to be performed under the U.S. EPA 2010 Brownfields Assessment Grant given to the Lehigh Valley Economic Development Corporation (LVEDC) for 2010 – 2013.  Forty-four firms submitted proposals to implement the grant for LVEDC.  In 2015, the contract was extended when LVEDC secured a second grant from the US EPA.

Under the contracts, EARTHRES has successfully completed Phase I All Appropriate Inquiry (AAI) Environmental Site Assessments and Phase II Environmental Site Assessments for both small and large brownfield sites located in the Lehigh Valley.  The work has included the preparation of Quality Assurance Project Plans (QAPPs); site-specific Health and Safety Plans (HASPs), Sampling and Analysis Plans (SAPSs); Remedial Investigation Work Plans (RIWP), Remedial Action Plans (RAPs); Cleanup Plans, and Remediation Bid Documents.

The Solution

EARTHRES completed Phase I Environmental Assessments following the American Society for Testing and Materials (ASTM) Standard E 1527-05 and E 1527-13 for Environmental Site Assessments (ESAs), which satisfies the U.S. Environmental Protection Agency (EPA) All Appropriate Inquiry (AAI) rule for commercial properties.  EARTHRES completed all Site Investigations/Phase II ESAs in compliance with ASTM E 1903-11: Standard Practice for ESAs: Phase II ESA Process. Also, investigations were customized to comply with the requirements of the U.S. EPA and Pennsylvania’s Land Recycling Program (Act 2).

These investigations included obtaining surface soil samples, obtaining subsurface soil samples using a geoprobe, soil gas sampling, surface water gaging and sampling, installation and sampling of groundwater monitoring wells, and conducting hydrogeologic investigations requiring the installation of groundwater monitoring wells, hydraulic testing and groundwater modeling.

Geophysical methods such as Electromagnetic Magnetic (EM) surveys and Ground Penetrating Radar (GPR) were used to identify and locate underground storage tanks, piping and other structures prior to implementing subsurface investigations (i.e. installing test borings, test pits, soil gas probes and groundwater monitoring wells).

The Results

EARTHRES completed all necessary brownfield investigations and remedial activities to support LVEDC’s ongoing community revitalization initiatives.

The post Brownfield Investigation and Development appeared first on EARTHRES | A Division of RESPEC.

Key West, Florida

The Challenge

Develop coastal restoration plans to restore the Naval Air Station (NAS) in Key West, Floria after a hurricane ripped through the area.  This extensive coastal restoration project would include conducting the necessary geotechnical evaluation and developing revetment designs.

The Solution

EARTHRES prepared the designs for multiple shoreline facilities located at Naval Air Station (NAS) Key West as part of a larger coastal restoration design/build project team.  Damaged by a recent hurricane, the coastal restoration project required the design and construction of rock revetments, concrete seawall, and replacement dock/boat ramp facilities.

EARTHRES prepared the work scope for the geotechnical evaluation and prepared the revetment designs for the prescribed areas. Design efforts included the performance of armor unit sizing and gradation calculations, preparation of grading plans and construction details, preparation of civil discipline technical specifications, and provided support for state and federal permitting efforts.

EARTHRES personnel attended project design review and construction progress meetings, assisted with identification and approval of suitable armor rock sources, provided training to contractor personnel for revetment construction methods, provided construction support services including assistance with materials quality control, submittal review, and verification of construction with design intent.

The Results

This coastal NAS facility is restored after coastal restoration and revetment.

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