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HomeMy WebLinkAbout6. Koch Refinery - Zoning Text Amendment Hearing+ � r CITY OF ROSEMOUNT 'EXECUTIVE SUMMARY FOR ACTION CITY COUNCIL MEETING DATE: July 16, 1991 AGENDA ITEM: Koch Refining - Zoning Text AGENDA SECTION: Amendment Hearing Public Hearing PREPARED BY: Lisa Freese, Director Planning AGENDA N��R M of ATTACHMENTS: PC Review, Text Amendment, APPRdVED EY:r Application Support Materials Koch Refining Sulfuric Acid Unit has petitioned the City to amend the Zoning Ordinance to permit a spent bauxite disposal facility as an interim use in the General Industrial (IG) Zoning District. Presently the Ordinance does not permit such disposal facilities in this district. The proposed text amendment would permit such facilities if they were accessory to a manufacturing operation and if an interim use permit were granted by the City. The proposed Interim Use Permit requirements for this facility are quite similar to those requirements made of USPCI for their containment facility. Basically the standards insure that the health, safety and welfare of the community is protected. The Planning Commission reviewed the proposed text amendment at the July 9 Regular Meeting. They recommended that City Council consider the concept of allowing a spent bauxite disposal facility as an accessory use via the interim use process. The Commission felt that prior to taking any final action on the text amendment that the City Council should establish a dialogue with Koch Refining to determine whether or not the interim use permit requirements can be resolved. At this time a copy of the ordinance has been provided to Koch Refinery but City staff has not had an opportunity to meet with Koch officials nor has Koch responded with any formal comments pertaining to the interim use permit requirements. Planning Staff recommends that the City Council proceed with the hearing and take public comment on the proposed text amendment, but withhold final action until City staff and Koch Refining Officials meet to discuss the details of the permit requirements. RECOMMENDED ACTION:1)Recommend that City staff enter into discussion with Koch Refining regarding the possible requirements of an Interim Use Permit for a spent bauxite disposal facility. 2) Recommend tabling final action of, -the text amendment until Koch/City discussions have occurred. COUNCIL ACTION: eity of (Rosemouni PHONE (612) 423-4411 2875 - 145th Street West, Rosemount, Minnesota MAYOR Vernon Napper FAX (612) 423-5203 Mailing Address: P. O. Box 510, Rosemount, Minnesota 55068-0510 COUNCILMEMBER`. Sheila Klassen TO: Planning Commission John Oxborough Harry Willcox Dennis Wippermanr FROM: Lisa Freese, Director of Planning ADMINISTRATOR Stephan Jilk DATE: July 5, 1991 SUBJ: July 9, 1991 Regular Meeting Reviews ATTACHMENTS: PROPOSED TEXT AMENDMENT ZONING PETITION EXECUTIVE SUMMARY LOCATION MAPS AND SITE PLAN METROPOLITAN COUNCIL REPORT 4A. KOCH REFINING TEXT ORDINANCE AMENDMENT PETITION --TO PERMIT A SPENT BAUXITE DISPOSAL FACILITY AS AN INTERIM USE. RECOMMENDED MOTION: Motion to recommend that the City Council consider the concept of allowing a spent bauxite disposal facility as an accessory use via interim use permit and to recommend that the City Council establish a dialogue with Koch Refining Company to determine whether or not the interim use permit issues/requirements can be resolved (as proposed in the attached ordinance) prior to taking final action on a zoning ordinance text amendment of this nature. NATURE OF REQUEST: Koch_ Refining Sulfuric Acid Unit has petitioned the City to amend the Zoning Ordinance to permit a Spent Bauxite Disposal Facility as an interim use in the General Industrial (IG) Zoning District. Spent Bauxite is a waste material consisting primarily of residual solids including aluminum oxide, aluminum silicate, silica material and other metallic oxides. These materials are considered non- hazardous solid waste. DISCUSSION: Presently the Zoning Ordinance does not permit such disposal facilities in the IG District. The Ordinance currently requires that waste management activities occur in the Waste Management Zoning District as interim uses. While it is clearly preferential to restrict waste management activities that are principal uses to the Waste Management Zoning District (i.e USPCI--Minnesota Industrial Containment Facility), Planning Staff realizes that some flexibility must be given to those manufacturers that produce waste by-products to allow them to have accessory disposal facilities on site. Generally, allowing such accessory disposal facilities provide convenience and cost saving to the manufacturer. Everything s COoming UP C- osemouvdy Applicant: Address: P.'' STATUS OF APP X LOCATION: REASON FOR RE Application n Fie: Planning Comm CITY OF ROSEMOUNT ORDINANCE NO. B-12 AN ORDINANCE AMENDING ORDINV CITY OF ROSEMOUNT ZONING ORDI) THE CITY COUNCIL OF THE CITY OF ROSEMOUNT, N FOLLOWS: SECTION 1. Section 3.2 Definitions of Ordinance B - Ordinance is amended by adding the following definitions: Spent Bauxite A non -hazardous industrial waste, coi aluminum oxide, aluminum silicate and silica material. Spent Bauxite Disposal Facility A facility that accepts only spent bauxite. A facility shall include containment cell systems, monitoring systems and other appurtenance: operation. SECTION 2. Section 6.14 IG General Industrial Distric Rosemount Zoning Ordinance is amended by adding the following D. Uses Permitted by Interim Use Permit 1. Spent Bauxite Disposal Facility as an accessory use only. SECTION 3. Section 11 Performance Standards - All Distr Rosemount Zoning Ordinance is amended by adding the following SECTION 11.4 SPENT BAUXITE DISPOSAL FACILITY A. Permit applicants shall submit the following information t information requested by the City: 1. The proposed project layout including site drawing access roads, buffers and major facilities. 2. Proposed technology and design. 3. A complete description of the proposed project's opera to phasing and anticipated operating lifetime, descrip methods, staffing, anticipated waste volumes, containm response plans. 4. A description of anticipated traffic generated by the f access to the site. 5. Identification of known and potential environment: construction, operation and closure of the facility. 6. Closure, post closure and contingency plans, includin 7. A description of the existing site and surrounding area and land uses, current zoning, transportation access to soil and hydrogeologic conditions, vegetation, wildlife 8. Need for City emergency services including fire, 1 medical. Sulphuric Acid Unit Land 141 acres, more or less, in a continuous tract generally described as: 1. All of the SW 1/4 NS 1/4 of Section 19, Township 115, Range 18. 2. The northeasterly approximately 35 acres of NW 1/4 SS 1/4 Section 19, Township 115, Range 18. 3_ 8 acres in the NW corner of N& 1/4 SS 1/4 Section 19, Township 115, Range 18- 4- The easterly approximately 13 acres of S& 1/4 NB 1/4 Section 19, Township 115, Range 18. 5. 8 acres in the SW corner of NS 1/4 NS 1/4 Section 19, Township 115, Range 18. 6. An approximately 37 acre tract in the NW 1/4 N& 1/4 Section 19, Township 115, Range 18. 7. An approximately 2 acre tract on the southerly line of and in SW 1/4 SB 1/4 of Section 18, Township 115, Range 18. METROPOLITAN COUNCIL Mears Park Centre, 230 East Fifth Street, St. Paul, MN. 55101 612 291-6359 January 28, 1991 .JAN 9991 Mr. Art Dunn Chief, Solid Waste Section ` Ground Water and Solid Waste Division Minnesota Pollution Control Agency 520 Lafayette Road St.Paul, Minnesota 55101 RE: Koch Refining Co. Solid Waste Permit Application Koch Refining Spent Bauxite Disposal Facility Metropolitan Council Referral He No. 13613-2 Dear Mr Dunn: r At its meeting on January 24, 1991, the Metropolitan Council considered the above referenced report. This consideration was based on a report of the Environmental Resources Committee, Referral Report No. 91-7. A copy of this report is attached. The Council adopted the following recommendations contained in the above report: 1. That the Metropolitan Council adopt the staff report and Findings of Fact and Conclusions dated January 2, 1991. 2. That the Metropolitan Council approve issuance of an industrial solid waste permit for construction and operation of the Koch Refining Spent Bauxite Facility Expansion. Sincerely, Mary E. Anderson Chair MEA:ly ..�-. Attachment cc: Stephan Jilk, Administrator, City of Rosemount Tony Foreman, Koch Refining Co., . Paul Smith, Metropolitan Council Staff Metropolitan Council Meeting of January 24, 1991 Business Item: E-6 METROPOLITAN COUNCIL Mears Park Centre, 230 East Fifth St., St. Paul, Minnesota 55101 291-6359 REPORT OF THE ENVIRONMENTAL RESOURCES COMMITTEE REFERRAL REPORT NO. 91-7 DATE: January 16, 1991 TO: Metropolitan Council SUBJECT: Foch Refining Spent Bauxite Disposal Facility Metropolitan Council Referral File No. 13613-2 Metropolitan Council District 16 BACKGROUND The committee at its meeting of Jan. 16, 1991 reviewed the above referenced report. The committee approved the recommendations with two abstentions. ISSUES AND CONCERNS A question was asked for clarification on the type of acid which is used to react with the bauxite. Tony Foreman, Koch Refining, said that spent acid from the refinery is rejuvenated and mixed with virgin acid. Concern was expressed about the land use east of the site and the potential for off-site contamination. Staff said there are some scattered homes, but generally it is an undeveloped area. Staff said there is little potential for off-site contaminant migration. The facility will be lined, and additional monitoring, wells will be installed. No contamination problems have occurred with the existing, unlined facility. The MPCA rules prohibit the off-site migration of contaminates. Concern was expressed about acidic liquids corroding the liner. Staff said moisture that accumulates both on top and bottom of the facility will be collected and recycled back to the refinery's Sulfuric Acid Plant. Leslie Davis, Earth Protectors, said this project is another time bomb. Council members noted that private facilities, such as Koch, do not contribute money to the solid waste management system, and this issue should be put on the Council's legislative agenda. RECONINfENDATIO'A'S 1. That the Metropolitan Council adopt the staff report and Findings of Fact and Conclusions dated January 2, 1991. - 2. That the Metropolitan Council approve issuance of an industrial solid waste permit for construction and operation of the Koch Refining Spent Bauxite Facility Expansion. Respectfully submitted, Michael McLaughlin, Chair f METROPOLITAN COUNCIL Mears Park Centre, 230 East Fifth Street, St. Paul, Minnesota 55101 REPORT OF THE METROPOLITAN WASTE MANAGEMENT ADVISORY COMMITTEE DATE: January 9, 1991 TO: Environmental Resources Committee SUBJECT: Koch Refining Spent Bauxite Disposal Facility Expansion Metropolitan Council Referral File No. 13613-2 Metropolitan Council District 16 BACKGROUND The Advisory Committee reviewed the above referenced report at its meeting of Jan. 8, 1991. A quorum existed for the meeting. ISSUES AND CONCERNS A question was raised about the availability of the Minnesota Industrial Containment Facility. Staff said this facility could potentially accept spent bauxite. The project developer intends to start construction of the containment facility in the fall of 1991. A question was raised about how often the spent bauxite is tested for pH. Tony Foreman, Koch Refinery, said the leachate is tested daily, but there are no plans to bring the material to a higher pH. Staff said they would check with the MPCA to see if there are concerns about the pH. RECOMMENDATIONS 1. That the Metropolitan Council adopt the staff report and Findings of Fact and Conclusions dated January 2, 1991. 2. That the Metropolitan Council approve issuance of an industrial solid waste permit for construction and operation of the Koch Refining Spent Bauxite Facility Expansion. Respectfully submitted, Betty Sindt, Chair --- METROPOLITAN COUNCIL Mears Park Centre, 230 East Fifth Street, St. Paul, Minnesota 55101 DATE: January 2, 1991 TO: Metropolitan Waste Management Advisory Committee FROM: Solid Waste Division (Paul Smith, 291-6408) SUBJECT: Koch Refining Spent Bauxite Disposal Facility Expansion Metropolitan Council Referral File No. 13613-2 Metropolitan Council District 16 INTRODUCTION Koch Refining Company has submitted to the Minnesota Pollution Control Agency (MPCA) an application to construct and operate an industrial solid waste land disposal facility. The proposal is for an expansion of Koch's spent bauxite facility in Rosemount. Spent bauxite is classified as a solid waste, not a hazardous waste. The spent bauxite disposal facility is operated in conjunction with the Koch Sulfuric Acid Unit which produces a sulfuric acid from elemental sulfur and spent alkylation acid, both of which are by-products from the Koch Refinery. The existing spent bauxite disposal facility was constructed in 1982, and it has a permitted capacity of 70,000 cubic yards. The proposed horizontal expansion will be constructed directly east of the existing facility, and it will have a disposal capacity of 60,000 cubic yards. The expansion will accommodate disposal of spent bauxite for the next 10 to 15 years. AUTHORITY FOR REVIEW The Council is required by Minn. Stat. Sec. 473.823, subd. 3 to approve proposed solid waste facilities in the Metropolitan Area before the MPCA can issue permits for such facilities. The Council's decision must be based on consistency with the Solid Waste Management Development Guide/PoIicv_ Plan. In making its determination, the Council must consider the areawide need and benefit of the applicant facility, and may consider the effect of the facility on existing and planned solid waste facilities described in a county report or master plan. The Council's approval may contain conditions to assure consistency with the Policy Plan. The Council has 60 days to complete its review unless a time extension has been authorized by the MPCA. This permit application was submitted to the Council on Nov. 8, 1990, and a time extension has been granted until Feb. 15, 1991. SUMMARY OF PREVIOUS REFERRALS AND EXPECTATION FOR RELATED SUBMISSIONS This project has had previous Council involvement. o Council approval of original permit application (1980) o Council approval of permit reissuance (1986) NOTIFICATION AND RESPONSE The following agencies and governments were notified that the Council has received this permit w application for review. City of Rosemount Dakota County Dakota County Soil and Water Conservation District Metropolitan Waste Control Commission Minnesota Department of Agriculture Minnesota Department of Health Minnesota Environmental Quality Board No comments have been received regarding the facility. DESCRIPTION OF PROPOSED FACILITY The facility is located on property owned by Koch Refinery Company on the south side of Highway 55, east of U.S. Highway 52 in Rosemount (see Figures 1 and 2). The site is zoned industrial and is part of the refinery's Sulfuric Acid Unit: The site is 140 feet above the Mississippi River and approximately 3,000 feet southwest of the river. Major access routes are Highways 55 and 52 although public roadways are not used for disposal of the material. Spent bauxite is piped to the site from the Sulfuric Acid Unit 500 feet to the west. The primary use of the sulfuric acid is as a catalyst in the oil refinery process. The used acid is returned to the plant and converted to fresh "virgin" acid. The finished acid is then used in the alum manufacturing process. During this process, sulfuric acid and bauxite, a naturally occurring mineral, are combined. Spent bauxite occurs after the raw material has been washed several times by water and weak alum solution. The resulting waste is weakly acidic (ph of 3) and high in silica material. Spent bauxite is a gray, gritty, Bandlike material. It is high in moisture content. The present site is 3 acres: 200 feet by 600 feet and 8 feet deep. The site is lined with compacted spent bauxite. Excess supernatant or precipitated liquid is pumped from the basin back into the plant or the treatment system. About 3,000 tons of material is deposited at the site each year. The proposed 3.8 acre horizontal expansion will be constructed directly east of the existing facility and will consist of a lined containment cell with surrounding dikes. The facility will be 275 feet wide by 600 feet long. The liner system will consist of a synthetic liner (60 mil HPDE) in conjunction with a 2 foot low permeability clay layer. Spent bauxite will be slurried into the new facility at the rate of 4,000 cubic yards per year via an above ground gravity drained spigot line. Supernatant that accumulates on top of the spent bauxite will be collected and returned for use in the manufacturing process. Leachate will be collected by a leachate collection system. The slotted leachate pipe will be surrounded by a coarse filter material and will drain by gravity into a collection manhole. The collected leachate will be recycled back to the acid plant for reuse. A ditch between the cells will be constructed to divert surface runoff. The ditch is designed to handle runoff at closure of the new facility due to a 100 -year, 1 hour rainfall. l ' - � -:� _--� . rrlr. •'.h `�L� fir, •.1 �{ \ — `' e _ \•.o I ' e `, 1 r •. ice. f� '• l� Pine Bend • •��.` � \ � •lS— � _ � �� Niter F, _ � Mete - __ •\. Dee [ �4 Cam C I Q �� f _- r • �I li _ it j If KOCH REFINERY mj 169J ��� S6_ — __i'�'; / `4 ^. I - • : �Ci.^- s� ..r 1 � _ "�J�C SAU Y ��Y '• • • C NR C'- S E SITE.: -�� Spent �--- Gravri s - Bauxi to ° Dispos$, :• Base Map: USGS 7 1/2 Minute Inver Grove Heights Ouadrangle 0 2000 4000 I I I Scale in Feet '- 3 Figure 1 LOCATION MAP Un aAwL noon • O O n[ • O • � N71 HINT O n VIKTW -AM WDI \ / ogb Q w-1 O 0/ OO O 100MOI1eS N LNE tA Y,m�•TSI . fToaaf \ u _LEGiNR_ M-10► • MELL LOCATION 90m"0 1600.5 SM PM"C LOCATION ////■'''' (VES. 19") V J SPEW 9-krx" 0 200 Li -A -L.11 1_1_L_LJ SCALE IN FEET WTD § Figure 2 ' PROPOSED EXPANSION LOCATION 1 KOCII REFINING CO. SULFURIC ACID UNIT (SAU) SOLID WASTE PERMIT APPLICATION REVIEW The review criteria in the Solid Waste Guide chapter are used to assess compliance with the Guide's solid waste policies and the Waste Reduction and Resource Recovery Development Schedule. Specific criteria applicable to this permit review include: waste management service impacts, capacity, location, environmental impacts, operation and economic effects. WASTE MANAGEMENT SERVICE IMPACTS AND CAPACITY (CRITERIA 1 AND 2) Solid Waste Guide criteria la and 2a say that proposed waste facility service areas and facility capacities shall be consistent with the Waste Reduction and Resource Recovery Development Schedule. Presently, there is no proposal by Koch to reuse the spent bauxite material. Because this material is generated on-site and not collected in the aggregate as municipal solid waste (MSW), it will not be subject to Dakota County's waste designation ordinance. The project does not conflict with the objectives of the Waste Reduction and Resource Recovery Development Schedule. A potential alternative to the facility is the proposed Minnesota Industrial Containment Facility, which will be located approximately one-half mile to the southeast. LOCATION (CRITERIA 4) Land Use Solid Waste Guide criterion 4a says that waste facilities should be compatible, to the extent possible, with Council land use policies. The Metropolitan Develooment and Investment Framework (MDIF) sets a general direction for future development patterns and establishes guidelines for making decisions about major regional facilities. The proposed site is located in the MDIFs General Rural Use Area. MDIF policies support the location of solid waste facilities in the General Rural Use Area as long as adequate services are provided and existing agricultural activities are not interrupted. Metropolitan Svstems Solid Waste Guide criterion 4b says that waste facility sites should be compatible with existing and planned metropolitan systems. There are no impacts on existing or planned metropolitan systems. The proposed site is not included in the metropolitan airport candidate search area in Dakota County. Appearance and Hours of Operation Solid Waste Guide criterion 4e says that waste facilities shall maintain proper site appearance and reasonable times of operation. The spent bauxite facility is located adjacent to the Sulfuric Acid Plant and is designed to accept spent bauxite during operating hours at the acid plant. 5 Traffic Solid Waste Guide criterion 4d says that waste facility sites shall be accessible year-round by nine -ton or better weight-bearing roads that have adequate capacity. Disposal of spent bauxite residuals will be accomplished using a slurry discharge line originating at the acid plant. Consequently, traffic control will not be necessary at the facility. End -Use Solid Waste Guide criterion 4e says that proposed waste facility sites should be capable, to the extent possible, of being returned to a use anticipated in the plan of a metropolitan agency, county or local unit of government after closure of the facility. A closure plan for the facility has been submitted to the MPCA. Within 90 days after closure, Koch will submit to Dakota County, the City of Rosemount and MPCA, a survey plat indicating the location of dimensions of the closed spent bauxite facility. The site of the closed facility will be designated "open space" by Koch. The site will not be developed for another use. ENVIRONMENTAL IMPACTS (CRITERIA 5) Land Disposal Solid Waste Guide criterion 5a says that land disposal facilities shall be located, designed and operated to prevent, to the greatest extent possible, discharge of leachate under or beyond the site boundaries. The glacial sediments beneath the site are outwash deposits of the Rosemount Outwash Plain. The outwash deposits are approximately 90 to 125 feet thick. The subcropping bedrock beneath the site is primarily the Prairie du Chien Formation, but the St. Peter Sandstone may be found to the southeast of the site. The depth to bedrock is approximately 100 to 130 feet. The surface of the saturated zone beneath the site is roughly 130 to 160 feet deep. The saturated thickness of the upper aquifer ranges from approximately 250 to 300 feet. Groundwater flow in the vicinity of the site is generally toward the Mississippi River which is the discharge zone for the upper aquifer. No groundwater contamination problems are anticipated to occur. The facility will be lined, and the collected leachate will be recycled back to the Sulfuric Acid Plant. MPCA staff have stated there have been no groundwater contamination problems with the existing spent bauxite disposal facility. Environmentally Sensitive Areas Solid Waste Guide criterion 5b says that sites should be not be approved that would adversely impact environmentally sensitive areas. An environmentally sensitive area includes areas that are important from an ecological or natural resources management standpoint. There are no known protected wetlands, floodplains and critical habitats of endangered species on the site. A site survey of critical habitats was not conducted. 0 Surface Water Runoff Solid Waste Guide criterion 5c says that waste facilities shall provide for appropriate handling and treatment of surface water runoff, wastewater and collected leachate. The existing basin is designed to channel runoff to naturally occurring drainageways. The expansion will include a ditch between the two basins that will divert surface runoff. The ditch is designed so that half of the runoff will be directed to drainageways to the north and the other half will be directed to drainageways to the south. The ditch is designed to carry runoff at closure of the new basin due to a 100 -year, 1 -hour rainfall event. Noise, Odors and Nuisances Solid Waste Guide criterion 5d says that suitable buffer areas, berms, barriers and vegetation shall be provided to minimize noise, odors, landfill gas migration, public safety, nuisances and other impacts on adjacent properties. Operation of the spent bauxite disposal facility is not anticipated to create noise or dust problems in the area. The high water content of the slurried spend bauxite is anticipated to preclude generation of dust. It is not anticipated that the spent bauxite facility will contain ignitable material. By virtue of the complex and potentially hazardous nature of refining, blending and storing petroleum products, Koch has, developed the capabilities and procedures necessary to minimize the potential risks posed by fires and explosion. Koch also maintains a contract with the City of Hastings for supplementary fire service. Environmental Monitoring Solid Waste Guide criterion 5e says that facility applicants shall develop environmental monitoring programs and contingency plans. - The existing monitoring network at the spent bauxite facility consists of three monitoring wells, two downgradient and one upgradient of the facility. MPCA staff has stated that additional monitoring wells will be provided for the facility. Land Disposal Development Schedule Solid Waste Guide criterion 5f says that proposed land disposal facilities or capacity shall accept only processed municipal waste residuals in accordance with the land disposal development schedule or other special waste materials. The proposed site will not be used for the disposal of processed MSW residuals. The operator proposes to dispose of only spent bauxite residuals which is defined as a solid waste in accordance with Minnesota Pollution Control Rules. OPERATIONS (CRITERIA 6) Operator Experience Solid Waste Guide criterion 6a says that waste facility applicants shall demonstrate ability to properly operate and maintain the facility. Koch generates and manages a variety of wastes at the refinery. These wastes include hazardous wastes, non -hazardous waste sludges, solid waste, wastewater, stormwater and flare line gases. These majority of these wastes are managed at the refinery by recovering as usable products or treated at the wastewater treatment facility. Some of the hazardous wastes are shipped to a hazardous waste landfill and some of the solid wastes are disposed of at the Pine Bend Landfill under a co -disposal permit. Controlled Access Solid Waste Guide criterion 6b says that facilities shall have controlled access. Access to the Sulfuric Acid Unit is controlled by a chain link fence around the perimeter of the facility. In addition, warming signs are posted around the Sulfuric Acid Unit. Additional security is provided by patrol's of the Koch Refining Company's Health and Safety Department. ECONOMIC EFFECTS (CRI'T'ERIA 8) Solid Waste Guide criterion 8c says that a waste facility should minimally impact surrounding land use development and property values. Guide criterion 8d says that a waste facility should not place burdens on local services without compensation. The surrounding land use is industrial and general rural use, and the proposed site should not adversely impact land use development and property values. The spent bauxite facility should not place a burden on the use of local public services. FINDINGS OF FACT AND CONCLUSIONS 1. The disposal of spent bauxite residuals does not conflict with the Waste Reduction and Resource Recovery Development Schedule. 2. MDIF policies support the location of solid waste facilities in the General Rural Use Area as long as adequate services are provided and existing agricultural activities are not interrupted. 3. There are no impacts on existing or planned metropolitan systems. 4. No groundwater contamination problems are anticipated. Hazardous or contaminated waste will not be accepted for disposal at the landfill. 5. There are no known protected wetlands, floodplains and critical habitats of endangered species on the site. 8 6. Surface water drainage will be controlled at the site by a ditch that direct surface runoff to drainageways. 7. There should be no problems with noise, odors, gas migration, public safety, nuisances and other impacts on adjacent properties. 8. Addition groundwater monitoring wells will be provided for the spent bauxite facility. 9. The facility applicant has the ability to properly operate and maintain the facility. 10. The spent bauxite facility should not adversely impact land use development and property values or place a burden on the use of local public services. 11. The issuance of an MPCA solid waste permit is consistent with the Solid Waste Management Policv Plan/Development Guide. RECOMMENDATIONS a 1. That the Metropolitan Council adopt the staff report and Findings of Fact and Conclusions dated January 2, 1991. 2. That the Metropolitan Council approve issuance of an industrial solid waste permit for construction and operation of the Koch Refining Spent Bauxite Facility Expansion. 9 r r EXECUTIVE SUMMARY KOCH REFINING COMPANY SULFURIC ACID UNIT SPENT BAUXITE DISPOSAL FACILITY EXPANSION Description of Spent Bauxite Residual The spent bauxite material discharged to the settling basin consists of the residue from the third washing of the digested bauxite ore. The physical appearance of the spent bauxite solids is similar to a grey, gritty sand. The grain size distribution (Figure 2) indicates that the solids have an estimated uniformity coefficient (D6o/Dlo) of 150 and an estimated coefficient of curvature (D3o2/D6o x DTo) of 2.7. The material is about 68 percent sand -sized, 17 percent silt -sized and 15 percent clay -sized particles. According to the Unified Soil Classification, the solids would fall into the GW soils group, indicating well -graded gravel or gravel -sand mixtures with little or no fines. Using the USDA textural classifications system, the material would be considered a sandy loam. Laboratory test performed on samples of the spent bauxite indicate the moisture content of the material is about 47 percent at placement and about 40 percent to 43 percent at field capacity. Primary constituents of the residual solids are aluminum oxide, aluminum silicate and silica material. Minor constituents are iron, titanium, and metallic oxides. Results of titration experiments with the saturated solids and with the supernatant indicate that the residual acts as a weak acid with a pK„ of about 3.6. This is to be expected, since alum is produced by reacting a weak base (aluminum oxide) with a strong acid (sulfuric acid). The pH of the supernatant is about 3. Supernatant discharged with the spent bauxite contains high concentrations of total dissolved solids, mainly aluminum and sulfate which are the ionic products of alum solvation. Other ionic constituents are generally present in minor quantities. Organic and carbonate constituents of the bauxite ore are converted to carbon dioxide and steam and emitted from the reactor during the digestion step. Description of Expansion The proposed horizontal expansion of the KSAU spent bauxite disposal facility will be located immediately adjacent to the site. The new facility will provide a location for the continued disposal of spent bauxite. The existing basin and horizontal expansion are located entirely within Koch Sulfuric Acid Unit property. The existing basin is 200 feet wide be 600 feet long and is surrounded by containment dikes approximately 8 feet high with a three horizontal to one vertical side slope. When constructed, the existing basin was approximately 16 fleet deep and had a permitted capacity of 70,000 cubic yards. The bottom of the existing facility and the core of the surrounding dikes were constructed of compacted spent bauxite. The bottom liner of the existing facility was constructed of 4 feet of compacted spent bauxite. The core of the surrounding dikes was also constructed of compacted spent bauxite. The inside slopes were covered with approximately one foot of compacted common excavation. The outside slopes were covered with compacted common excavation and one foot of topsoil. The proposed horizontal expansion of the KSAU spent bauxite disposal facility will be 275 feet by 600 feet with a capacity of approximately 60,000 cubic yards. The new basin will be lined with a composite liner system consisting of a clay layer compacted to a thickness of 2 feet, overlaid by a 60 mil high density polyethylene (HDPE) liner. The liner and inside slopes will be constructed at a 4:1 slope with the minimum of about 3 feet of fill and/or spent bauxite over the liner to act as frost protection. The outside slopes will be graded at a 4:1 slope. The proposed basin will also contain a leachate collection system installed along the basin centerline. The slotted leachate collection pipe will be surrounded by a coarse filter material and will drain by gravity into a collection manhole at one end of the basin. The collected leachate will be M pumped back to the alum plant for recycling. The basin slopes and bottom will be constructed of fill material capable of conveying drainage to the collection system. ,� i '—E°' Lv — ' .uii w V 1 ; "•N^u ` •w. I 1 Lir" I � 1 � Ww.l• �Y. ' St.a..H. 4AMeE�kill' P O L� j ",«..~.. C 3A ;, UN —Z -," I AUt Il �rr.dlc C,� ( ( `� it 1 1 1 E:.''.1p 1 \� _%.. tai ►' - �'"� i D IL C. M.sn1 I 1 aAI 1 � 1 •KM • \ 1 SL +1YI 1 ' I ///�+ �►II , I ' LYl � J t Sl Paul 7 — A..«.fl yt 1 1 is W Pb" , SI«.rw.n/t• /{ � �"� GeLM Gnaw � � 1 /UMw 1 1 �� vLVMSif Ic� �i r• 1 I I i1 'M ' LYI w.IN ,,%1 1 ArrrwMYnt r 1 1 Koch �> ► I =" Refining 1 � �7 DAKOTA Compa i I %!VER i ur wtN i EMF+RE i/'G«w.dl..w , MAR MAN AVEC' t ; ' I j 1 ry.w.I.�tM 1 1 _ Ew N-AAKE7 1 EL EKA j GS—.' -E ROCK N Figure 1 GENERAL. LOCATION MAP ' " 650 Its 34 Pine Bend �i,: ��1\ C) 50 i10' �'� - //C�1 l , _� 1\27 N\ 8 4' \ x 1 .11AV, �_ 866 ��•. U ;,+ .cam-- \, '-..I (- - , \ `\�..�r�`�_� �\ \ (� \,�- - O ° \ '� •' of : • • • •.• � •.� � � � �� ,,,,S�1 '�'1�.��p0 � �_ _-__ 61 LlI 01i- NA\N so: KOCH REFINERY' 926 990 JII'. .I ISI � O h � - �• .� 892 56 � 11 I -� • �� �- - nJR SAU 1 v - C _ S 1 T E 803 -, ==907 EAST=====eJ l 912i. ..-•`., 'i f� . n 1 7 f1,- 863 �� (- .. \ _ . ('.O i ) C, (. .. �,� �� =--'+' =•y �\'^� J 'iii � — � � �' - Base Map: USGS 7 1/2 Minute Inver Grove Heights Quadrangle 0 2000 4000 Figure 2 1 1 1 Scale in Feet LOCATION MAP