LEACHATE GENERATION AND

TREATMENT AT THE BUKIT TAGAR

LANDFILL, MALAYSIA

A P KORTEGAST*, S F ELDRIDGE*, B A RICHARDS*, S YONG**, E T

CHOCK***, A BRYCE*, H ROBINSON****, M CARVILLE****
* Tonkin & Taylor Ltd, New Zealand
** TT Konsult, Malaysia
*** Berjaya KUB, Sdn Bhd, Malaysia
**** Enviros Consulting, United Kingdom

SUMMARY: Development of the 130Mm3 mega-landfill at Bukit Tagar near Kuala Lumpur
Malaysia, represents a major step forward in waste management technology for Malaysia’s
largest city and the surrounding Klang Valley region. A review of leachate generation after the
first year of operation highlighted the limitations of commonly adopted predictive methods (that
are mainly derived from landfill performance in temperate to dry climates), when assessing
leachate generation at landfills in tropical climates. The importance of landfill operational
controls, the influence of tropical rainfall patterns, the significance of the water content of the
waste as received are highlighted, and the influence of these variables on total and peak leachate
generation are discussed. The volume and chemistry of the leachate imposed considerable
demands on the design of a suitable leachate treatment plant. The on-site leachate storage that
was required in order to cater for leachate generation prior to treatment plant commissioning, of
itself resulted in significant pre-treatment of the leachate and promoted methanogenesis. The key
elements of the leachate treatment plant design are outlined, and initial performance data are
presented. These show the leachate treatment process to be very effective with a high quality
final effluent being produced; suitable for spray irrigation to plantation land on site.

1. INTRODUCTION

Following a fast-track development planning process, construction of an advance cell was

completed in early 2005 at the Bukit Tagar Landfill, located 40km north of the Malaysian
capital, Kuala Lumpur. Design of the Advance Phase was completed by TTKonsult in
association with Tonkin & Taylor International. Construction commenced in 2004 and the site
opened in April 2005. The site received about 0.5Mt of municipal solid waste in its first year of
operation. The amount of waste received has now increased to an average of some 2000t/d. The
first major cell of the main landfill has recently been constructed and is scheduled to commence
accepting waste in late 2007.
This paper summarises the original basis for leachate generation calculations, the principal
findings of a review conducted after one year’s flow data became available, and the design
operation and performance of the leachate treatment plant.
 Sardinia 2007, Eleventh International Waste Management and Landfill Symposium

2. LEACHATE GENERATION

The site was proposed as a modern, lined landfill generally following the USEPA Subtitle D
design approach – although not rigorously. It was designed to receive a mix of non-hazardous
commercial and domestic putrescible and inert waste. It is situated in a hot tropical climate and
receives some 3m of rainfall annually, reasonably evenly distributed throughout the year.
Monthly rainfall typically ranges from 150-360mm, with no distinct monsoon season.
Estimates of leachate generation rates were undertaken at the preliminary design stage using
the USEPA HELP model in conjunction with a simple water balance model.
The preliminary design assessment of leachate generation for the 4 ha Advance Phase of the
landfill was based on the following assumptions:
Mean annual rainfall of 2767 mm
30% rainfall percolation through intermediate cover
100% rainfall percolation at the working face
Rainfall always exceeds evaporation
Incoming waste at field capacity
Good cover and runoff management applied to minimise infiltration.
From these assumptions, the average leachate flow from the Advance Phase was estimated as 90
to 160m3/d, with an assessed peak of 180m3/d. The operational methods that were initially
adopted were aimed at trialling semi-aerobic landfill technology and hence cover practices were
deliberately not optimal in terms of excluding rainfall. This factor, together with the even wetter
than estimated nature of the waste, meant that the initial estimates of leachate generation proved
to be low. Furthermore, commencement of operation of the Advance Phase was brought forward
and consequently significant quantities of leachate were generated prior to commissioning of the
Leachate Treatment Plant, which did not occur until April 2006. In the interim, a proportion of
the leachate was recirculated into drier areas of waste, but by the time the treatment plant was
commissioned, a total of some 150,000m3 of leachate had accumulated, stored in five lagoons.
In April 2006 an updated water balance model was developed to back-analyse what had
occurred in relation to leachate generation during initial Advance Phase development. This was
aimed at providing a comparison with the leachate generation estimates made during the
preliminary design phase, and at developing more accurate estimates of future leachate
generation as guidance for site management practices.
Back-analysis of actual leachate flow data to create a leachate generation model is becoming
recognised as an important tool in predicting leachate generation in tropical climates. This is
because conditions differ markedly from those typically experienced at landfills in the USA and
Western Europe, and for which operational data are the most widely published.
For any leachate generation model to continue to be useful throughout the operational life of a
landfill, it must be continually updated and re-calibrated against actual site data. Thus the
regular collection of accurate data is of considerable importance in the ongoing development of
any landfill, and now forms part of the ongoing monitoring record at Bukit Tagar.
The key influences on leachate generation at Bukit Tagar are:
Rainfall – The site’s climate is tropical and characterised by high annual rainfall (average 2.8
m). There are four months of higher than normal rainfall, but overall rainfall occurs consistently
throughout the year. This high rainfall quantity and regular pattern impose considerable
constraints on the landfill development and operations.
Waste moisture content - The average waste moisture content is very high (65% to 70%).
Most loads exhibit free liquid and most waste deposited tends to be at greater than field capacity.
This resulted in a higher than anticipated leachate base flow, which was a significant factor in
initial under-estimation of leachate generation.
 Sardinia 2007, Eleventh International Waste Management and Landfill Symposium

Operational practices – Landfill and operational practices are of critical importance in

determining the amount of leachate produced and ultimately collected. Good surface water
control during operation of the landfill, which includes minimising the area of the working face,
diversion of clean stormwater away from the working face, and timely and appropriate use of
daily and intermediate cover soil, are critical management methods needed to minimise the
quantity of leachate produced at a landfill site. In this case there was significant pressure from
government and environmental agencies to trial semi-aerobic landfilling techniques in the
Advance Phase. The landfill was therefore designed to permit a high degree of rainfall ingress.
However, this approach distorted the initial generation estimates, led to leachate management
and other difficulties and was soon discontinued in favour of stringent water exclusion from the
waste mass.

Model development and findings

An updated leachate generation model was developed and calibrated against leachate flow data
recorded during the first year of site operation, to ascertain appropriate assumptions for
infiltration and base flow. Rainfall data recorded on the site was supplemented with off site data
where required.
The infiltration rates and base flow assumptions were varied until the analysis provided a
good correlation with the recorded leachate volume data. The resulting calibrated parameters are
as follows:
Infiltration: intermediate cover – slopes 30% of rainfall
Infiltration: intermediate cover – platforms 40% of rainfall
Infiltration:final cover (none placed to that point) 20% of rainfall
Infiltration: tipping area and daily cover 100% of rainfall
Direct flow from up-gradient slope 100% of rainfall
Base flow during drier months (Jan - Mar, May - Sept) 15% of waste weight
Base flow during wetter months (Apr, Oct - Dec) 20% of waste weight
Average base flow 17% of waste weight
Figure 1 summarises the results of the analysis and back-calibration.
160,000

140,000 Modelled leachate volume Recorded leachate volume

120,000

100,000

80,000

60,000

40,000

20,000

0
Apr.05 May.05 Jun.05 Jul.05 Aug.05 Sep.05 Oct.05 Nov.05 Dec.05 Jan.06 Feb.06 Mar.06 Apr.06

Figure 1. Revised leachate generation model results for the first year’s operation.
 Sardinia 2007, Eleventh International Waste Management and Landfill Symposium

The April 2006 model provided a good correlation with the cumulative leachate volume data and
the analysis highlighted the following points:
The lower leachate collection rate in the early months of operation of the landfill was
probably a result of buffering within the waste mass.
The base flow derived from the free leachate within the deposited waste was estimated to
have contributed approximately 60% of the leachate generated to that point and is thus a
crucial component. This component is significantly greater than the base flow typically
attributed to similar waste streams even in Hong Kong (dry season 5%, wet season 10%).
This is consistent with reports of the moisture content of the incoming waste mass of 65% to
70% at Bukit Tagar, compared with typical Hong Kong values of 60%. Furthermore, the
regular rainfall pattern in Malaysia and the lack of a significant dry season is thought to
generally increase the average moisture content of the waste mass as little is lost by
evaporation.
Limitations of the leachate flow data available to that point prevented more detailed back
analysis such as estimation of peak daily flows as a result of individual storm events. Thus a
clear delineation of the avoidable (i.e., that which can be avoided by altering landfill
operation practices), and unavoidable (i.e., open face area and baseflow) leachate generation
could not be achieved. However, the April 2006 analysis suggests that approximately 15% to
20% of the total leachate is likely to be the direct result of surface water from up-gradient
formation slopes running into the waste mass. This is clearly avoidable to a significant extent
with careful site management practices.
Approximately 10% to 12% of the leachate volume is shown to be generated from rainfall on
the tipping face, and approximately 13% to 18% from infiltration through intermediate cover
areas.
The modelled average daily leachate prediction based on the (then) site operational practices and
waste volumes was in the order of 325 - 550m3/d. This is much closer to actual experience than
the original estimates.
Figure 2 summarises the results of the modelling of daily leachate flows. Typically within the
landfill there is a lag and attenuation of leachate flow between the time when rain falls, and the
time at which leachate emerges from the collection system. This effect is included in the model
by calculating moving averages over 4 days.

2,500
Daily leachate volume Attenuated
2,000

1,500

1,000

500

0
Apr.05 May.05 Jul.05 Aug.05 Oct.05 Dec.05 Jan.06 Mar.06

Figure 2. Daily leachate flow model results

 Sardinia 2007, Eleventh International Waste Management and Landfill Symposium

The model indicated that based on the (then) current operational practices, daily flows for the
Advance Phase might reach peaks as high as 1150m3/d following a significant rainfall event.
This predicted peak flow was alarming and had major implications for the design and operation
of future phases of the site as these were to be considerably larger. It also had significant
implications for the physical requirements for leachate treatment, and both the capital and
operating costs for the plant.
This analysis confirmed that given the high cost of treating leachate, semi-aerobic landfilling
methods were unlikely to be sustainable at the site and reversion to traditional anaerobic
landfilling with meticulous operational control focused on exclusion of excess water would be
essential to the ongoing viability of the site.

3. LEACHATE TREATMENT

Leachate Treatment Plant Design

In February 2004 Enviros Consulting was commissioned as specialist subconsultants to
TTKonsult, to prepare detailed designs for a leachate treatment plant at Bukit Tagar. Based on
extensive experience at similar tropical landfills (eg Robinson, 2007; Robinson and Luo, 1991),
predictions were made for the composition of leachate anticipated at the site (Table 1).

Table 1. Parameters used for the design of the Bukit Tagar leachate treatment plant
Determinand Units ACETOGENIC METHANOGENIC
leachate effluent leachate effluent
pH-value pH 6.0 8.0 7.5 8.0
COD mg/l 20000 800 3000 1200
BOD5 mg/l 12000 10 600 <30
ammoniacal-N mg/l 1250 <2 1500 ~2
alkalinity (CaCO3) mg/l 7500 500 8000 500
nitrate-N mg/l <1.0 <50 <1 <1200
nitrite-N mg/l <0.1 0.2 <0.1 <1

These estimated parameters were based on likely long-term mean values for the quality of each
type of leachate, and recognised that peak values in leachates from specific site areas would
exceed these figures on some occasions. The fact that leachate being treated would, in the long-
term, be a blend of leachates from different cells and site areas, and that some control could be
imposed on this, increased confidence in identifying an optimum design.
Predictions were also made for the quality of effluent that could reliably be achieved by an
on-site biological treatment plant, with some effluent polishing, and the predicted effluent
characteristics are also included in Table 1. The initial plant was sized to provide treatment of
up to 1000m3/d of methanogenic leachate, and about half that volume of acetogenic leachate.
Subsequent pilot-scale treatment trials allowed this to be confirmed in practice, after the full-
scale plant was actively treating methanogenic leachate.
In Malaysia, discharges of treated wastewaters into surface watercourses are controlled by a
set of national quality criteria known as Standards A and B. At Bukit Tagar, Standard B would
be applied, and the treated leachate quality could readily comply with every limit, except that of
100mg/L for COD. Specific polishing treatment for removal of non-biodegradable COD would
have involved the use of activated carbon and could not be justified based on technical and cost
considerations. Arrangements were therefore made that final effluent would instead be irrigated
 Sardinia 2007, Eleventh International Waste Management and Landfill Symposium

into the extensive areas of palm oil plantation surrounding the landfill, where concentrations of
nitrate would be beneficial, and COD values would be attenuated in the soil.
A treatment plant design was prepared that was based on experience from similar tropical
regions (e.g., Robinson and Luo, 1991; Robinson and Carville, 1991). It comprised the
following treatment processes:
1) Biological Treatment: Biological removal of biodegradable COD and nitrification of
ammoniacal-N would take place in four 5000m3 HDPE-lined lagoons (see Plate 1), each of
which is equipped with six floating surface aerators to provide oxygenation and mixing of solids.
The lagoons operate in parallel as sequencing batch reactors (SBRs), such that temperatures
within the lagoons do not exceed about 38oC, above which inhibition of treatment would occur.
The lagoons are designed to operate in sequence on a 24-hour cycle, receiving inputs of leachate
from a single large raw leachate balance tank (RLBT). Operation was arranged such that a
discharge of SBR effluent was made by one lagoon every 6 hours, into a Treated Leachate
Balance Tank (TLBT). The whole process was automated, with pH-values being maintained at
optimum levels by means of dosing with sodium hydroxide solution.
2) DAF Treatment: SBR effluent is passed through a proprietary, automated dissolved air
flotation (DAF) plant, sized and specified to remove almost all residual suspended solids, and
some colloidal COD material. Dosing with polyelectrolyte and flocculant solution was
optimised by on-site testing.
3) Reed Bed Polishing: Effluent from the DAF process is polished by passage through one
of two banks of four reed beds, having a total area of 1Ha. Beds were lined with HDPE, and
filled to a depth of 600mm with gravel. After planting the first four beds with reed plants, rapid
growth was quickly established and it was possible to populate the second bank of beds entirely
using reed cuttings from the first beds. The rapid growth allowed reeds in each bed to achieve a
height in excess of 5m within one year of planting (see Plate 1).
4) Effluent Irrigation: Reed bed effluent flows by gravity to a storage lagoon. From there,
it is pumped into a high level header lagoon, which feeds the extensive (100Ha) palm oil
irrigation scheme.

Plate 1. Bukit Tagar Leachate Treatment Plant, Malaysia: one of the four SBR lagoons,
and part of the extensive reed bed polishing system, April 2007.

Leachate Characteristics at Bukit Tagar

The site received about 1500t/d of waste over the first year of operation, prior to leachate
treatment plant commissioning. During this period, substantial volumes of leachate were
generated, and were stored in secure lined holding ponds. Table 2 presents detailed analytical
data characterising the changes in the leachate chemistry in one such holding pond, Pond 3,
 Sardinia 2007, Eleventh International Waste Management and Landfill Symposium

during this period. It can be seen from Table 2 that initial (acetogenic) leachate changed in
composition during storage in the lagoon, in the tropical climate, and as development of
methanogenic conditions occurred within the body of leachate in the holding pond, a substantial
reduction in COD values occurred by anaerobic degradation. This is considered in more detail in
a separate paper.

Table 2: Results from the Bukit Tagar leachate treatment system, Kuala Lumpur, Malaysia
Source: Pond 3 Pond 3 Pond 3 Pond 3 RLBT TLBT Final
date: 15.3.06 29.3.06 12.4.06 12.12.06 12.3.07 12.3.07 Effluent
12.3.07
determinand
suspended solids 930 870 445 350 700 93 16
COD 33268 15900 9880 4636 4710 450 403
BOD20 22340 12406 7931 2609 1922 32 24
BOD5 17630 11360 6657 1834 1784 23 16
TOC 6804 3842 2159 540 958 194 60
fatty acids (as C) 3085 2127 1142 461 349 28 17
Kjeldahl-N 2021 1853 1729 1330 1904 16.1 13
ammoniacal-N 1923 1703 1456 1239 1634 3.2 0.9
nitrate-N* - - - - 27.4 1286 1336
nitrite-N 0.2 <0.1 <0.1 <0.1 <0.1 0.1 0.2
alkalinity (CaCO3) 8074 6700 6530 5515 9755 136 178
pH-value 5.4 5.52 8.04 8.5 8.3 7 6.8
chloride 1568 1790 1687 1615 27036 1889 1873
sulphate (SO4) 50 32 70 1 1 6 21
phosphate (as P) 40 11 8.2 8.8 12.8 4.4 6.2
conductivity (µS/cm) 22000 16200 15600 15660 23600 15340 15640
sodium 723 726 853 1175 1294 860 936
magnesium 150 132 113 126 155 132 142
potassium 827 752 1020 1055 1810 1450 1345
calcium 1038 302 537 73 51.5 61.4 65.8
chromium 0.56 0.09 0.08 0.07 0.05 <0.01 0.02
manganese 4.11 0.26 0.04 0.02 <0.01 <0.01 <0.01
iron 38.9 27.6 0.08 10.4 12.4 0.94 0.65
nickel 0.68 0.16 0.14 0.14 0.21 0.16 0.14
copper 0.14 0.02 0.01 <0.01 0.03 0.02 0.02
zinc 6.24 0.74 0.06 0.2 0.23 0.22 0.18
cadmium 0.04 <0.01 <0.01 0.03 0.05 0.07 0.06
lead 0.38 0.12 0.03 0.20 0.16 0.14 0.13
arsenic 0.09 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01
mercury 0.043 <0.001 0.005 <0.001 <0.001 <0.001 <0.001
Notes: • All results in mg/l except pH-value and conductivity (µS/cm)
• * nitrate results unreliable in raw leachates, presume <1
• SBR eff. = effluent from SBR lagoons
• Final = final effluent from reed beds, awaiting irrigation

Therefore, by the time the treatment plant was commissioned during April 2006, the leachate had
become methanogenic in nature. Figure 3 presents data for the changes in COD during the first
year of operation. The data demonstrate the rapid change from acetogenic to methanogenic
characteristics; they show impacts of flushing through more recently-formed leachate; but most
 Sardinia 2007, Eleventh International Waste Management and Landfill Symposium

importantly, they demonstrate consistent and reliable treatment, with final effluent COD values
of typically 300 - 500mg/L, in spite of variability in raw leachate COD values, as occasionally
more acetogenic leachates were treated. Figure 4 shows equivalent data for removal of
ammoniacal-N, concentrations of 1000 - 2000mg/l being routinely reduced to below 10mg/L in
the final effluent. Removal was primarily by complete conversion to nitrate-N (see Figure 5).
16000 5000

4500

SBR Effluent and Final Effluent COD value (mg/l)

14000

4000
12000 Raw Leachate SBR Effluent Final Effluent
Raw Leachate COD value (mg/l)

3500

10000
3000

8000 2500

2000
6000

1500
4000
1000

2000
500

0 0
6

7
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06

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l-0
n-

b-

n-
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ug
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pr

pr
ar

ar
ct
Ju
Ju

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Fe
Ja
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M
A

A
M

M
D
N
S
A

Figure 3. Removal of COD during passage through the leachate treatment plant
2000 50

SBR Effluent and Final Effluent NH4-N concentration (mg/l)

1800 Raw Leachate SBR Effluent Final Effluent
Raw Leachate NH4-N concentration (mg/l)

1600 40

1400

1200 30

1000

800 20

600

400 10

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0 0
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Figure 4. Removal of ammoniacal-N during passage through the leachate treatment plant
 Sardinia 2007, Eleventh International Waste Management and Landfill Symposium

2500

Raw Leachate NH4-N Final Effluent NO3-N Final Effluent NO2-N

Concentration - Nitrogen Species (mg/l)

2000

1500

1000

500

0
6

7
6

7
6

06

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-0
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A

Figure 5. Conversion of ammoniacal-N in leachate to nitrate-N in final effluent

Future Development Planning

During the first 12 months of treatment plant operation, over 300,000m3 of leachate was reliably
and consistently treated, leaving the leachate holding ponds available again to balance peak
flows of leachate, and also to provide some additional treatment of degradable COD by
encouraging development of methanogenic conditions. This is likely to be important as filling
progresses into Phase 1 of the main Landfill area. Initial high flow rates of acetogenic leachate
from the new tipping area will benefit considerably from flow balancing and storage within these
holding ponds, as was the case for leachates from the advance cell.
Now that the leachate treatment plant has demonstrated it is able to treat at design flow rates
and to specified standards, there are no immediate plans to extend it, but land is available if this
is required at a future date.

4. CONCLUSIONS

The Bukit Tagar Landfill is sited in Malaysia’s tropical climate, characterised by high annual
rainfall reasonably evenly throughout the year. At the preliminary design stage a paucity of local
or published leachatre generation data from sites with similar climates meant that initial
generation estimates were approximate. Initial estimates were based on conservative
assumptions, but still proved to be low due to the high proportion of leachate base flow
generated by the saturated nature of the incoming waste. In addition the site management
practices adopted for semi-aerobic landfill trials in the Advance Phase contributed significantly
to total leachate flows. Consequently individual rainfall events resulted in high leachate flows
over the days following major rain events.
An updated water balance model prepared in April 2006 and calibrated against site data from
the first year of operation, showed the significant influence of cover practices and baseflow on
leachate generation. This reassessment of leachate generation rates in the Advance Phase was
used as the basis for the next phase of the leachate management review aimed at addressing
longer term leachate management for the main Landfill development. The findings of this review
are presented in Eldridge et al (2007).
The high moisture content of the incoming waste stream at Bukit Tagar has a significant
 Sardinia 2007, Eleventh International Waste Management and Landfill Symposium

impact on the leachate generation. The resulting base flow ( 15 to 20 % of the mass of incoming
waste), is significantly higher than experienced even in Hong Kong (5 % to 10 % of the waste
mass) and is a major contributor to total flow (approximately 60% at Bukit Tagar on an annual
basis). The paper also provides calibrated estimates of infiltration for intermediate cover slopes
and confirms the critical nature of rigorous water exclusion measures in such a wet climate.
The chemical characteristics of leachates at Bukit Tagar have proven to be very close to those
predicted, and were used to design what is one of the largest leachate treatment plants in the
world. Extended storage of leachate in holding ponds in advance of leachate plant construction
has allowed strongly methanogenic conditions to become established, allowing increased
volumes of leachate to be treated by the plant.
The treatment plant provides biological treatment in four large aerated lagoons, operated as
SBRs, to achieve reduction in COD values, and essentially complete nitrification of very high
concentrations of ammoniacal-N. Biological effluent is treated by passage through a DAF plant,
with final polishing through extensive reed beds, followed by safe irrigation onto a large area of
palm oil plantation.
The plant has performed in close accordance with the design, now routinely treating up to
1000 cubic metres of leachate per day, to the standards it was designed to achieve. The plant is
operated automatically, by state-of-the-art software, which includes many fail-safe features, and
allows for remote interrogation of plant operation.

4. ACKNOWLEDGEMENTS

The Authors wish to thank KUB-Berjaya Enviro Sdn Bhd for permission to publish this paper
and for the supply of the data presented.

5. REFERENCES

Carville M S and Robinson H D (1991). Landfill leachate in Hong Kong: Characterisation and
treatment with special reference to ammonia removal. Paper presented to Polmet ‘91,
International Conference on Pollution in the Metropolitan and Urban Environment, Hong
Kong, 9 - 13 December 1991, 30 pp.
Eldridge J., Knox K., Chock E., Eldridge S., Richards B., Kortegast A. (2007) Leachate
management strategies at large tropical landfills: A case study Proceedings Sardinia 2007,
Eleventh International Waste Management and Landfill Symposium, S. Margherita di Pula,
Cagliari, Italy; 1 - 5 October 2007
Knox, K. (2002), Development of a Novel Process for Treatment of Leachate with Very High
Ammoniacal Nitrogen Concentrations.
Hydrological Data, Rainfall and Evaporation Records for Malaysia, (1986-1990), Drainage &
Irrigation Division, Ministry of Agriculture, Malaysia.
Robinson, H and Luo, M (1991). Characterisation and treatment of leahates from Hong Kong
landfill sites. Journal of the Institution of Water and Environmental Management, June 1991,
5, (6), pages 326-332.
Robinson, H (2007). The composition of leachates from very large landfills: An international
review. Communications in Waste and Resource Management, (UK CIWM Journal), June
2007, 8 (1), pages 19-32.
Qasim, Syed R & Chiang, Walter (1994), Sanitary Landfill Leachate, Techtomic Publishing.