ANNUAL ENVIRONMENTAL REPORT 2009 · Annual Environmental Report 2009 ... Not possible to sample GS2...

Annual Environmental Report 2009

ANNUAL ENVIRONMENTAL REPORT 2009 (Ref. IPPC Licence Register No. P0530-01)


ANNUAL ENVIRONMENTAL REPORT 2009 (Ref. IPPC Licence Register No. P0530-01)

Prepared By: A.McDonald, Operations Manager.

Date : 23rd March 2010.


Table of Contents

1.0 Introduction

2.0 Summary Information

2.1 Emissions to Atmosphere

2.2 Ambient Dust Deposition Monitoring

2.3 Emissions to Surface Waters

2.4 Waste Management

2.5 Resource Consumption

2.6 Noise Monitoring

2.7 Environmental Incidents and Complaints

2.8 Tank and Pipeline Testing and Inspection

2.9 Review of Residuals Management & Quarry Restoration Plan

3.0 Management of the Activity

3.1 Schedule of Environmental Objectives and Targets

- Environmental Management Programme Proposal 2010

- Environmental Management Programme Report 2009

3.2 Pollution Emission Register Proposal 2010

3.3 Pollution Emission Register Report 2009

4.0 Licence-Specific Reports

None.

APPENDICES 1 - 5


1.0 Introduction

Licence Register No.: P0530-01

Company Name: Ormonde Brick Limited.

Location: Ardra, Castlecomer, Co.Kilkenny.

Description of Activity: Manufacture of fired-clay facing bricks from locally occuring shale

and fireclay extracted mainly from quarries at Coolbawn and Gurteen,

Castlecomer, Co.Kilkenny. The shale is crushed in a jaw crusher, the

shale / fireclay is ground in a dry pan-mill, screened and mixed with

water to provide wet clay for shaping. The wet clay is extruded and

wire-cut to the required size and shape. The wet brick is dried in chamber

driers by utilising hot air from the kiln roof and kiln cooling zone.

After drying, the product is automatically set on refractory kiln cars for

firing to approximately 1000oC in a tunnel kiln.

Finally, the fired product is sorted and packed automatically by machine

or by hand into packs bound with steel or plastic strapping and covered

with plastic packaging.

Environmental Policy: A copy of the company Environmental Policy is shown in Appendix 1.

The company Environmental Management System is approved to

ISO 14001 by C.I.C.S.Ltd.

Organisation: The Operations Manager is the Person in Charge in relation to contacts

with the Agency concerning the IPPC Licence and Environmental issues.

The Operations Manager also has the role of Quarry Manager and is

responsible for environmental issues relating to the quarries located

locally at Coolbawn & Gurteen.


2.1 EMISSIONS TO ATMOSPHERE

2.1.1 General

There was no production in the Works during 2009. Kiln no. 2 was shut down at end of December

2008 and was not re-commissioned during 2009.

2.1.2 Summary of Monitoring during 2009

There was no emission monitoring carried out during 2009 as the Kiln and Works operations were

shut down for the entire period.

2.1.3 Summary of Mass Emissions during 2009

As stated above, the Kiln did not run during 2009 and hence there were no mass emissions

to report for the year.

2.1.4 Continuous HF Monitor

There were no continuous HF Monitor readings during 2009 as the Kiln was out of commission.

2.1.5 Herbage Analysis

At the request of the Agency, a programme of grass sampling for fluorides commenced in April

2005. The results of Herbage Analysis for 2009 are shown in Table 1 below. Sampling was carried

out in April only. Herbage sampling has ceased, by agreement with the Agency, due to the Kiln and

Productiuon operations being out of commission. (A new site will have to be located before sampling

resumes as the current site will not be made available to the Company).

The tolerance level identified for domesticated animals is 30 mgF/kg of herbage.

Location Date of Sampling

06-Apr 30-May 27-Jun 23-Jul 01-Sep 03-Oct 29-Oct Average

GS1 4.0 --- --- --- --- --- --- 4.0

GS2 --- --- --- --- --- --- --- ---

GS3 3.2 --- --- --- --- --- --- 3.2

GS4 2.7 --- --- --- --- --- --- 2.7

Notes: (i) Sampling carried out during the growing season from April to October.

(ii) Not possible to sample GS2 due to poor growth and bad ground conditions.

Table 1 : Herbage Analysis for Fluorides


2.1.6 Agency Monitoring and Enforcement 2009

During 2009, there was no monitoring of emissions to atmosphere carried out by the Agency.

2.2 AMBIENT DUST DEPOSITION MONITORING

2.2.1 Dust monitoring is normally required to be carried out during the months of May to September.

However, due to the shutdown of both Factory and Quarry operations it was agreed with the Agency

that there was no requirement to carry out dust monitoring during 2009.

2.3 EMISSIONS TO SURFACE WATERS

2.3.1 Surface water and groundwater are discharged from the site at ref. point SW3F. The main discharge

is from groundwater springs at the rear of the facility, roof run-off, yard run-off including storm

events and run-off from adjoining forestry lands.

2.3.2 The results of sampling and analysis by BHP Laboratories for monitoring as required for 2009 are

shown in Table 2 below. The monthly records for the daily Visual Inspections for 2009 are shown in

Appendix 2.

Parameter Units Month

Average Jan Feb Mar Apr May Jun Jul Aug Sept Oct Nov Dec

B.O.D. mg/l 3 1 1 7 3 4 11 6 3 7 12 5 5

Conductivity µS/cm @ 20oC 433 611 433 355 514 475 322 279 501 267 285 443 410

Ammonia mg/l NH4 0.04 0.01 0.01 0.09 0.01 0.01 0.01 0.02 0.01 0.01 0.01 0.01 <0.02

Nitrite mg/l NO2 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05

Nitrate mg/l NO3 0.1 5.05 5.48 5.35 11.2 7.8 2.4 5.12 7.6 3.8 11.1 4.7 5.81

pH pH units 8.15 7.90 7.61 8.02 8.16 8.11 7.54 7.22 6.56 6.56 7.13 7.72 7.56

Suspended

Solids mg/l 1 4 2.8 20.4 1 1 13 6 1 23 56 3 11.0

Table 2 : Summary Table for Surface Water Discharge Monitoring

Notes: (i) In our IPPC Licence, there are no Emission Limit Values in Schedule 3(i) Surface

Water Discharge Monitoring.

(ii) Overall, the water quality at SW3F has remained consistent in comparison to the

previous year 2008.

(iii) There is no volumetric measure on the discharge at SW3F and therefore no summary

for Mass Emissions can be provided.


2.4 WASTE MANAGEMENT

2.4.1 The summary for Non-Hazardous Waste is shown in Table 11.1 and the summary for Hazardous Waste is shown in Table 11.2. and further

monthly

waste analysis is shown in Tables 11.3 (a) & 11.3 (b). The Waste Contractors and Permit / Register Numbers employed are shown in Table 11.4.

Table 11.1 : Summary Table for Non-Hazardous Waste

Information on each waste stream EWC Code as per

2001/118/EC

HAZ

Yes/No

Description of

Waste

Quantity (tonnes/annum)

Method of

Disposal/Recovery

Location of

Disposal/Recovery

Name of Waste Disposal

/Recovery Contractor

1 0 1 2 0 1 No Green Brick 0 Returned to process

where possible (D1)

Used in restoration of

quarry.

Wholesale Suppliers Ltd.

1 0 1 2 0 8 No Waste fired brick 0 Construction fill (R0) n/a

2 0 0 3 0 1 No Domestic &

Canteen Waste

7.64 Landfill (D1) Kilkenny County

Council.

Greenstar Noble

1 6 0 1 0 3 No Tyres 0 Re-cycled (R3) Crumb Rubber Ltd,

Dundalk.

Kieran Mooney Haulage

2 0 0 1 3 8 No Wood (Broken

Pallets)

0 Re-cycled (R3) Erwin Cobbe,

Portarlington.

Greenstar Noble

2 0 0 1 4 0 No Waste metal 4.69 Re-cycled (R4) ACB, Spain. A1 Metal Recycling

1 5 0 1 0 1 No Paper & Cardboard 5.42 Re-cycled (R3) Kilkenny County

Council.

Greenstar Noble

1 5 0 1 0 2 No Plastic Wrap 3.72 Re-cycled (R5) Eurokey Recycling,

UK.

Greenstar Noble

2 0 0 3 0 4 No Sludge from Septic

Tank

0 Pumped into sewage

treatment plant (D8)

Purcellsinch Water

Treatment Works,

Kilkenny

Quick Sharp Ltd.

1

7 0 1 0 7 No Construction &

Demolition Waste

0 Landfill (D1) Kilkenny County

Council.

Greenstar Noble


Information on each waste stream EWC Code as per

2001/118/EC

HAZ Yes/No

Description of

Waste

Quantity

Method of

Disposal/Recovery

Location of

Disposal/Recovery

Name of Waste Disposal /

Recovery Contractor

1 4 0 6 0 3* Yes Degreasing

Solvents

0 litres Re-cycled (R2) Safety Kleen Ltd.

Sheffield, England.

Safety Kleen Ireland Ltd.

1 5 0 1 1 0 Yes Pigment Bags 0 Landfill (D1) KTK Landfill, Shannon. Enva

2 0 0 1 2 1* Yes Fluorescent Tubes 0 kg Recycled (R4/R5) (i) Glass – Quinn Glass, IRL.

(ii) Mercury Contaminated

Filters & Sludge

- Claushuis Metaals, NL.

(iii) Aluminium End Caps

- A1 Metal Recycling.

Irish Lamp Recycling.

1 6 0 6 0 4 Yes Primary Batteries 0 Re-cycled (R4/R5) (i) Acid neutralised

(ii) Lead & Plastic exported

to smelting plant for re-use.

Returnbatt Ltd.

1 6 0 2 0 9* Yes Capacitors &

Transformers

0 PCB Disposal

Contractor (D10)

R.F. Winder Electrical Ltd. R.F. Winder Electrical Ltd.

1 3 0 8 9 9* Yes Waste Oils 2,000 litres Re-cycled (R8) Enva, Portlaoise, Co.Laois. Enva

1 6 0 1 0 7* Yes Oil Filters 0 Re-cycled (R3) Hegarty Metal Recycling,

Limerick

Enva

1 3 0 8 9 9* Yes Solid Oily Waste 250 kg Re-cycled (R1) Solid oily extract exported

to Germany for re-cycling.

Enva

1 3 0 7 0 1* Yes Contaminated

Water

0 Re-cycled (R9) Enva, Portlaoise, Co.Laois. Enva

1

7 0 6 0 5* Yes Construction Waste

containing Asbestos

0 Landfill (D1) Germany BIS Willich Industrial

Services Ltd

Notes:

(1) Engine, hydraulic and gear waste oils were mixed in the same waste oil storage container.

(2) Contaminated water was water which was contaminated with diesel oil within a bund, hence the EWC number is for diesel oil.

Table 11.2 : Summary Table for Hazardous Waste


Month Degreasing

Solvents

Litres

Pigment

Bags

No.

Fluorescent

Tubes

Kg

Primary

Batteries

Litres

Capacitors &

Transformers

No.

Waste

Oils

Litres

Solid

Oily

Waste

Kg

Oil

Filters

Litres

Construction

& Demolition

Waste

Tonnes

Construction

Waste

Containing

Asbestos

Tonnes

Tyres

Tonnes

Waste

Metal

Tonnes

Jan 0 0 0 0 0 0 0 0 0 0 0 4.69

Feb 0 0 0 0 0 0 0 0 0 0 0 0

Mar 0 0 0 0 0 0 0 0 0 0 0 0

Apr 0 0 0 0 0 0 0 0 0 0 0 0

May 0 0 0 0 0 0 0 0 0 0 0 0

June 0 0 0 0 0 0 0 0 0 0 0 0

July 0 0 0 0 0 0 0 0 0 0 0 0

Aug 0 0 0 0 0 0 0 0 0 0 0 0

Sep 0 0 0 0 0 0 0 0 0 0 0 0

Oct 0 0 0 0 0 0 0 0 0 0 0 0

Nov 0 0 0 0 0 0 0 0 0 0 0 0

Dec 0 0 0 0 0 2,000 250 0 0 0 0 0

Total 0 0 0 0 0 2,000 250 0 0 0 0 4.69

Table 11.3 (a) : Summary Table for Waste Analysis


Month Sludge from

Sediment

Trap

@ SW3F

Tonnes

Sludge from

Septic Tanks

Tonnes

Green Brick

Tonnes

Waste Fired

Brick

Tonnes

Domestic &

Canteen

Waste

Tonnes

Timber

(Broken

Pallets)

Tonnes

Cardboard

& Paper

Tonnes

Plastic Wrap

Tonnes

Contaminated

Water

Litres

Jan 0 0 0 0 0 0 0.06 0 0

Feb 0 0 0 0 0 0 0.06 0 0

Mar 0 0 0 0 0 0 0.06 0 0

Apr 0 0 0 0 0 0 0.06 0 0

May 0 0 0 0 3.98 0 0.06 0 0

June 0 0 0 0 0 0 0.06 0 0

July 0 0 48 0 0 0 0.62 3.72 0

Aug 0 0 36 0 0 0 0.06 0 0

Sept 0 0 48 0 3.66 0 0 0 0

Oct 0 0 60 0 0 0 0.06 0 0

Nov 0 0 72 0 0 0 0 0 0

Dec 0 0 24 0 0 0 0 0 0

Total 0 0 288 0 7.64 0 1.1 3.72 0

Table 11.3 (b) : Summary Table for Waste Analysis


Table 11.4 : Summary Table for Waste Contractors and Permit / Register Numbers

Waste Contractor / Broker Permit / Register Number Issuing Authority

Greenstar WCP/KK/053/02 Kilkenny County Council

A1 Metal Recycling WMP 007 Kilkenny County Council

Quick Sharp Ltd. WCP/KK/126(A)/05 Kilkenny County Council

Safety Kleen Ltd. W0099-01 Environmental Protection Agency

Security in Shredding WCP/KK/225/04 Kilkenny County Council

Irish Lamp Recycling WCP/KK/030(A)/05 Kilkenny County Council

Returnbatt Ltd. WCP/KK/001/02 Kilkenny County Council

Enva WCP/KK/059(A)/07 Kilkenny County Council

Wholesale Suppliers Ltd. WCP/KK/122/02 Kilkenny County Council

Irish Environmental Services Transit Station Licence no. 40/1 Environmental Protection Agency

RILTA Environmental Transit Station Licence no.192/2 Environmental Protection Agency

KTK Landfill Ltd. W0081-03 Environmental Protection Agency

Crumb Rubber Ireland Ltd. WCP/KK/143(A)/07 Kilkenny County Council

Kieran Mooney Haulage Ltd. WCP/KK/386/07

WCP/OY/525/07

Kilkenny County Council

Offaly County Council


2.5 RESOURCE CONSUMPTION

2.5.1 Energy Consumption

The energy consumption figures for 2009 are shown in Table 3 below.

Energy Type Consumption Converted to MWhr

Natural Gas 0 kWhr 0

LPG (Propane) 7,540 litres 56

Diesel Oil (for Mobile Plant) 2,000 litres 24

Gas Oil (for Kiln firing) 0 litres 0

Electricity 190,000 kWhr 190

Table 3 : Summary Table for Energy Consumption

2.5.2 Water Consumption

The water consumption figures for 2009 are shown in Table 4 below.

The utilisation of on-site ground water was 0% in 2009 (in comparison to 18% for 2008).

Source Consumption (m3)

On-site Ground Water 0

Municipal Supply 5,644

Table 4 : Summary Table for Water Consumption


2.6 NOISE MONITORING

The Annual Noise Survey was not completed in 2009 as both the Factory and Quarry operations

were closed down for the year.

2.7 ENVIRONMENTAL INCIDENTS AND COMPLAINTS

2.7.1 Environmental Incidents

There were no environmental incidents in 2009.

2.7.2 Environmental Complaints

There were no environmental complaints received during 2009.

2.8 TANK AND PIPELINE TESTING AND INSPECTION

2.8.1 Tank and Pipeline Testing and Inspection

A leak test was completed in August 2005 on the main LPG line from the storage tanks. A

further leak test had been scheduled for 2009 – was completed in Feb 2010.

2.8.2 Inspection of Overground Flanges and Valves

Due to the Factory shutdown since December 2008 the frequency of inspections has been reviewed

on the over ground flanges and valves at the Diesel Tank supplying mobile plant, Generator, Clay

Conditioner line, Slop Manganese line, Tank Farm at rear of Factory and the LPG line. These

installations are now inspected on a monthly basis.

Sample reports for Week 28/2008 & 43/2008 are included in Appendix 3 and no problems were

recorded during 2009.


2.9 REVIEW OF RESIDUALS MANAGEMENT & QUARRY RESTORATION PLAN

2.9.1 The Residuals Management & Quarry Restoration Plan as required by Condition 12 of our IPC Licence

was completed in March 2002 and submitted as part of the 2001 AER.

2.9.2 The following is a review of progress in 2009 in the reinstatement of worked out quarry areas:

Quarry Ref.P.811/89, Coolbawn

Considerable progress was achieved on the Top-soil reinstatement of Phase 1. Work was also carried

out on the sloping of Shale faces in Phase 2 .

Quarry Ref. P.312/88, Gurteen

Work was carried out on creating a drainage sump using rejected fired bricks. Earth-moving work was

also carried out in progressing Sub-soil and Top-soil reinstatement on site.


3.0 MANAGEMENT OF THE ACTIVITY

3.1 Schedule of Environmental Objectives and Targets

The Environmental Management Programme - Proposal 2010 and the Environmental Management

Programme - Report 2009 are shown on the following pages.


Emissions to Atmosphere (1)

Operation Emission Target Objective Target

Date

Responsible

Person

Comments

Emissions from

Kiln stack

AS2-1BF

10 mg/Nm3

(AS2-1BF)

Minimise

Hydrogen Fluoride

emissions from

Kiln No.2 to

< 10 mg/Nm3

Continue with the Process Abatement

Project.

Ongoing

A.McDonald

In the event of the Kiln being

re-commissioned, proposals similar to

those outlined in Proposal 2009 will be

actioned,namely,

- Further increase of CaCo3

addition to clay mixes

- further increase of

perforation size

- further improvement of Kiln

seals

Document Approved By:

Ormonde Brick Limited

Ardra, Castlecomer,

Co.Kilkenny.

Revision: 0

Page: 1 of 11

Issued: 20.03.10 Operations Manager

Title:

Environmental Management Programme – Proposal 2010




Ardra, Castlecomer,

Co.Kilkenny.

Revision: 0

Page: 2 of 11

Issued: 20.03.10

Operations Manager

Title:




Date

Responsible

Person

Comments

Emissions from

Kiln stack AS2-

1BF

10 mg/Nm3

(AS2-1BF)

Ensure ground level

concentration of

Fluorides < 30mg/kg.

Continue with Monthly ‘Herbage

Sampling’ programme during the

growing season from April –

October.

Ongoing

A.McDonald

Resume herbage sampling to verify

ground level concentrations from HF

emissions

Fugitive Dust

Emissions

Not

determined

Reduction in fugitive

dust emissions from

Factory and Quarry

sites.

Continue with 2 weekly visits by

contractor Yard Sweeper / Washer

and more frequently if necessary

Ongoing

A.McDonald

Resume increased frequency of Yard

Sweeping activities to control fugitive

dust emissions.

Emissions from

Dust Filters

-

Ensure that dust

emissions are

controlled.

Carry out Annual Supplier

Inspections of dust filters DF1, DF2

& DF5.

Ongoing

A.McDonald

Resume Supplier Inspections & Audits

to compliment in-house maintenance

checks.




Ardra, Castlecomer,

Co.Kilkenny.

Revision: 0

Page: 3 of 11


Title:




Date

Responsible

Person

Comments

All

Atmospheric

Emissions

Not

determined

Ensure that air

emissions/odour do

not impair

significantly the

amenity value of the

environment beyond

the site boundary.

Continue with daily visual and

olfactory checks of impact of

emissions on amenities adjacent to

the site boundary as part of EMS..

Ongoing

A.McDonald

To ensure there is no impact on

local air quality due to emissions

from the facility.

Compliance

Monitoring

-

Continue Monitoring

Schedule as per

Condition 5.2 of the

IPC licence # 530.

Provision of satisfactory system of

measurement and monitoring of

emissions to ensure compliance in

accordance with schedule 1 (ii)

Monitoring of Emissions to the

atmosphere.

Ongoing

A.McDonald

To provide regular monitoring of

emissions to atmosphere.




Ardra, Castlecomer,

Co.Kilkenny.

Revision: 0

Page: 4 of 11


Title:


Emissions to Surface Waters


Date

Responsible

Person

Comments

Surface water

Discharge of

Hazardous Materials

Loading and unloading

of

Hazardous Materials

Compliance

Monitoring

Not

determined

Not

Determined

-

The assurance that no

potentially polluting

substance discharges

from the site into the

receiving surface

water medium.

Minimise the risk of

Accidental discharges

of hazardous

materials to surface

waters

Continue Monitoring

Schedule as per

condition 8.1.2 of the

IPPC Licence # 530

Fortnightly inspections, cleaning

and preventative maintenance as

required of the sediment trap to be

recorded as part of site EMS.

Clean out Sediment Trap at SW3F

Arrange staff training in the general

awareness of the dangers in the

handling of hazardous materials and

the procedure to be followed in the

event of a spillage occuring.


measurement/monitoring of

emissions to ensure compliance with

Schedule 3(i)

Ongoing

Ongoing

Ongoing

A.McDonald

A.McDonald

A.McDonald


Emissions to Ground Waters (1)


Date

Responsible

Person

Comments

Chemical Storage

on-site

Incidental

To protect

ground/surface waters

in the event of a

spillage from the

storage of hazardous

materials stored on-

site

(i) Monthly inspection of all bunds

to ensure that any leaks or spills

are detected.

(ii) Strictly operate the procedure

for the emptying of bunds in

an environmentally responsible

manner.

Ongoing

Ongoing

A.McDonald

A.McDonald

To provide for the protection of

groundwater / surface water in the

event of a spillage from the

chemical storage area.

Piping of chemicals

on-site

Incidental

To protect

ground/surface waters

in the event of a

spillage from the

piping of chemicals

on-site.

Fortnightly inspection and log of all

over-ground pipes and flanges

carrying materials other than water.

Carry out leak test on LPG line

Feb 2010

A.McDonald

A.McDonald

Inspections carried out on a less

frequent basis as plant was not in

operation.



Ardra, Castlecomer,

Co.Kilkenny.

Revision: 0

Page: 5 of 11


Title:





Ardra, Castlecomer,

Co.Kilkenny.

Revision: 0

Page: 6 of 11


Title:


Emissions to Groundwaters (2)


Date

Responsible

Person

Comments

Foul water emissions

2.85 kg/day

BOD

To protect the

subsurface and

underlying

groundwater

from sewage

contamination.

Carry out 6-monthly checks on the

LRD50 Treatment System.

Ongoing

A.McDonald

Maintenance contract in place

with Enviropak Ltd for 6 monthly

checks on the performance of the

system.

Brick Cutting

Operation

Not

determined

To protect the

subsurface and

underlying

groundwater from

wastewater discharges

generated at the Brick

Cutting Operation.

Control and maintenance of the

sedimentation tanks as part of the

site EMS.

Omgoing

A.McDonald

The system installed eliminates

discharges of dirty cutting-saw

water to ground.




Ardra, Castlecomer,

Co.Kilkenny.

Revision: 0

Page: 7 of 11


Title:


Emissions as Noise


Date

Responsible

Person

Comments

Annual Noise Survey

-

To survey the noise

generated on-site

(i) Submit notification to the

Agency confirming that Noise

Survey will be completed in

accordance with the

Environmental Noise Survey

Guidance Document.

(ii) Carry out Noise Survey at

Factory and Quarry Sites.

Sep 2010

Oct 2010

A.McDonald

A.McDonald

Assuming normal operations have

resumed at the Quarries and Factory;

To assess the impact of noise on the

surrounding environment.




Ardra, Castlecomer,

Co.Kilkenny.

Revision: 0

Page: 8 of 11


Title:


Utilities and Energy Consumption


Date

Responsible

Person

Comments

Water Usage

Plant Wide

As

wastewater

Mininmise water

wastage plant wide.

(i) Continue with monthly reading

of water meter on supply from

site well.

(ii) Identify, implement appropriate

water conservation measures.

Ongoing

Ongoing

A.McDonald

A.McDonald

Assuming normal operations resume at

the Factory;

To assess water volumes used from

site well which is supplied from

groundwater springs.

Power Consumption

Plant Wide

Not

Applicable

Minimise energy

wastage plant wide.

Continue with implementation of

energy conservation programme by

ensuring that all electrical

equipment is fitted with control

devices (e.g. Thermostats,

lights, occupancy sensors etc.) to

minimise power consumption.

Omgoing

A.McDonald


Emissions as Solid / Hazardous Waste (1)


Date

Responsible

Person

Comments

All wastes generated on-

site

To be

accurately

determined

Develop and

implement a waste

management strategy

for the site.

(i) Log and control all waste

generated on-site, the final

destination of this waste, the

method of treatment and

details of the contracted party.

(ii) Ongoing training of staff on the

types of waste generated on-

site.

Ongoing

Ongoing

A.McDonald

A.McDonald

Volume and number of distinct waste

streams will be directly related to the

level of operations at the Factory;

To provide control and tracking of all

waste generated on site.

Training of staff is ongoing.



Ardra, Castlecomer,

Co.Kilkenny.

Revision: 0

Page: 9 of 11


Title:





Ardra, Castlecomer,

Co.Kilkenny.

Revision: 0

Page: 10 of 11


Title:



Operation Emission Target Objective

Target

Date

Responsible

Person

Comments

Hazardous Waste

Generation

Not

determined

Reduction in quantity

of fluorescent tubes

for disposal.

Installation of longer life lighting.

Ongoing

A.McDonald

Routine replacement of fluorescent

tube lighting with halogen bulb

lighting.

General Packaging

Waste

To be

quantified

accurately

To reduce the quantity

of packaging waste

generated on-site.

(i) Report on progress in achieving

reduction in quantities of refuse

and minimisation of waste

plastic, steel strapping,

cardboard and timber pallets

sent for recycling.

(ii) Provide ongoing training of

staff in procedure relating to

waste management.

Dec 2010

A.McDonald

A.McDonald

To target reductions in quantity of

waste generated in the Works.




Ardra, Castlecomer,

Co.Kilkenny.

Revision: 0

Page: 11 of 11


Title:


Residuals Management & Quarry Site Restoration


Target

Date

Responsible

Person

Comments

Reinstatement of Quarry

Sites

-

To restore worked out

quarry areas.

Complete top-soil in Phase 1 of

Quarry ref. P811/89, Coolbaun.

Aug 2010

A.McDonald

To ensure that worked out areas of

the quarry are reinstated as asoon as

practicable.




Ardra, Castlecomer,

Co.Kilkenny.

Revision: 0

Page: 1 of 10


Title:

Environmental Management Programme – Report 2009


Operation Emission Target Objective Responsible

Person

Comments

Emissions from

Kiln stack

AS2-1BF

10 mg/Nm3

(AS2-1BF)

Minimise Hydrogen

Fluoride emissions

from Kiln No.2 to

< 10 mg/Nm3

Continue with the Process Abatement Project.

E.Power

Due to significant reduction in demand

for brick products Kiln 2 was shut

down in Dec 2008 and was not re-lit

during 2009. The Agency was advised

of closure in Dec 2008 and of decision

not to re-commission during 2009.

Emissions from

Kiln stack AS2-

1BF

10 mg/Nm3

(AS2-1BF)

Ensure ground level

concentration of

Fluorides <

30mg/kg.

Continue with Monthly ‘Herbage Sampling’

programme during the growing season from

April – October.

E.Power

Herbage was sampled in April 2010

and was compliant. No further

sampling carried out

- No factory emissions

- Land owner has asked Company

to stop monitoring on current site

Fugitive Dust

Emissions

Not

determined

Reduction in

fugitive dust

emissions from

Factory and Quarry

sites.

Continue with 2 weekly visits by contractor

Yard Sweeper / Washer and more frequently if

necessary

E.Power

Requirements reviewed due to Quarry

and Works operations shutdown. Yard

sweeper available as required.




Ardra, Castlecomer,

Co.Kilkenny.

Revision: 0

Page: 2 of 10

Issued: 20.03.10

Operations Manager

Title:




Person

Comments

Emissions from

Dust Filters

-

Ensure that dust

emissions are

controlled.

Carry out Annual Supplier Inspections of dust

filters DF1, DF2 & DF5.

E.Power

Supplier Inspections & Audits on hold

pending resumption of Works operation

All Atmospheric

Emissions

Not

determined

Ensure that air

emissions/odour do

not impair

significantly the

amenity value of the

environment

beyond the site

boundary.

Continue with daily visual and olfactory checks

of impact of emissions on amenities adjacent to

the site boundary as part of EMS.

E.Power

Daily checks on hold pending

resumption of Kiln operation.

Compliance

Monitoring

-

Continue

Monitoring

Schedule as per

Condition 5.2 of the

IPC licence # 530.


measurement and monitoring of emissions to

ensure compliance in accordance with schedule

1 (ii) Monitoring of Emissions to the

atmosphere.

E.Power

Monitoring schedule on hold pending

resumption of Kiln operation.


Emissions to Surface Waters


Person

Comments

Surface water

Discharge of

Hazardous

Materials

Not

Determined

The assurance that

no potentially

polluting substance

discharges from the

site into the

receiving surface

water medium.

Fortnightly inspections, cleaning and

preventative maintenance as required of the

sediment trap to be recorded as part of site

EMS.

Clean out Sediment Trap at SW3F

E.Power /

A.McDonald


frequent basis. No issues raised.

Not completed. Extend to July 2010.

Loading and

unloading of

Hazardous

Materials

Not

determined

Minimise the risk

of accidental

discharges of

hazardous materials

to surface waters.

Continue staff training in the general

awareness of the dangers in the handling of

hazardous materials and the procedure to be

followed in the event of a spillage occuring.

E.Power /

A.McDonald

Yard staff and supplier are well briefed

re occasional delivery of Diesel.

Compliance

Monitoring

-

Continue

Monitoring

Schedule as per

Condition 8.1.2 of

the IPC licence #

530.

Provision of a satisfactory system of

measurement and monitoring of emissions to

ensure compliance, in accordance with

Schedule 3(i) Surface Water Discharge

Monitoring.

E.Power /

A.McDonald

Inspections completed as required and

monthly analyses carried out.



Ardra, Castlecomer,

Co.Kilkenny.

Revision: 0

Page: 3 of 10


Title:





Ardra, Castlecomer,

Co.Kilkenny.

Revision: 0

Page: 4 of 10


Title:




Person

Comments

Chemical Storage on-site

Incidental

To protect ground /

surface waters in

the event of a

spillage from the

storage of

hazardous materials

stored on-site

(i) Monthly inspection of all bunds

to ensure that any leaks or spills

are detected.

(ii) Strictly operate the procedure

for the emptying of bunds in

an environmentally responsible

manner.

E.Power /

A.McDonald

Inspections completed on a less


operation.

Procedure strictly enforced.

Bund Integrity test carried out on

Slop Mangalox / Clay Conditioner

Bund Area

Diesel Tank Bund - Bulk of

remaining contents in Gas Oil Tanks

removed.

Piping of chemicals on-site

Incidental

To protect ground /

surface waters in

the event of a

spillage from the

piping of chemicals

on-site.

Fortnightly inspection and log of all over-

ground pipes and flanges carrying materials

other than water.

Carry out leak test on LPG line

E.Power /

A.McDonald



operation.

Pressure test delayed due to lack of

availabilty of experienced Engineer .

(Test completed early 2010 )




Ardra, Castlecomer,

Co.Kilkenny.

Revision: 0

Page: 5 of 10


Title:




Person

Comments

Foul water

emissions

2.85 kg/day

BOD

To protect the

subsurface and

underlying

groundwater

from sewage

contamination.

Carry out 6-monthly checks on the LRD50

Treatment System.

E.Power /

A.McDonald

Integrity test carried out on 3 no.

Enviropak Tanks to ensure no leakage.

Brick Cutting

Operation

Not

determined

To protect the

subsurface and

underlying

groundwater from

wastewater

discharges

generated at the

Brick Cutting

Operation.

Control and maintenance of the

sedimentation tanks as part of the

site EMS.

E.Power /

A.McDonald

No maintenance required during 2009

due to minimal activity.




Ardra, Castlecomer,

Co.Kilkenny.

Revision: 0

Page: 6 of 10


Title:


Emissions as Noise


Person

Comments

Annual Noise

Survey

-

To survey the noise

generated on-site

(i) Submit notification to the Agency

confirming that Noise Survey will

be completed in accordance with the

Environmental Noise Survey

Guidance Document.

(ii) Carry out Noise Survey at Factory

and Quarry Sites.

E.Power /

A.McDonald

E.Power /

A.McDonald

Annual Noise Survey not carried out, in

agreement with the Agency, as both

Quarry and Factory were not in

operation at any time during the year.

All Activities

Not

Determined

Reduce the noise

generated from high

noise site activities

Continue with Noise Abatement

Programme.

E.Power / A.McDonald

Programme on hold pending

re-commissioning of Factory

operation.




Ardra, Castlecomer,

Co.Kilkenny.

Revision: 0

Page: 7 of 10


Title:


Utilities and Energy Consumption


Person

Comments

Water Usage

Plant Wide

As

wastewater

Mininmise water

wastage plant

wide.

(i) Continue with monthly reading

of

water meter on supply from

site well.

(ii) Identify and implement

appropriate

water conservation measures.

E.Power /

A.McDonald

No water taken from site well for process during 2009.

Conservation programme on hold pending re-commissioning

of Factory operation

Power

Consumption

Plant Wide

Not

Applicable

Minimise energy

wastage plant

wide.

Continue with implementation of

energy conservation programme

by ensuring that all electrical

equipment is fitted with control

devices (e.g. Thermostats,

lights, occupancy sensors etc.) to

minimise power consumption.

E.Power /

A.McDonald

Energy conservation initiatives carried out in office area

Factory based initiatives on energy conservation on-hold

pending re-commissioning.




Ardra, Castlecomer,

Co.Kilkenny.

Revision: 0

Page: 8 of 10


Title:




Person

Comments

All wastes

generated

on-site

To be

accurately

determined

Develop and

implement a waste

management

strategy for the site.

(i) Log and control all waste

generated on-site, the final

destination of this waste, the

method of treatment and

details of the contracted party.

(ii) Ongoing training of staff on

the types of waste generated

on-site.

E.Power /

A.McDonald

E.Power /

A.McDonald

All waste streams identified – only packaging and domestic

waste applied during 2009.

Yard and office staff are well briefed on correct handling of

applicable waste streams.




Ardra, Castlecomer,

Co.Kilkenny.

Revision: 0

Page: 9 of 10


Title:




Person

Comments

Hazardous

Waste

Generation

Not

determined

Reduction in

quantity of

fluorescent tubes

for disposal.

Installation of longer life lighting.

E.Power /

A.McDonald

Routine replacement of fluorescent tube lighting with

halogen bulb lighting.

General

Packaging

Waste

To be

quantified

accurately

To reduce the

quantity of

packaging waste

generated on-site.

(i) Report on progress in

achieving reduction in

quantities of refuse and

minimisation of waste plastic,

steel strapping, cardboard &

timber pallets sent for

recycling.

(ii) Provide ongoing training of

staff in procedure relating to

waste management.

E.Power /

A.McDonald

E.Power/

A.McDonald

Low level of operations – low volumes of packaging waste

produced.




Ardra, Castlecomer,

Co.Kilkenny.

Revision: 0

Page: 10 of 10


Title:


Residuals Management & Quarry Site Restoration


Responsible

Person

Comments

Reinstatement

of Quarry

Sites

-

To restore worked

out quarry areas.

Reinstate top-soil in Phase 1 of

Quarry ref. P811/89, Coolbaun.

E.Power /

A.McDonald

Reinstatement of top-soil in Phase 1 is now well advanced.

Grading of excavation slopes carried out on phase 2.


3.2 Pollution Emission Register Proposal 2010

It is proposed , when the Kiln and Production Operations are re-commissioned, to continue with the existing PER for the monitoring of Hydrogen

Fluoride and Hydrogen Chloride emissions on the following basis:-

- Hydrogen Fluoride (HF) is a significant pollutant being emitted in the kiln exhaust gases.

The Company has expended significant resources in order to accurately quantify the amount of this emission. A continuous HF monitor is in place

since March 2004 and HF profiles are being logged for all the clay mix types and firing conditions. The Company is committed to the reduction of

HF by process abatement techniques in accordance with GG166 in order to comply with the ELV of 10mg/m3 which applied from January 2006.

Project work was completed on the kiln in July 2005, based on the Lingl proposal for exhaust gas recirculation, which has succeeded in further

reducing HF concentration levels in emissions. In conjunction with this strategy, body additive trials using finely ground calcium carbonate were

completed and all clay mixes now contain calcium carbonate since 1st April 2006. Based on emission results, adjustments are made to the calcium

carbonate addition rates to clay mixes as required. Sampling and analysis for Fluorine in the input raw materials and the finished fired-bricks has

also been completed.

- Hydrogen Chloride (HCl) which is also emitted in the kiln exhaust gases, is mainly derived from the use of Clay Conditioner (contains approx.

5% Barium Chloride) which is used in all products and PDV Salt (Sodium Chloride) which is used on the surface of some products for

appearance purposes. There is ongoing assessment of the usage rate of Clay Conditioner and there has been a reduction in the volume of PDV Salt

consumed per unit of production and product development work is on-going in order to reduce the use of PDV Salt, which can also lead to rejects

due to fluxing in the kiln.

3.3 Pollution Emission Register Report 2009

The Pollution Emission Register for 2009 is shown overleaf.

The following are some explanatory notes :

Hydrogen Fluoride (HF)

- the Gross Usage as reported is the total Fluorine estimated in the clay raw materials consumed in the process based on analysis carried out

between 2002 & 2006.

- the mass emission of HF reported in section 2.1.3 for 2009 was 0 tonnes compared to 0.9 tonnes in 2008.

- the Process Optimisation Project is ongoing in accordance with GG166 and the CaCO3 addition rates

for all clay mixes were increased further in July 2008. Coupled with Exhaust Gas Re-circulation and

ongoing process modifications, the average Concentration / average Mass Emission of HF are

decreasing satisfactorily year on year.


Hydrogen Chloride (HCl)

- the two inputs associated with HCl are Barium Chloride (Clay Conditioner) and Sodium Chloride

(PDV Salt) and classified as inputs of Chloride.

- the products manufactured all contain Clay Conditioner but only some of those contain PDV Salt.

- the mass emission of HCl reported in section 2.1.3 for 2009 was 0 tonnes compared to 2.2 tonnes

in 2008.

- there is no Liquid Waste for PDV Salt, Liquid Waste for Clay Conditioner is that which is in product

rejected before firing and Solid Waste is PDV Salt also on rejected product.


FACILITY IDENTIFICATION

Facility Name Ormonde Brick Limited

IPC Register No. 530

National Grid Reference 2542E, 1735N

Reporting Period January 2009 to December 2009

Production Units tonnes

Employee No.

POLLUTANTS SUMMARY Pollutant Name CAS No. Input Gross

Usage

Outputs Unaccounted Eco-

Productivity

Indices

Air MOM Liquid

Waste

MOM Solid

Waste

MOM Product MOM Recovery IGEE INEE

Hydrogen Fluoride - Fluorine

(in Shale and Fireclay)

7782-41-4

0

0

0

M

0

0

B

0

M

0

0

0

0

Hydrogen Chloride - Chloride (in Clay Cond.)

- Chloride (in Salt)

10361-37-2

7647-14-5

0

0

0

0

0

M

0

B

0

B

0

0

0

0

0

0

0

0

* Data on HF in Product Output is variable, which questions it’s reliability

MOM – Method of Measurement

This refers to the method used in determining losses to Air, Water and Land. The following codes are to be used to demonstrate the method used:

Method Code

Direct Measurement M

Material Balance B

Not Determined ND

Engineering Estimates E

Other O

Environmental Form


Ardra, Castlecomer, Co.Kilkenny.

Document : PER 2009


_____________________________________

A.McDonald, Operations Manager.

Revision: 1

Page: 1 of 1

Issued: 23rd March 2010

Title:

2009 Pollution Emissions Register Tracking List


4.0 LICENCE-SPECIFIC REPORTS

There are no licence–specific reports attached to this AER.

Date post:	08-Apr-2018
Category:	Documents
Upload:	trinhquynh
View:	214 times
Download:	0 times

ANNUAL ENVIRONMENTAL REPORT 2009 · Annual Environmental Report 2009 ... Not possible to sample GS2...

Documents