Annual Environmental Report ANNUAL ENVIRONMENTAL REPORT 2012

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1 ANNUAL ENVIRONMENTAL REPORT 2012

2 Contents 1.0 Introduction Site Activities Company Environmental Policy Organisation chart for Environmental Management Summary Information Emissions to water/sewers Emissions to atmosphere Waste Management Agency Monitoring and Enforcement Energy and Water Consumption Environmental Incidents and Complaints Submission of AER Summary Data Environmental Management Programme Objectives and Targets report for Objectives and Targets for Energy Efficiency Audit Report Summary Efficiency of the use of raw materials in processes and the reduction in waste generated Minimisation of water demand and trade effluent discharge volumes Development/Infrastructural works summary Financial Provision, Management & Staffing Structure & Public Information Residuals Management Plan Environmental Liabilities Risk Assessment Appendix 1 The Linde Group Safety, Health, Environment & Quality (SHEQ) Policy Appendix 2 Organisation chart Appendix 3: Waste Disposal Record Appendix 4: 5 Year Strategy Appendix 5 Diesel Tank / BundTest Appendix 6 Flow Meter / Data Logger & Composite Sampler Service report Appendix 7 Noise monitoring report summary Appendix 8 Notice of Environmental Liability Insurance Policy

3 1.0 Introduction Licence Register No: P Licensee: BOC Gases Ireland Ltd Location of Installation: P.O. Box 201, Bluebell, Dublin 12 BOC Gases Ireland is part of the Linde Group, which has its headquarters in Wiesbaden, Germany. It is the largest gas business in the world, operating in 55 countries and employing 55,000 people. BOC Gases has been operating in Ireland for over 65 years as a manufacturer and distributor of industrial, medicinal and specialized gases. BOC Gases Ireland Ltd. is located on an 11 acre site in the Bluebell Industrial Estate in South Dublin. It employs approximately 150 people and is engaged in the manufacturing of oxygen, nitrogen, argon and hydrogen. The bulk of the gases (nitrogen, oxygen and argon) produced at Bluebell are derived from the initial separation of air into its constituent components after it is passed through the air separation unit (ASU) plant. Hydrogen is produced at the hydrogen plant from an electrolytic process where water is split into hydrogen and oxygen using potassium hydroxide as the electrolyte. Operating hours for the air separation unit is 24 hours per day, 7 days per week, while the hydrogen plant is operated for 12 hours per day, 5 days per week. 1.1 Site Activities Activities carried out at the BOC Bluebell site include: Hydrogen manufacture; Air separation for the manufacture of nitrogen, oxygen and argon; Bulk storage of gases; Cylinder storage of gases manufactured off-site (special gases); Gas cylinder filling, testing and distribution; and Waste storage for eventual transfer to the UK for recovery Ancillary activities include administration (management, financial, marketing, and purchasing), engineering, maintenance shops and garage areas. 1.2 Company Environmental Policy See appendix 1 The Linde Group Safety, Health, Environment & Quality (SHEQ) Policy. 1.3 Organisation chart for Environmental Management See appendix 2 3

4 2.0 Summary Information 2.1 Emissions to water/sewers Non-compliances logged for period 2012 The was one non-compliance logged for 2012 which related to an exceedance of the ELV for FOG identified in the analysis results of the sample taken at SE4 in January. This noncompliance and details of the investigation & remedial actions taken was reported to South Dublin County Council and to the Environmental Protection Agency. The corrective actions put in place to prevent recurrence of this issue were to the satisfaction of the Agency. 4

5 2.2 Emissions to atmosphere There are no environmental emissions to atmosphere as per condition 5.2 of the IPPC Licence. 2.3 Waste Management See Appendix 3 Waste Disposal Record 2.4 Agency Monitoring and Enforcement An Agency site visit was conducted on 22nd August 2013 by Agency Inspector, Mr Patrick Kenny. Special attention was paid to water emissions ELV compliance and reporting, bunding, emergency / incident response procedures and WEEE storage. The following documentation was requested for review: Monitoring of emissions to sewer Monitoring of storm water emissions Waste Management Records Site Emergency Procedures One non-compliance was raised during the visit. This related to the storage of containers of potentially polluting liquids in an area without the provision of appropriate secondary containment. The issue has been resolved and reported back to the Agency. Three observations were noted to which BOC have reported back to the Agency with closure. 2.5 Energy and Water Consumption The Company continues to run the key energy using processes as efficiently as possible by setting energy usage targets and monitoring these on a weekly basis. These targets are expressed as Kw of electrical energy usage per hundred cubic metres (HCMS) of gas produced and in all cases the target usage has been met. The Energy Consumption summary table shows total usage for the site for

6 Energy Consumption Summary Table Energy Type Electricity Natural gas 1092 MWh Water Consumption Summary Table Municipal Supply m Environmental Incidents and Complaints No environmental incidents occurred or complaints were raised at the facility in

7 2.7 Submission of AER Summary Data 7

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13 3.0 Environmental Management Programme 3.1 Objectives and Targets report for 2012 Transport i) Objective: Establish fuel efficiency targets for the business. Outcome: Fuel efficiency targets established and reported monthly. ii) Objective: Introduce fuel reporting for drivers. Outcome: Fuel reporting introduced reports posted on fuel noticeboards and database used to support fuel management process. iii) Objective: Introduce Eco-driving training to improve driver skills and assist with better fuel efficiency. Outcome: Eco-driving implemented for compressed and bulk drivers, training is now part of ongoing training program. PG&P (Cylinder Filling) i) Objective: Introduce waste collection service for production materials. Outcome: Waste management system implemented for production. ii) Objective: Reduction of waste - Continue project to reuse valves. Target 10,000 valves. Outcome: Due to change in internal standards this project has been terminated. Tonnage (ASU Plant) i) Objective: Monitor real time plant performance through 4 newly installed power meters to optimise plant efficiencies. Outcome: The performance of individual high power consumption plant items is now tracked in real time ensuring optimum plant operation. ii) Objective: Track and monitor energy usage for the Dublin ASU Plant to ensure compliance with the following target 75.5kW/HCMs. Outcome: 75.4Kw/HCMs

14 3.2 Objectives and Targets for 2013 Transport i) Objective: Investigate the viability of using alternative fuels in transport fleet. ii) Objective: Monitor tyre performance across transport fleet iii) Objective: Monitor fuel efficiency targets for the business. PG&P (Cylinder Filling) i) Objective: Review performance of lighting project & consider expanding use of induction lighting. ii) Objective: Gas losses reduction program to minimise gas losses at Helium plant. Tonnage (ASU Plant) i) Objective: Investigate water saving possibilities when plants are off line. ii) Objective: Track and monitor energy usage for the Dublin ASU Plant to ensure compliance with the following target 75.5kW/HCMs. 3.3 Energy Efficiency Audit Report Summary Energy Efficiency audit and IS393 gap analysis was carried out by Viegand & Maagoe and Ethos Ltd on behalf of Sustainable Energy Ireland on 9th June A copy of the report has previously been submitted to the Agency and many of the recommendations have been implemented by the Energy Management Team established in Efficiency of the use of raw materials in processes and the reduction in waste generated. As per condition 7.4 the efficiency of raw materials (power) is incorporated into our schedule of environmental objectives and targets 2012 & 2013 (see above). The amount of waste generated is specified in Appendix 3. A review of the company s waste management programme was carried out and the level of waste produced on site decreased (see Figure 1a.) while the level of waste sent to landfill was in line with the trend of recent years. Figure 1a 14

15 Annual Waste Streams - BOC Gases Dublin Tonnes Total Waste Hazardous Non Hazardous Landfill/incinerated Recycled/Recovered FY05 FY06 FY07 FY08 FY09 FY10 FY11 FY12 Figure 1b 3.5 Minimisation of water demand and trade effluent discharge volumes Currently the cooling water effluent discharged from the ASU plant is running at optimum efficiency. Meter readings of the water usage and blowdown on the cooling tower is monitored and measured continuously to ensure this optimum level is maintained. A Water Leakage and Conservation survey was carried out by GMC Civil & Mechanical Engineering Ltd Water Division. Remedial works to infrastructural pipelines were conducted as a result of the survey. 3.6 Development/Infrastructural works summary Previous Year - Inspection, maintenance of diesel tanks, bunds, Appendix 5. - Inspection, service and calibration of data logger, Appendix 6 - Repairs to yard hard-standing areas as a result of frost damage. - Investigate the feasibility of building a new Test Shop, eliminating painting of cylinders for powder coating. Current Year - Water System project - reduction of water storage capacity and treatment chemicals used. Upgrade of water supply at administration building. - Investigate centralising the hot water system & reducing the use of under sink heaters. - Project to develop increased Liquid Nitrogen storage capacity. - Upper Tier Seveso project - Review environmental incident emergency response capabilities in line with upper tier emergency plan requirements. 15

16 3.7 Financial Provision, Management & Staffing Structure & Public Information Financial Provision As part of the annual company budget cycle financial provision to meet the conditions of the licence is included as part of this process. Furthermore, in the event of environmental incidents (unknown liability provision) the company has underwritten the cost for remedial action through the policy outlined in Appendix 8. Management and staffing structure All managers within our operational areas have Loss Prevention Responsibilities for health, safety and the environment. These include responsibilities for ensuring IPPC licence conditions are complied with. Furthermore, all management and staff roles that have an impact on licence conditions have had the appropriate environmental training. Public Information Requests for public information can be made through the BOC Gases Ireland website at or by telephone. Information that can be sought includes: (i) The Linde Group Safety, Health, Environment & Quality Policy. (ii) The Environmental Objectives for the current year, i.e. the current year Environmental Action Plan. (iii) All reports listed in Schedule D of IPPC Licence. 3.8 Residuals Management Plan A review of the RMP was carried out and no changes were noted. (Copy of RMP sent as part of 2008 AER) 3.9 Environmental Liabilities Risk Assessment No relevant site changes to report. Review to be completed every 3 years, next due (Copy of ELRA sent as part of 2008 AER) 16

17 Appendix 1 The Linde Group Safety, Health, Environment & Quality (SHEQ) Policy 17

18 Appendix 2 Organisation Chart Area Business Manager Adam Jennings- Frisby Finance TMM Operations Manager David Condon Area Sureserve Manager Ian Reynor Area Sales Manager Eamonn Bolton Area Transport Manager Niall Cotton Area Production Manager Mark Kelly Janine Griffiths Healthcare Area Commercial Manager Dermot Browne Area Business Support Executive Elva Burke Area SHEQ Manager Bob Loade Robert Patterson Dublin CSC Tonnage Paul Waters Dublin CSC Manager SHEQ Specialist Paschal Byrne GMP &SHEQ Specialist Jordan Costello Pat O Cleary 18