Carton Bros. Darkley Shercock Co. Cavan ANNUAL ENVIRONMENTAL REPORT Compiled 31 st March IPPC LICENCE No. P

Transcription

1 Darkley Shercock Co. Cavan ANNUAL ENVIRONMENTAL REPORT 2009 Compiled 31 st March 2010 IPPC LICENCE No. P

2 TABLE OF CONTENTS Page No. List of Tables 3 List of Graphs 4 List of Appendices Introduction Site Description Emissions from the installation Wastewater Surface Water EPA Monitoring and Enforcement Summary waste management record Resource consumption summary Complaints summary Schedule of Environmental Objectives and Targets Environmental management programme - report for previous year Environmental management programme - proposal for current year Pollutant Release and Transfer Register - report for previous year Pollutant Release and Transfer Register - proposal for current year Noise monitoring report summary Ambient monitoring summary Bunded Tank testing and inspection report Tank and Pipeline Testing and Inspection Reporting Reported incidents summary Report on Odour Management Programme Report on Implementation of the Noise Reduction programme Energy efficiency audit report summary Assessment of the efficiency of use of raw materials in processes and the reduction in waste generated Report on progress made and proposals being developed to minimise water demand and the volume of trade effluent discharges Toxicity Testing Of Final Untreated Effluent Reports on financial provision made under this licence, management and staffing 45 structure of the installation, and a programme for public information Decommissioning Management Plan Environmental Liabilities Risk Assessment Review (every three years or more frequently as dictated by relevant on-site change including financial provisions). 47 2

3 List of Tables Table No. Table Description 1 Average Monthly Final Effluent Results for January - December Monitoring of Storm water Emissions SW2 Monitoring Point 3 Monitoring of Storm water Emissions SW3 Monitoring Point 4 Summary of EPA Monitoring Dates at 5 Waste Summary of Materials Removed off site at Carton Bros 6 Resource consumption summary at Carton Bros during 2009 Reporting Period 7 Objectives and Targets for 8 Environmental Management Programme for current year 9 Measured noise levels, Carton Bros Ltd, August Boiler No.1 Combustion Efficiency 11 Boiler No.2 Combustion Efficiency 12 Bund Matrix 13 Energy Audit Summary for 3

4 List of Graphs Graph Graph Description No. 1 Average ph Results for Final Effluent at SW1 Monitoring Point for the Reporting period 2 Average Suspended Solids Results for Final Effluent at SW1 Monitoring Point for the Reporting period 3 Average BOD Results for Final Effluent at SW1 Monitoring Point for the Reporting period 4 Average COD Results for Final Effluent at SW1 Monitoring Point for the Reporting period 5 Average Total Phosphorus as P for Final Effluent at SW1 Monitoring Point for the Reporting period 6 Average Nitrogen as Total N for Final Effluent at SW1 Monitoring Point for the Reporting period 7 Average Ammonia for Final Effluent at SW1 Monitoring Point for the Reporting period 8 Average Fats Oils & Greases (FOG) Results at SW1 Monitoring Point for the Reporting period 9 Average Nitrate Results at SW1 Monitoring Point for the Reporting period 10 Average ph Results for Surface Water SW2 Monitoring Point for the Reporting period 11 Average COD Results for Surface Water SW2 Monitoring Point for the Reporting period 12 Average Conductivity Results for Surface Water SW2 Monitoring Point for the Reporting period 13 Average ph Results for Surface Water SW3 Monitoring Point for the Reporting period 14 Average COD Results for Surface Water SW3 Monitoring Point for the Reporting period 15 Average Conductivity Results for Surface Water SW3 Monitoring Point for the Reporting period 16 Tonnage of Blood, Offal and Feathers removed from Carton Bros during the reporting period 17 Tonnage of Wastewater Sludge removed from Carton Bros during the reporting period and in storage. 18 General Waste, Cardboard and Mixed Construction Waste removed during the Reporting Period 19 Electricity usage for 2009 compared to 2008 at Carton Bros 20 Oil usage on site for reporting period Jan -Dec

5 List of Appendices Appendix No. Appendix Description Appendix 1 Proposed Nutrient Management Plan for 2010 Appendix 2 Environmental Management Programme 2009 Summary Appendix 3 Proposed Environmental Management Programme for 2010 Appendix 4 Monitoring of Surface water Emissions Results Sw1 Monitoring Point Jan Dec 2009 Appendix 5 Monitoring of Storm water Emissions Results Sw2 and Sw3 Jan Dec 2009 Appendix 6 GW Monson Service Report Appendix 7 Environmental Liabilities Risk Assessment Report Appendix 8 Environmental Noise Survey Appendix 9 Energy Audit For Ltd Appendix 10 Pollutant Release Transfer Register Report 2009 Appendix 11 Proposed Pollutant Release Transfer Register Report 2010 Appendix 12 Environmental Protection Agency Monitoring Results during 2009 Appendix 13 Environmental Protection Agency Inspection Reports during 2009 Appendix 14 Final Effluent Organics Screening 2009 Appendix 15 Waste Management Records

6 1.0 Introduction This Annual Environmental Report (AER) for the Facility at Darkley, Shercock, County Cavan and covers the reporting period January to December The Environmental Protection Agency (EPA) granted an IPPC Licence (Register No. P ) on the 10th October The AER has been prepared in compliance with Condition 11.8 of IPPC licence The content of the AER is based on Schedule D: Content of Annual Environmental Report and has been compiled with the aid of the EPA Guidance Note for Annual Environmental Reports. Environmental Management Structure Vincent Carton Managing Director Senior Management Support Provide financial resources Austin Kiely General Manager Management and operational support Reviews systems and effectiveness Ensures that adequate resources and personnel are available to meet all environmental requirements. Stacey Smith Environmental Officer Maintain Environmental Systems Provides reports to top management Day to day running of the environmental issues and compliance to the IPPC Licence from EPA John Farnan Maintenance Manager Provision, installation and maintenance of equipment Responsibility for ensuring that equipment and purchases, new, remanufactured and modifications are in line with current environmental practices Rectify equipment at the wastewater treatment plant to ensure compliance. MJ O Connor Purchasing Manager Responsibility to ensure that chemical substances are received, stored and distributed correctly. Increase vendor s environmental awareness Wastewater Treatment Plant Operatives Day to day running of the wastewater treatment plant To inform the maintenance manager when equipment breaks down Environmental Laboratory Technicians Daily collection and of wastewater samples To test the wastewater samples and report non compliance to the Environmental Officer and Maintenance Manager All Other Employees Ensuring that activities performed comply with the environmental policy and quality systems 6

7 Environmental Policy Carton Group LTD Environmental Policy Statement Carton Group Processing is committed to protecting the environment. Environmental concern is a fundamental part of our business responsibility. It therefore is important that Carton Group Ltd should to the best of its ability to ensure that adverse environmental impacts are minimised. Our primary objectives are: To review all environmental aspects of poultry processing and strive for the ultimate in environmental performance. To support the concept of environmental sustainability compatible with economic development. To fully understand and meet our environmental legislative and regulatory requirements. To practice proper disposal and recycling of waste, but this is not a substitute for efforts of waste reduction. We will use continuous process improvement principles to identify and reduce major sources of environmental effects through the environmental program. To build relationships of confidence, trust and partnership with local authority agencies, Fisheries and all our customers. For all our employees to be responsible and accountable for environmental effects of their work. Carton Group shall provide adequate resources, including finance; human resources, equipment, and training, to assure environmental initiatives are secured. The Directors of Carton Group are totally committed to the above policies and as appropriate, set new environmental objectives to ensure implementation of this policy in process management. Signed: Vincent Carton Chief Executive Date: 7

8 2.0 Site Description slaughter and process poultry to produce fresh poultry for human consumption. Production at the installation is 24 hours per day, six days per week and the daily throughput is 140,000 to 160,000 birds six days per week. Processing onsite involves the slaughter, plucking, evisceration and preparation of chickens for sale as fresh poultry products (whole chickens or sections thereof). The main emission from the activity is trade effluent which is discharged to Lough Sillan following treatment in the on-site waste water treatment plant. The activities on-site fall under the following classes of the IPPC Directive (Council Directive 96/61/EC), Class 6.4. (a) Slaughterhouses with a carcase production capacity greater than 50 tonnes per day and Class 6.4 (b) Treatment and processing intended for the production of food products from: animal raw materials (other than milk) with a finished product production capacity greater than 75 tonnes per day. 8

9 3.0 Emissions From the installation implement a comprehensive environmental monitoring programme to assess the significance of emissions from site activities. The programme includes Storm water, Waste water, and Noise monitoring. An overview of the results of the monitoring conducted in the reporting period is presented in this section. 3.1 Wastewater Wastewater samples are collected from monitoring location SW-1. The wastewater monitoring is a requirement of the licence. The range of analysis was as specified in Schedule C2.2 of the licence and include Temperature, ph, Chemical Oxygen Demand, Biochemical Oxygen Demand, Suspended solids, Total Nitrogen, Nitrates (as N) Ammonia (as N) Total Phosphorus (as P) Ortho-phosphate, Oils, Fats and greases. Toxicity Testing is to commence in 2010 once agreed with the EPA. All of the parameters were below the Emission Limit Values (ELVs) set in the Licence. 9

10 Table No. 1: Average Monthly Final Effluent Results for January - December 2009 Parameter Unit Average Results Final Effluent SW1 Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Licensed Emission Mass Emission m 3 Limit Value Compliant/ Non Compliant BOD mg/l O * Compliant COD mg/l O * Compliant Suspended Solids mg/l Compliant ph Compliant Total Phosphorus mg/l P Compliant Ortho P Compliant Ammonia mg/l N Compliant Total Nitrogen mg/l N * Compliant Nitrate mg/l Compliant F.O.G mg/l < < Compliant Conductivity ms/m *This emission limit value shall apply from 1/10/

11 Waste Water Emissions Monitoring Point 1: (SW1) Location: E271962, N Volume Emitted: The Maximum volume of final effluent emitted on any given day is 1,300m 3, with a maximum of 75m 3 per hour. BOD: The average BOD during the reporting period was 8.03mg/l, with a maximum and minimum value of 21.70mg/l and 1.60mg/l respectively. The values were well within the limit emission value of 25mg/l. COD: The average COD result during the reporting period was 54.77mg/l, with a maximum and minimum value of 124mg/l and 14mg/l respectively. A limit emission value of 125mg/l was implemented from 01 st October Suspended Solids: The average Suspended Solids result during the reporting period was 23.10mg/l, with a maximum and minimum value of 35mg/l and 1.5mg/l respectively. The values were all within the limit emission value of 35mg/l. ph: The ph at SW1 ranged from 6.17 to 7.87 between January and December The values are within the normal range. Total Phosphorus: The average value for Total Phosphorus during the reporting period was 0.43mg/l, with a maximum and minimum value of 1mg/l and 0.1mg/l respectively. The values were within the limit of 1mg/l for all events. Ammonia: The average value for Ammonia during the reporting period was 1.23mg/l, with a maximum and minimum value of 7.3mg/l and 0.1mg/l respectively. The values were within the limit emission value of 10mg/l. Total Nitrogen: Since the 01 st October 2009 an emission limit value of 15mg/l became effective. An Anoxic zone was installed as part of the treatment system to ensure compliance with the IPPC Licence Limit. 11

12 Fats, Oils and Greases: The average value for Fats, Oils and Greases during the reporting period was 1.77mg/l, with a maximum and minimum value of 3.4mg/l and <1mg/l respectively. The values were within the limit of 10mg/l of the IPPC Licence Limit. Graph 1 Showing average ph Results for Final Effluent at Carton Bros Ltd at SW1 Monitoring Point for the period January December Graph Showing ph Results for Final Effluent for 2009 at Carton Bros Ltd at SW1 Monitoring Point ph Units Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Month 12

13 Graph 2 Showing average Suspended Solids Results for Final Effluent at Carton Bros Ltd at SW1 Monitoring Point for the period January December Graph Showing Suspended Solids Results for Final Effluent for 2009 at Carton Bros Ltd at SW1 Monitoring Point mg/l Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Month Graph 3 Showing average BOD Results for Final Effluent at Carton Bros Ltd at SW1 Monitoring Point for the period January December Graph Showing BOD Results for Final Effluent for 2009 at Carton Bros Ltd at SW1 Monitoring Point mg/l O Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Month 13

14 Graph 4 Showing average COD Results for Final Effluent at Carton Bros Ltd at SW1 Monitoring Point for the period January December Graph Showing COD Results for Final Effluent for 2009 at Carton Bros Ltd at SW1 Monitoring Point mg/l COD Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Month Graph 5 Showing average Total Phosphorus as P Results for Final Effluent at Carton Bros Ltd at SW1 Monitoring Point for the period January December Graph Showing Total Phosphorus Results for Final Effluent for 2009 at Carton Bros Ltd at SW1 Monitoring Point mg/l Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Month 14

15 Graph 6 Showing average Nitrogen as Total N Results for Final Effluent at Carton Bros Ltd at SW1 Monitoring Point for the period January December 2009 mg/l Graph Showing Total Nitrogen Results for Final Effluent for 2009 at Carton Bros Ltd at SW1 Monitoring Point Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Month Graph 7 Showing average Ammonia Results for Final Effluent at Carton Bros Ltd at SW1 Monitoring Point for the period January December Graph Showing Ammonia Results for Final Effluent for 2009 at Carton Bros Ltd at SW1 Monitoring Point mg/l Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Month 15

16 Graph 8 Showing average Fats Oils & Greases (FOG) Results for Final Effluent at Carton Bros Ltd at SW1 Monitoring Point for the period January December Graph Showing FOG Results for Final Effluent for 2009 at Carton Bros Ltd at SW1 Monitoring Point mg/l Jan Feb Mar Apr May Jun Jul Aug Month Graph 9 Showing Average Nitrate Results for Final Effluent at Carton Bros Ltd at SW1 Monitoring Point for the period January December 2009 mg/l Graph Showing Ortho-phosphate Results for Final Effluent for 2009 at Carton Bros Ltd at SW1 Monitoring Point Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Month 16

17 3.2 Surface Water Water samples are collected by grab sampling from monitoring locations SW-2 (surface water from roofs) and SW-3 (surface water from paved areas). The surface water monitoring is a requirement of the licence. The range of analysis was as specified in Schedule C2.3 of the licence which includes ph, COD, Conductivity and a Visual Inspection. Table 2: Monitoring of Stormwater Emissions SW2 (E272023, N305871) Surface water from Roofs on site (Average Monthly Results) Month ph COD mg/l Average Monthly Conductivity Colour & Odour ms/m January No Colour or Odour present February No Colour or Odour present March No Colour or Odour present April No Colour or Odour present May No Colour or Odour present June No Colour or Odour present July No Colour or Odour present August No Colour or Odour present September No Colour or Odour present October No Colour or Odour present November No Colour or Odour present December No Colour or Odour present 17

18 Graph 10 Showing Average ph Results for Surface Water Monitoring at Carton Bros Ltd SW2 Monitoring Point for the period January December Graph Showing average ph Results for each month during 2009 for surface water monitoring point (SW2) mg/l Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Month Graph 11 Showing Average COD Results for Surface Water Monitoring at Carton Bros Ltd SW2 Monitoring Point for the period January December 2009 Graph Showing average COD Results for each month during 2009 for surface water monitoring (SW2) mg/l Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Month 18

19 Graph 12 Showing Average Conductivity Results for Surface Water Monitoring at Carton Bros Ltd SW2 Monitoring Point for the period January December 2009 Graph Showing average Conductivity Results for each month during 2009 for surface water monitoring (SW2) us/cm Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Month 19

20 Table 3: Monitoring of Stormwater Emissions - SW3 (Location E272026, N305880) Surface water from paved areas after petrol/oil interceptor Month ph COD mg/l Average Monthly Conductivity Colour & Odour ms/m January No Colour or Odour present February No Colour or Odour present March No Colour or Odour present April No Colour or Odour present May No Colour or Odour present June No Colour or Odour present July No Colour or Odour present August No Colour or Odour present September No Colour or Odour present October No Colour or Odour present November No Colour or Odour present December No Colour or Odour present Graph 13 Showing Average ph Results for Surface Water Monitoring at Carton Bros Ltd SW3 Monitoring Point for the period January December Graph Showing average ph Results for each month during 2009 for surface water monitoring point (SW3) mg/l Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Month 20

21 Graph 14 Showing Average COD Results for Surface Water Monitoring at Carton Bros Ltd SW3 Monitoring Point for the period January December 2009 Graph Showing average COD Results for each month during 2009 for surface water monitoring (SW3) mg/l Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Month Graph 15 Showing Average COD Results for Surface Water Monitoring at Carton Bros Ltd SW3 Monitoring Point for the period January December 2009 Graph Showing average Conductivity Results for each month during 2009 for surface water monitoring (SW3) us/cm Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Month 21

22 3.3 EPA Monitoring and Enforcement During 2009 there was 2 monitoring visits by Agency staff. A summary of results of analysis carried out by the Agency is detailed below in Table 4. The full EPA Monitoring results are included in Appendix 12 Table No. 4 EPA Monitoring Dates Date Sampled By EPA Date Results Sent to EPA Report No Surface Water Sampling Point SW1 22/09/09 14/01/ All Results Compliant 28/10/09 14/01/ All Results Compliant 22

23 4.0 Summary Waste Management Record Waste Quantities (1 st January st December 2009). Table 5 summarises the types and quantities of waste removed for over the period 1 st January 2009 to 31 st December Table 5 Waste Summary of Materials Removed off site at Carton Bros (Jan Dec 2009) Waste Material EWC Code Waste Collector Blood John Power Waste Collection Permit Number Non Applicable Total Tonnes Removed 3, N Ruminants College Proteins Non Applicable Offal College Proteins Non Applicable 13, Feather College Proteins Non Applicable 5, Wastewater Sludge John Conlon Oxigen General Waste Environmental Ltd WCP MH/2006/34/B WCP/MH/2001/46C General Waste Ecological Ltd MH09/ Construction Waste Ecological Ltd MH09/ Cardboard Oxigen Environmental Ltd Retech Processing Plastic Pallets Ltd Cardboard Ecological Ltd WCP/MH/2001/46C MH/2004/84B 2.63 MH09/

24 Graph 16: Tonnage of Blood, Offal and Feathers removed from Carton Bros during the reporting period 1300 Tonnage of Offal, Feathers and Blood removed from Carton Bros Tonnes Removed Offal Feathers Blood Jan Feb Mar Apr May June Jul Aug Sep Oct Nov Dec Month Graph 17: Tonnage of Wastewater Sludge removed from Carton Bros during the reporting period and in storage. Total Wastewater Sludge Removed From during Tonnages January February March April May June July Aug Sept Oct Nov Dec Month 24

25 Graph 18: Tonnage of General Waste, Cardboard and Mixed Construction Waste removed from Carton Bros during the Reporting Period 35 Tonnage of General Waste, Cardboard and Mixed Construction Waste removed from Carton Bros Tonnes Removed Municipal Waste Cardboard Mixed Construction Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Month 25

26 5.0 Resource consumption summary. The main energy use at includes: Electricity, Oil and Gas A review of electricity, oil and gas bills for the period from 01 st January 2009 to 31 st December 2009 shows that used the following quantities. Table 6: Resource consumption summary at Carton Bros during 2009 Reporting Period Energy Unit Total Used in 2009 Electricity KWh 9,543,592 Oil Litres 181,324 Gas Litres 4,188 Water M 3 474,500 Graph 19: Graph Showing Electricity usage for 2009 compared to Electricity usage at Carton Bros for 2009 compared to ,000, , , ,000 Kwh 600, , , , , ,000 Energy Usage 2008 Energy Usage Jan Feb Mar Apr May Jun Jul Aug Sept Oct Nov Dec Month 26

27 Graph 20: Graph Showing Oil usage on site for reporting period Jan -Dec Oil usage at Carton Bros for Jan-Dec Litre Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Month 6.0 Complaints Summary 6.1 Complaints There was one complaint during the reporting period January December The complaint was lodged at the end of September The complaint related to an anonymous phone call to the Agency that a contractor was spreading organic sludge which had originated at Ltd on lands adjacent to their house which had not been approved for landspreading. After an investigation by Carton Bros environmental department in conjunction with Cavan Co. Council Environmental Section it was proven that the sludge was not from 27

28 7.0 Schedule of Environmental Objectives and Targets. The Objectives and Targets, which are currently on-going, or planned, are set out below. Table 7: Objectives and Targets Number Environmental Objective & Target 1 Increase environmental awareness among Ltd management and employees 2 Reduce fugitive emissions 3 Reduce levels of process waste sent to landfill 4 Improve site housekeeping 5 Achieve consistent bund integrity and suitability 6 Improve fire safety on site. 7 Reduce energy usage on site 8 To be a good and considerate neighbour. 9 To improve and maintain good quality of Final Effluent. 10 To protect Groundwater Quality on the site. 11 Reduce water usage on site. 28

29 8.0 Environmental Management Programme report for previous year Please refer to the Appendices of the AER for the Environmental Management Programme summary report for the 2009 period. 9.0 Environmental Management Programme report for current year The projects, which are currently on-going, or planned, are set out below and are described in more detail in Appendix 3. Table 8: Environmental Management Programme for current year Section Project Title 2.1 Odour Management Programme 2.2 Concrete Upgrading 2.3 Minimise Fugitive Emissions 2.4 Energy management system 2.5 Incident Prevention (Leak inspection) 2.6 Effluent Plant Final Discharge 2.7 Air Emissions - Boiler Assessment Programme 2.8 External Housekeeping Programme 2.9 Staff Training 2.10 Environmental Management System (EMS) 2.11 Organic Waste Storage/Disposal 2.12 Operations and Maintenance Programme 2.13 Groundwater Quality Monitoring 2.14 Noise Monitoring Programme 2.15 High Level Alarms installation 2.16 Communications 2.17 Solid waste minimisation recovery and reuse 2.18 Reduction of BOD Load Entering the WWTP New Blood Tank and Bunding 2.20 Solid Waste Minimisation, Recovery and Reuse 2.21 Reduction of Water Consumption On Site 2.22 Toxicity Testing Of Untreated Final Effluent 29

30 10.0 Pollutant Release and Transfer Register - report for previous year. Please refer to the Appendix 10 for the completed PRTR report for previous year Pollutant Release and transfer Register - proposal for current year. Please refer to the Appendix 11 for the completed PRTR report for current year Noise Monitoring Report Summary An Environmental Noise Survey was carried out on the 18 th, 20 th and 21 st of August 2009 to monitor compliance with the noise limits assigned in Integrated Pollution Prevention and Control (IPPC) Licence Register No. P issued by the Environmental Protection Agency (EPA). The licence assigns a noise limit of 55dB(A) L Aeq (30 minutes) by day and 45dB(A) L Aeq (30 minutes) by night at the nearest noise sensitive location/boundary. In addition, there shall be no clearly audible tonal or impulsive noise component in the noise emission from the activity at any noise sensitive location. During the environmental noise survey, noise measurements were recorded at all locations around the site. The specific noise levels at the site boundary ranged from db (A) in the day survey and the specific noise levels for the night-survey ranged from db (A). Since none of these five locations are noise sensitive locations, the specific noise levels do not breach the limit value as stated in the IPPC licence No. P

31 Table 9. Measured noise levels, Carton Bros Ltd, August 2009 Measured Noise Level db(a) Label Time 1 L Aeq L A90 L A50 L A10 Specific Comments Daytime 18 th August 2009 N1 12: <49.6 N2 12: <50.0 N <52.4 N <49.7 N <56.4 NSL <46.7 NSL <44.0 Nighttime 20 th /21 st August 2009 N <47.3 N <45.3 N <49.0 N <39.4 N <51.0 NSL <39.0 NSL <37.8 Distant traffic noise, Short steady plant noise (Centre Fuse) Speed Boat on Lough Sillan, Traffic noise, steady plant noise (chillers and boiler) Continuous traffic noise, steady plant noise (chillers and boiler) Continuous traffic noise, lower level noise from Continuous traffic noise, High level noise from refrigerated lorries. Continuous traffic noise, lower level noise from Continuous traffic noise, lower level noise from Distant traffic noise, Short steady plant noise (Centre Fuse) Traffic noise, steady plant noise (chillers and boiler) Continuous traffic noise, steady plant noise (chillers and boiler) Continuous traffic noise, lower level noise from Continuous traffic - Moderate level noise from refrigerated lorries. Continuous traffic noise, lower level noise from Continuous traffic noise, lower level noise from 31

32 13.0 Ambient Monitoring Summary Boiler Efficiency commission an independent boiler engineer (JW Monson to carry out an annual assessment of the efficiency of the boilers at the facility. The results of the boiler test on April 2009 are shown below. Table 10: Boiler No.1 07 th April 2009 Parameter Result Low High Efficiency % Table 11: Boiler No.2-07 th April 2009 Parameter Result Low High Efficiency % Bunded Tank testing and inspection report commissioned independent contractors to survey the integrity of the bunds on site during Bund Inspection reports are kept on site and are available for inspection. A new blood tank and bund will be installed during Bunds are inspected on site by the Environmental Department and records are available for inspection in the Environmental Department. 32

33 Table 12 Bund Matrix at Bund Reference No Location Test Result Next Test Due Bund No.1 Beside Maintenance Pass Shed Bund No.2 Beside Maintenance Pass Shed Bund No.3 Behind Offal shed Fail New Blood tank and Bunding to be installed on site. Bund No.4 Beside Security Office Pass Bund No.5 Beside Offal Shed Pass Bund No.6 Beside WWTP Pass Bund No.7 Beside Clarifier Pass Bund No.8 Beside Water Intake Pass Area Bund No.9 Beside Water Intake Pass Area Bund No.10 Beside Water Intake Pass Area Bund No.11 Beside Water Intake Pass Area Bund No.12 Beside Water Intake Pass Area Tank and Pipeline Testing and Inspection Reporting An Underground CCTV pipe survey was carried out by Mc Breen Environmental Services Ltd, Alacken, Cavan Co. Cavan during During this survey it was noted that some cracks were evident. Repairs were carried out to the affected lines. Survey report and DVDs are kept on file in Environmental Section at Shercock. 33

34 16.0 Reported incidents summary There was no reported incidents between January and December Report on Odour Management Programme A number of procedures have been implemented on site to minimise odour emissions from the site, including: Sludge Handling / Landspreading: There is a risk of odours been released when sludge is moved from the storage location. During the year sludge produced at the plant is mixed with lime at a ratio of 5 to 1 based on dry solids. Lime stabilisation has a number of advantages in that it kills off all micro organisms and creates an inhabitable environment for such biodegrading organisms. This minimises odours emanating from the sludge so it can be stored on site without causing nuisance. There are legislative restrictions in place in relation to landspreading sludge, therefore Carton Bros have to store a certain amount of sludge during the winter months. When this sludge is disturbed after long periods it can release an odour which has been classed as moderate. In order to minimise odours released there are a number of controls implemented during sludge handling: To minimise sludge disturbance a Digger with large buckets is used for loading, All sludge is removed from site as efficiently as possible to eliminate extended periods of disturbance, Staff have been trained and informed on procedures for sludge handling, Attention is paid to weather conditions and wind direction during this process. DAF Tank DAF waste (Dissolved Air Floatation) by its very nature is a pungent material that has the potential to cause offensive odours. installed an enclosed DAF storage tank complete with submersible mixer and level controls. This ensures that there are minimal odours from this system. Balance Tank This balance tank is designed into the wastewater treatment plant to accept, hold and mix influent over a 24 hour period of time. This tank has the capacity to hold 1,000 cubic metres of raw influent. By their very nature at a wastewater treatment plant, balance tanks are generally the highest risk in terms of odour potential. There is generally what is classed as a slight odour emanating from this tank on a daily basis. 34

35 In order to minimise odourous conditions the following controls have been put in place: The tank is aerated to prevent anaerobic conditions from developing; Reduced retention times are aimed for at the plant to minimise the occurrence of odour. The plant is generally run at a retention time of 12 hours as opposed to the designed 24 hour retention; Automated level controls are in place to ensure retention in the tank is kept to a minimum; Regular plant inspections and effluent analysis are carried out to ensure optimum conditions are maintained in the tank; In worst case scenario, procedures are in place to dose the tank with odour abatement chemicals. This would only be used if there was a major odour problem at the facility. Offal, Feathers and Blood Management All offal and feathers are stored in a sealed trailer in a partially enclosed area on site, and removed daily for rendering. It is essential that the offal and feathers trailers be removed frequently off site for further processing. All drains are flushed regularly and significant debris building up is prevented through design. The yard surface of the chicken intake area is kept clean at all times. The Dead-On- Arrival (DOA) skip is now located at the back of factory near the effluent plant. This is considered to be high risk odour emission source. This skip is removed off site 3 times per week for further off-site processing. This storage skip should also be enclosed to ensure no risk of significant odour emissions. Review Following the implementation of the odour management programme and objectives set in the Environmental Management Plan, no complaints were received in relation to odour during

36 18.0 Report on implementation of the Noise Reduction Programme The noise management programme is ongoing at Carton Bros and there has been no complaints relating to Noise received by the factory Energy efficiency audit report summary An audit of the energy efficiency of the site was carried out on site in Michael Doyle from Energy Conservation Options carried out an energy audit on site on behalf of the Sustainable Energy Ireland during January Following on from this initial audit carried out a more in depth energy audit at the end of It is proposed to carry out the recommendations of this energy audit during The completed Energy Audit is included in Appendix 9. 36

37 Table 13 Energy Audit Summary at Ref Opportunity Indicative Benefits Implement Energy 01 Management System Improved Energy Management Implement Energy Performance 02 Indicator (EPI) Improved Energy Management Carry out detailed audit of energy 03 use. Improved Energy Management 04 Improve energy housekeeping and Lower energy energy awareness use Cost Category Range Target Additional Information Date An energy management system can help to deliver sustained savings. In addition, 12 Medium Organisational Months practices can be improved and monitored with the use of a simple EPI. Simple regular checklists can be useful. This step is important to provide structural backup for decisions. A simple EPI (Energy Performance Indicator) would be usable here based on taking regular electrical readings and relating to production tonnage. This can be expressed No / Low Organisational 3 Months in kwh/tonne and /tonne to monitor progress. With more detailed work, this could also be split for various items of plant to help optimise energy use within process. A comparative figure is given elsewhere in the report. In order to inform future decisions and investments a more accurate picture is required. This can be supported by a detailed energy audit. This would also look at Medium Technical 6 Months opportunities for heat recovery using perhaps pinch analysis to highlight opportunities. Possible areas for concentration are the refrigeration system as well as the wastewater treatment plant. No / Low People 3 Months All areas can benefit from this - SEI has energy awareness information available on These measures are important as each individual who comes in contact with a switch or thermostat has an effect. They all add up. Specific training can also be developed based on measured energy use at this site. Energy use in general might form part of employee performance reviews. Improved understanding of energy use in the process will help key staff to minimise use. 37

38 Ref Opportunity 05 Develop a motor replacement policy 06 Develop start-up and shutdown procedures 07 Review use of light switches - possibly install more. Indicative Benefits Lower energy use Lower energy use Lower energy use Cost Range Category Target Date Additional Information Efficiency is generally considered when replacing motors. This could be formalised so that in the event of an emergency the likelihood of being able to utilise an efficient motor is increased. For example above a determined size and load factor, there may be a case for looking beyond standard eff1 etc and doing a cost benefit using the exact efficiency figures (which may be higher again). The viability of No / Low Organisational 6 Months keeping certain smaller motors in stock (or call-off from suppliers) can also be assessed as can the losses associated with rewinds. Motors and drives are estimated to account for the majority of electricity use so if work spent on this issue delivered even a 1% saving that might otherwise be missed due to the demands of fixing a breakdown quickly, this would translate to about 90,000 kwh or 10,000. Startup and shutdown procedures could be looked at from an energy point of view. For example, depending on the energy used there may be a case for Medium Organisational 3 Months installing a transfer station to allow part of the line to stop during breaks. By using startup protocols, start can be delayed so that the plant comes on stream when needed. The same logic can be applied to shutdown. Some areas had lighting on but no occupancy. It may be necessary to change No / Low Technical 6 Months switching set-up to allow areas to be turned off individually but viability can be checked. A minimal level of lighting may need to be maintained in certain areas for safety reasons. 38

39 Ref Opportunity 08 Specify energy efficiency when purchasing equipment 09 Lighting improvements 10 Steam boiler measures Indicative Benefits Lower energy use Lower energy use Lower energy use Cost Range Category Target Date Additional Information The best opportunity to influence energy efficiency is at the purchasing stage. When Require suppliers to provide projections of energy use. If required, seek No / Low Organisational Opportunity independent advice to compare running cost of various alternatives. Sometimes Arises but not necessarily, extra capital costs may be incurred but with very short paybacks. There are a number of areas where it may be possible to replace lamps with drop-in alternatives without an appreciable drop in lighting levels. In other areas where refurbishment is feasible, the firm can also take account of what can be a When significant reduction in maintenance cost due to longer life of T5 lamps (20000 Medium Technical Opportunity hrs as opposed to 8000 hrs). It's important to specify fittings with a high Light Arises Output Ratio (better efficiency) and adequate controls such as absence detectors. Installing a separate set of fittings to provide minimum lighting may get around the safety concerns of using sensors in areas where machinery is running. See attached lighting information also. There may be opportunities for heat recovery on the boiler but some detailed work would need to be carried out to assess this. There may be more opportunities to improve insulation on steam piping and valves. Boiler Medium Technical 12 Months combustion controls can improve efficiency by up to 5. Simple operational and maintenance improvements as well as heat recovery from blowdown can also be investigated. A combustion efficiency test at the time of boiler maintenance will quantify losses. Steam traps should be checked regularly. 39

40 Ref Opportunity 11 Adapt MIC level (Maximum Import Capacity for Electricity) 12 Carry out spot monitoring of energy use 13 Using floating head pressure control for condenser 14 Arrange dedicated coldstore for value-added ingredients Indicative Benefits Lower energy use Improved Energy Management Lower energy use Lower energy use Cost Range Category Target Date Additional Information The MIC is currently 2500 kva. The highest noted max demand was over the period considered was 2017 kw. Based on this, there should be scope to reduce Medium Technical 6 Months the level. Reduction for example to 2250 kva could save of the order of 7,000. This would need to be checked and any future plans would need to be considered. The primary energy users have been identified. These could be monitored with No / Low Technical 3 Months simple portable equipment to better quantify use and in turn the savings by improvements. Savings could be ring fenced to finance further improvements. In the winter months the wet bulb temperature is low. If condenser pressure can be controlled relative to wet bulb and allowed to float rather than using fixed setpoints for fan control etc, then lower overall condensing temperatures Medium Technical 12 Months could be achieved with significant energy savings. Each degree lower condensing temperature represents a 3% saving in electrical power for this system. This approach would also allow the full condenser capacity to be used in the when load is low by using a lower condensing pressure. This could be a followup to an energy audit of the refrigeration plant. Medium Technical 12 Months One large cold store is being used to store ingredients for value-added products. Most of this cold store is empty and a much smaller store would suffice. In addition doors are open at both ends and the store is held at about -10 C. This is an unusual storage temperature and alternatives may be possible. A substantial saving should be possible. 40

41 Ref Opportunity 15 Check icing of coolers 16 Arrange online monitoring service from electricity supplier 17 Check power factor correction equipment 18 Monitor oil deliveries 19 Seal holes in ceilings, access hatch etc in palleting area 20 Install monitoring and targeting system Indicative Benefits Lower energy use Improved Energy Management Lower energy cost Improved Energy Management Lower energy use Improved Energy Management Cost Range Category Target Date Additional Information Many coolers particularly in the storage areas are severely iced at the ends. It is No / Low Technical 3 Months likely that the unseen parts of the coils are also iced which lower and evaporating temperature and increase energy can use. No / Low Organisational 3 Months The use of this monitoring service would help build understanding of energy usage patterns. The account manager can be contacted for details. No / Low Technical 3 Months There is approximately 1000 in charges low power factor per year. A check and possible adjustments to PFC equipment can help avoid this charge Keeping a log of oil usage from the main tank can help in comparing usage with No / Low Organisational 3 Months production. This can be metered, tank volume can be regularly checked or deliveries can be more frequent and on a regular day so that the tank is kept full and deliveries relate directly to usage. This area was formerly a production area and many alterations have meant that No / Low Organisational 3 Months the ceiling is not very well sealed. The area is maintained close to 0 C so good sealing is important to minimise ingress of heat and moisture. A monitoring system would allow better a better understanding of precisely Medium Technical 12 Months where energy is used to help tune controls and reduce energy use. This would help in the peak management and help maximise use of night rate electricity. Some spot monitoring as described above could be done beforehand. 41

42 Ref Opportunity Indicative Benefits 21 Check segregation of different Lower energy temperature areas. use 22 Check pumping levels for WTP and Lower energy WWTP use 23 Water treatment plant measures Lower energy use 24 Wastewater plant measures Lower energy use 25 Check water nozzles used Lower energy use Cost Range Category Target Date Additional Information Medium Organisational 12 Months The barriers between areas at different temperatures can be checked. Particularly in the older areas, some doors etc are in bad repair or absent. A review of possible repair, use of curtains or where possible rearrangement to avoid the problem can be worthwhile. No / Low Technical 6 Months By optimising switching levels for pumps in the water treatment and wastewater treatment plants they can potentially be allowed to work at more efficient points on the pump curve. This typically involves adaptation of controls to allow holding tanks etc to work at a higher level if the pump is discharging. Medium Technical 12 Months Measures that can be investigated include the provision of sufficient storage for treated water to minimise processing at peak times. This could help reduce peak electrical demand and potentially allow water production at night rate. Filter backwash can also be scheduled for off-peak periods are possible. No / Low Technical 12 Months Measures that can be investigated include automatic control of duration of aeration blowers using dissolved oxygen sensors; shutting off sections was not needed of the aeration basins and the addition of buffer capacity to manage the in fluent flow rate and minimise on peak processing. Medium Technical 12 Months Use of less water has a threefold benefit: water treatment cost; energy cost for heating water; energy and other cost for treating of resultant effluent. 42

43 20.0 Assessment of the efficiency of use of raw materials in processes and the reduction in waste generated. There have been targets set over previous years to reduce waste volumes produced on site. There have been large improvements made on waste management structures and training over the past five years. This has resulted in a streamlined process, with emphasis on efficient use of raw materials and waste reduction. In 2010 it is proposed to further reduce waste produced by examining all incoming raw materials and packaging to eliminate the amount of back door waste being received on site Report on progress made and proposals being developed to minimise water demand and the volume of trade effluent discharges. As part of the EMP for 2009, a project to reduce volume of water used on site was implemented. A number of suspect lines were replaced or repaired over the first two quarters of There are ongoing improvements been implemented to further reduce leaks on site. Progress reports are made to all members of staff on improvements implemented in water consumption and volumes of wastewater generated. A new feather press was installed to reduce the amount of water sent for rendering with the feathers. Water is reused into the production process Toxicity Testing of Final Effluent Limited are required as part of their EPA IPPC licence P to carry out toxicity tests on a sample of undiluted final effluent to organisms from four different trophic levels. Shannon Aquatic Toxicity Laboratory will carry out the following toxicity tests in May 2010: 96 h LC to Oncorhynchus mykiss h EC to Daphnia magna h IC to Pseudokirchneriella subcapitata 50 5, 15 min EC to Vibrio fischeri 50 43

44 23. Reports on financial provision made under this licence, management and staffing structure of the installation, and a programme for public information. As per condition Communications Programme has established and maintains a Public Awareness and Communications Programme to ensure that members of the public can obtain information at the installation, at all reasonable times, concerning the environmental performance of the installation. Information kept in the Public Information File the licences relating to the installation; the current EMS for the installation; A copy of the most recent AER; records of all sampling, analyses, measurements, examinations, calibrations and maintenance carried out in accordance with the requirements of this licence and all other such monitoring which relates to the environmental performance of the installation; relevant correspondence with the Agency; up to date site drawings/plans showing the location of key processes and environmental infrastructure, including monitoring locations and emission points; up to date Standard Operational Procedures for all processes, plant and equipment necessary to give effect to this licence or otherwise to ensure that standard operation of such processes, plant or equipment does not result in unauthorised emissions to the environment; and any elements of the licence application documentation referenced in this licence. 44