For inspection purposes only.

Transcription

1 WYG Environment... part of the WYG group 8 26 th October \ Administration Office of Licence and Guidance Environmental Protection Agency PO Box 3000 Johnstown castle County Wexford Dear Sir I Madam, L Re: Application to the Environmental Protection Agency by Quinn Cement Limited for an Integrated Pollution Prevention and Control licence for the Quinn Cement Limited facility at Ballyconnell, SCotchtown, County Cavan Please find enclosed an Integrated Pollution Prevention and Control (IPPC) Licence application made on behalf of Quinn cement Limited for the Ballyconnell facility, SCotchtown. This IPPC Licence application is submitted in relation to the activities undertaken at the Ballyconnell facility under Class 10.1 'The Production ofcement'and Class 11.1 'The recovery or disposal ofwaste in a facility, within the meaning ofthe Actof 1996, which facility is connected or associated with another activity specified in this SChedule in respectof which a licence or revised licence under PartIVis in force or in respect ofwhich a licence under the said Part is or will be required'of the First SChedule of the Protection of the Environment Act The cement manufacturing processes currently undertaken on-site are authorised within IPPC Licence registration number This process is licensed for the production of 1.4million tonnes per annum of cement. Quinn cement Limited are seeking a revision to the existing IPPC Licence at the Ballyconnell facility to reflect proposals for an additional fuel for the production of cement. Currently, the sole fuel used at the Ballyconnell facility is coal, however, Quinn Cement Limited proposed to substitute 55% of this coal burden through the use of solid recovered fuel (SRF). Although the cement manufacturing process will remain unchanged, some modifications will need to be made to the existing plant to facilitate use of 5RF. These include the following: Installation of new fuel storage and feeding system; Installation of new calciner; Modify bypass set up (With new conditioning tower and moving existing bypass filter); Installation of new fan; Installation of new selective non catalytic reduction system for control of nitrogen oxide emissions; Modification to existing abatement systems; Installation of new silo at cement mill for bypass dust; and, Installation of new monitoring equipment. A new IPPC Licence is therefore required to reflect the above modifications. Planning permission is currently being applied for through cavan County Council and a Environmental Impact Statement has been submitted. A copy of the Environmental Impact Statement is included within the electronic files of this Licence application for reference. A formal letter of notification has been sent to cavan County Council in order to meet the notification requirements of section 87(1)(a) of the Environmental Protection Agency Act 1992 (as amended). This letter detailed the documentation submitted as part of the Licence Application and included copies of the Newspaper Notice and Site Notice as required by the Regulations. The newspaper article was placed in the Anglo Celt on 21 st October creative minds safe hands Regatta House, Oippers Quay, Salford Quays, Manchester, M50 3XP Tel: +44 (0) Fax: +44 (0) enviro.manchester@wyg.com W'fG Envtronment Planning Ttansport ltd RegIstered In England Number: RegIstEred ofllce: AmdaIe Court. Otley Road, Headlnglev I SirlUl.. EPA Export :16:44:20

2 Page 2 The fees for the IPPC Licence Application have been calculated at 22,8S4. This figure has been obtained from the SChedule of IPPC Licensing fees as set out in the EPA (Licensing Fees) (Amendment) Regulations 1994 to Since Quinn Cement Limited employ more than 50 pegple at their facility and the gross capital cost is expected to exceed more than 3.8M, it is classed as a Large Activity as specified in the Regulations. Class of Activity: 10. Cement: 11. Waste: 12,697 10,lS7 The fees for both activities are summed for the IPPC Application. I enclose the following documentation as part of this application for an IPPC Licence: 1No. signed original and 1No. copy of the IPPC Licence Application; 2No. electronic (CD ROM) copies of the IPPC Licence Application; 1No. electronic (CD ROM) copy of the Digital Drawing Files in DWG format; and, A cheque for 22,8S4 being the relevant fee for this application. An EIS has been undertaken by Quarryplan on behalf of Quinn Cement Limited for the SRF co-fuelling proposals of the Ballyconnell facility. The relevant number of hard and electronic copies of the EIS has been forward to the EPA by Quarryplan under separate cover on Quinn Cement Limited's behalf. I trust that we have provided all of the information which you require and I look forward to an early response in respect of the Application. Yours faithfully for WYG ENVIRONMENT Graeme Blacklock senior Environmental Consultant EPA Export :16:44:20

3 Integrated Pollution Prevention and Control (IPPC) Licensing Application Form EPA Reg. N o : (Office use only) Environmental Protection Agency P.O. Box 3000, Johnstown Castle Estate, Co. Wexford Lo Call: Telephone: Fax: Web: info@epa.ie EPA Export :16:44:20

4 IPPC Application Form V1/07 CONTENTS ABOUT THIS APPLICATION FORM... 3 SECTION A: NON-TECHNICAL SUMMARY... 4 SECTION B: GENERAL... 5 SECTION C: MANAGEMENT OF THE INSTALLATION... 9 SECTION D: INFRASTRUCTURE & OPERATION... 9 SECTION E: EMISSIONS... 9 SECTION F: CONTROL & MONITORING SECTION G: RESOURCE USE AND ENERGY EFFICIENCY SECTION H: MATERIALS HANDLING SECTION I: EXISTING ENVIRONMENT & IMPACT OF THE ACTIVITY SECTION J: ACCIDENT PREVENTION & EMERGENCY RESPONSE SECTION K: REMEDIATION, DECOMMISSIONING, RESTORATION & AFTERCARE SECTION L: STATUTORY REQUIREMENTS SECTION M: DECLARATION ANNEX 1: TABLES/ATTACHMENTS ANNEX 2: CHECKLIST FOR ARTICLE 10 COMPLIANCE Page 2 of 80 EPA Export :16:44:20

5 IPPC Application Form V1/07 ABOUT THIS APPLICATION FORM This form is for the purpose of making an application for an Integrated Pollution Prevention and Control (IPPC) Licence under the Environmental Protection Agency Acts, 1992 and There are separate application forms for licensees who wish to apply for a review of existing licences and for Pig & Poultry sector applicants. The Application Form must be completed in accordance with the instructions provided in the IPPC Licensing Application Guidance Note. The Guidance Note gives an overview of IPPC Licensing, outlines the licence application process (including number of copies required) and specifies the information to be submitted in the application. The Guidance Note and application forms are available to download from the IPPC Licensing pages of the EPA s website at A valid application for an IPPC licence must contain the information prescribed in the Environmental Protection Agency (Licensing) Regulations, 1994 to Article 10 of the Regulations sets out the statutory requirements for information to accompany a licence application. The application form is designed in such a way as to set out these questions in a structured manner and not necessarily in the order presented in Article 10. In order to ensure a legally valid application in respect of Article 10 requirements, please complete the Article 10 Checklist provided in Annex 2. This Application Form does not purport to be and should not be considered a legal interpretation of the provisions and requirements of the Environmental Protection Agency Acts, 1992 and 2003 and the Environmental Protection Agency (Licensing) Regulations 1994 to While every effort has been made to ensure the accuracy of the material contained in the Application Form, the EPA assumes no responsibility and gives no guarantees, undertakings and warranties concerning the accuracy, completeness or up-to-date nature of the information provided herein and does not accept any liability whatsoever arising from any errors or omissions. Should there be any contradiction between the information requirements set out in the Application Form and any clarifying explanation contained in the accompanying Guidance Note, then the requirements in this Application Form shall take precedence. Page 3 of 80 EPA Export :16:44:20

6 IPPC Application Form V1/07 SECTION A: NON-TECHNICAL SUMMARY A non-technical summary of the application is to be included here. The summary should identify all environmental impacts of significance associated with the carrying on of the activity/activities, and describe mitigation measures proposed or existing to address these impacts. This description should also indicate the normal operating hours and days per week of the activity. The following information must be included in the non-technical summary: A description of: the installation and its activities, the raw and auxiliary materials, other substances and the energy used in or generated by the installation, the sources of emissions from the installation, the environmental conditions of the site of the installation (e.g. soil and groundwater, air, noise, surface water), the nature and quantities of foreseeable emissions from the installation into each medium as well as identification of significant effects of the emissions on the environment, the proposed technology and other techniques for preventing or, where this is not possible, reducing emissions from the installation, where necessary, measures for the prevention and recovery of waste generated by the installation, further measures planned to comply with the general principles of the basic obligations of the operator i.e. (a) all the appropriate preventive measures are taken against pollution, in particular through application of the Best Available Techniques (BAT); (b) no significant pollution is caused; (c) waste production is avoided in accordance with Council Directive 75/442/EEC of 15 July 1975 on waste; where waste is produced, it is recovered or, where that is technically and economically impossible, it is disposed of while avoiding or reducing any impact on the environment; (d) energy and other resources are used efficiently; (e) the necessary measures are taken to prevent accidents and limit their consequences; (f) the necessary measures are taken upon definitive cessation of activities to avoid any pollution risk and return the site of operation to a satisfactory state. measures planned to monitor emissions into the environment. Supporting information should form Attachment N o A.1 Page 4 of 80 EPA Export :16:44:20

7 IPPC Application Form V1/07 SECTION B: GENERAL B.1. Owner/Operator Name*: Quinn Cement Limited Address: Scotchtown Ballyconnell County Cavan Ireland Tel: Fax: * This should be the name of the applicant which is current on the date this IPPC Licence Application is lodged with the Agency. It should be the name of the legal entity (which can be a limited company or a sole trader). A trading/business name is not acceptable. Name and Address for Correspondence Only application documentation submitted by the applicant and by the nominated person will be deemed to have come from the applicant. Name: Address: Tel: Fax: Quinn Cement Limited c/o Steve Tonry Scotchtown Ballyconnell County Cavan Ireland As above As above Steve.tonry@quinn-group.com Address of registered or principal office of Body Corporate (if applicable) Address: Quinn Cement Limited Scotchtown Ballyconnell County Cavan Tel: Fax: If the applicant is a body corporate, the following information must be attached as Attachment B1: a) a Certified Copy of the Certificate of Incorporation. b) the Company s Registration Number from the Companies Registry Office. c) Particulars of Registered Office of the Company. Page 5 of 80 EPA Export :16:44:20

8 IPPC Application Form V1/07 Name and address of the proprietor(s) of the Land on which the Activity is situated (if different from applicant named above): Proprietor s Name: Quinn Cement Limited c/o Steve Tonry Address: Scotchtown Ballyconnell County Cavan Ireland Tel: Fax: Steve.tonry@quinn-group.com Name and address of the owner(s) of the building and ancillary plant in which the activity is situated ( if different from applicant named above): Name: Address: Tel: As above B.2. Location of Activity Name: Quinn Cement Limited Address*: Scotchtown Ballyconnell County Cavan Ireland Tel: Fax: Contact Name: Steve.tonry@quinn-group.com Position: Business Manager Renewable Energy and Environment Manager Steve.tonry@quinn-group.com * Include any townland. National Grid Reference (12 digit 6E,6N) , Location maps ( A3), appropriately scaled, with legible grid references should be enclosed in Attachment B.2. The site boundary must be outlined on the map in colour. Geo-referenced digital drawing files (e.g. AutoCAD files) in Irish Grid projection of the site boundary and overall site plan, including labelled emission, monitoring and sampling points, are also required. This data should be provided to the Agency on a separate CD- Rom containing sections B.2, E.6 and F.3. Name of geo-referenced digital drawing files Name of CD-Rom with digital drawing files Boiler Emissions points- geo reference.dwg; MAIN EMISSIONS POINTS- geo reference.dwg; Minor Emissons points- geo reference.dwg Noise Emissions-geo reference.dwg Surface water & Sewer emission points- geo reference.dwg SW-FW-D- geo reference.dwg Quinn Cement Application DGW Files Page 6 of 80 EPA Export :16:44:20

9 IPPC Application Form V1/07 B.3. Class of Activity Identify the relevant activities in the First, Third or Fourth Schedule of the PoE Act 2004 to which the activity relates: Schedule Class Description Note The production of cement The recovery of waste Note 1: In order to give a precise identification select only those words from the description of the class or classes that best describes the nature of the activity for which the licence is being applied for. B.4. Employees/ Capital Cost Give- (i) In the case of an established activity, the number of employees and other persons working or engaged in connection with the activity on the date after which a licence is required and during normal levels of operation, or (ii) In any other case, the gross capital cost of the activity to which the application relates. Number of Employees (existing facilities): 98 Gross Capital Cost (new proposals) 20million B.5. Relevant Planning Authority Give the name of the planning authority in whose functional area the activity is or will be carried out. Name: Cavan County Council Address: County Council Offices Court House, Farnham Street Cavan County Cavan Tel: (049) Fax: (049) Planning Permission relating to this application: has been obtained is being processed is not yet applied for is not required Local Authority Planning File Reference N o : Awaiting receipt application yet to be processed Attachment B.5 should contain all planning permissions, including a copy of all conditions, and the required copies of any EIS should also be enclosed. For existing activities, Attachment N o B.5 should also contain all licences and permits past and present in force at the time of submission. Page 7 of 80 EPA Export :16:44:20

10 IPPC Application Form V1/07 B.6. Relevant Sanitary Authority. In the case of a discharge of any trade effluent or other matter to a sewer of a sanitary authority, give the name of the sanitary authority in which the sewer is vested or by which it is controlled. Name: Cavan County Council Address: County Council Offices Court House, Farnham Street Cavan County Cavan Tel: (049) Fax: (049) In the case of a discharge of any trade effluent or other matter to a sewer not vested by a sanitary authority, the applicant must supply as Attachment N o B.6; (a) the name and address of the owner(s) of the sewer and the waste water treatment plant to which the sewer discharges and who are responsible for the quality of the treated effluent discharging to waters and (b) a copy of the effluent regulations and the agreement between the applicant and the aforementioned. Name: Address: Tel: Fax: N/A B.7. Relevant Health Board Region The applicant should indicate the Health Board Region where the activity is or will be located. Name: Health Service Executive Dublin North East Address: Cavan PCCC Office Lisdaran Cavan Co. Cavan Tel: Fax: B.8 Site Notice, Newspaper Advertisement and Planning Authority Notice. Attachment N o B.8 should contain a copy of the text of the site notice, a map (no larger than A3) showing its location on site (in accordance with Article 7 of the Regulations) and a copy of the newspaper advertisement. A copy of the notice given to the Planning Authority should also be included. B.9 Seveso II Regulations State whether the activity is an establishment to which the EC (Control of Major Accident Hazards involving Dangerous Substances) Regulations (S.I. No. 74 of 2006) apply. If yes, outline how the process comes under these regulations. Page 8 of 80 EPA Export :16:44:20

11 IPPC Application Form V1/07 Supporting information should be included in Attachment N o B.9. B.10 IPPC Directive Specify whether the activity is a category of industrial activity referred to in Annex I of the IPPC Directive (96/61/EC) and if yes specify the category. Supporting information should be included in Attachment N o B.10. SECTION C: MANAGEMENT OF THE INSTALLATION C.1 Site Management & Control Details should be provided on the management structures for the activity. Organisational charts and all relevant environmental management policy statements, including provisions for on-going assessment of environmental performance, are required. C.2 Environmental Management System (EMS) Indicate whether an Environmental Management System has been developed for the installation. If yes, specify which standard and include a copy of the accreditation certificate. C.3 Hours of Operation Provide details of the hours of operation for the installation, including: (a) Proposed hours of operation. (b) Proposed hours of construction and development works and timeframes. (c) Any other relevant hours of operation expected. This information should form Attachment N o C. SECTION D: INFRASTRUCTURE & OPERATION D.1. Operational Information Requirements Describe the plant, methods, processes, ancillary processes, abatement, recovery and treatment systems, and operating procedures for the activity, to include a copy of such plans, drawings or maps, (site plans and location maps, process flow diagrams), and such other particulars, reports and supporting documentation as are necessary to describe all aspects of the activity. Maps and drawings must be no larger than A3 size. A development and operational history of the site should be included here. Attachment N o D should contain a list of all unit operations (processes) to be carried out, including flow diagrams of each with any relevant additional information. SECTION E: EMISSIONS E.1. Emissions to Atmosphere E.1.A. Details of all point emissions to atmosphere Page 9 of 80 EPA Export :16:44:20

12 IPPC Application Form V1/07 Details of all point emissions to atmosphere should be supplied. Complete Table E.1(i) for Boiler Emissions and Table E.1(ii) and E.1(iii) for all other main emission points. Complete Table E.1(iv) for minor emission points. A summary list of the emission points, together with maps and/or drawings (no larger than A3), and supporting documentation should be included as Attachment N o E. Plans of emission elevations, relevant roof heights, etc., should also be included, as should detailed descriptions and schematics of all abatement systems. The applicant should address in particular any emission point where the substances listed in the Schedule of S.I. 394 of 2004 are emitted. For emissions outside the BAT guidance limit, a full evaluation of the existing abatement/treatment system must be provided. A planned programme of improvement towards meeting upgraded standards is required. This should highlight specific goals and a time scale, together with options for modification, upgrading or replacement as required to bring the emissions within the limits as set out in the BAT guidance note(s). These notes can be found on the EPA website at E.1.B. Fugitive and Potential emissions Give summary details of fugitive and potential emissions in Table E.1(v). In relation to activities listed in the Schedule of Council Directive 1999/13/EC on the limitation of emissions of volatile organic compounds due to the use of organic solvents in certain activities and installations; specify the relevant category of activity in the Schedule specify how the requirements in relation to fugitive emissions will be met. Full details and any supporting information should form Attachment E.1.B E.2 Emissions to Surface Waters Tables E.2(i) and E.2(ii) should be completed. A summary list of the emission points, together with maps/drawings (no larger than A3) and supporting documentation should be included as Attachment N o E.2. The applicant should address in particular any emission point where the substances listed in the Schedule of S.I. No. 394 of 2004 are emitted. Details of all List I and List II substances listed in the Annex to EU Directive 76/464/EEC (as amended), contained in any emission must be presented. All surface water runoff and storm water drains discharging to surface water bodies must be included. A National Grid References (12 digit, 6E, 6N) must be given for all discharge points. The identity and type of receiving water (river, ditch, estuary, lake, etc.) must be stated. For emissions outside the BAT guidance limit, a full evaluation of the existing abatement/treatment system must be provided. A planned programme of improvement towards meeting upgraded standards is required. This should highlight specific goals and a time scale, together with options for modification, upgrading or replacement as required to bring the emissions within the limits as set out in the BAT guidance note(s). E.3 Emissions to Sewer Tables E.3(i) and E.3(ii) should be completed. Page 10 of 80 EPA Export :16:44:20

13 IPPC Application Form V1/07 A summary list of the emission points, together with maps and/or drawings (no larger than A3) and supporting documentation should be included as Attachment N o E.3. Details of all List I and List II substances listed in the Annex to EU Directive 76/464/EEC (as amended), contained in any emission must be presented. All relevant information on the receiving sewer, including any effluent treatment/abatement systems, not already described, with schematics as appropriate should also be included in Attachment N o E.3. For emissions outside BAT guidance limit (where given), a full evaluation of the existing abatement/treatment system must be provided. A planned programme of improvement towards meeting upgraded standards is required. This should highlight specific goals and a time scale, together with options for modification, upgrading or replacement as required to bring the emissions within any limits set out in the BAT guidance note(s). E.4. Emissions to Ground Describe the existing or proposed arrangements necessary to give effect to Articles 3,4,5,6, and 7 of Council Directive 80/68/EEC of 17 December 1979 on the protection of groundwater against pollution by certain dangerous substances. The applicant should supply details of the nature and quality of the substance (agricultural and non-agricultural waste) to be landspread (slurry, effluent, sludges etc) as well as the proposed application rates, periods of application and mode of application (e.g., pipe discharge, tanker). For emissions outside the BAT guidance limit, a full evaluation of the existing abatement/treatment system must be provided. A planned programme of improvement towards meeting upgraded standards is required. This should highlight specific goals and a time scale, together with options for modification, upgrading or replacement as required to bring the emissions within the limits as set out in the BAT guidance note(s). E.5 Noise Emissions Give particulars of the source, location, nature, level, and the period or periods during which the noise emissions are made or are to be made. Table E.5(i) should be completed, as relevant, for each source. Supporting information should form Attachment N o E.5 For emissions outside the EPA Guidance Note for Noise in elation to Scheduled Activities 2 nd Edition (2006), a full evaluation of the existing abatement/treatment system must be provided. A planned programme of improvement towards meeting upgraded standards is required. This should highlight specific goals and a time scale, together with options for modification, upgrading or replacement as required to bring the emissions within the limits as set out in the Guidance Note. E.6 Tabular Data on Emission Points Applicants should submit the following information for each emission point: Point Code Provide label ID s assigned in section E Point Type Easting Northing Verified Emission A=Atmospheric SW=Surface Water SE = Sewer GW=Groundwater N = Noise 6E-digit GPS Irish National Grid Reference 6N-digit GPS Irish National Grid Reference Y = GPS used N = GPS not used e.g. SO 2, HCl, NH 3 Page 11 of 80 EPA Export :16:44:20

14 IPPC Application Form V1/07 SL=Soil/Ground WS=Waste An individual record (i.e. row) is required for each emission point. Acceptable file formats include Excel, Access or other upon agreement with the Agency. A standard Excel template can be downloaded from the EPA website at This data should be submitted to the Agency on a separate CD-Rom containing sections B.2, E.6 and F.3. SECTION F: CONTROL & MONITORING Describe the proposed technology and other techniques for preventing or, where this is not possible, reducing emissions from the installation/facility. F.1: Treatment, Abatement and Control Systems Details of treatment/abatement systems (air and effluent emissions) should be included, together with schematics as appropriate. For each Emission Point identified complete Table F.1(i) and include detailed descriptions and schematics of all abatement systems. Attachment N o F.1 should contain any supporting information. F.2: Emissions Monitoring and Sampling Points Identify monitoring and sampling points and outline proposals for monitoring emissions. Table F.2(i) should be completed (where relevant) for air emissions, for emissions to surface waters, for emissions to sewers, for emissions to ground, and for waste emissions. Where ambient environment monitoring is carried out or proposed, Table F.2(ii) should be completed as relevant for each environmental medium. Include details of monitoring/sampling locations and methods. Attachment N o F.2 should contain any supporting information. F.3: Tabular Data on Monitoring and Sampling Points Applicants should submit the following information for each monitoring and sampling point: Point Code Provide label ID s assigned in section F3 Point Type Easting Northing Verified Pollutant M=Monitoring S=Sampling 6E-digit GPS Irish National Grid Reference 6N-digit GPS Irish National Grid Reference Y = GPS used N = GPS not used e.g. SO 2, HCl, NH 3 An individual record (i.e. row) is required for each monitoring and sampling point. Acceptable file formats include Excel, Access or other upon agreement with the Agency. A standard Excel template can be downloaded from the EPA website at This data should be submitted to the Agency on a separate CD-Rom containing sections B.2, E.6 and F.3. Point source monitoring/sampling refers to monitoring from specific emission points (e.g. from a boiler stack or outlet from a wastewater treatment plant). Examples of ambient Page 12 of 80 EPA Export :16:44:20

15 IPPC Application Form V1/07 monitoring includes monitoring of ambient air quality (e.g. boundary or off-site) or monitoring of river quality upstream/downstream of an effluent discharge. SECTION G: RESOURCE USE AND ENERGY EFFICIENCY G.1 Give a list of the raw and ancillary materials, substances, preparations, fuels and energy which will be produced by or utilised in the activity. The list(s) given should be very comprehensive, all materials used, fuels, intermediates, laboratory chemicals and product should be included. Particular attention should be paid to materials and product consisting of, or containing, dangerous substances as described in the EU (Classification, Packaging, Labelling and Notification of Dangerous Substances) Regulations 1994 [SI 77/94]. The list must classify these materials in accordance with Article 2 of these Regulations, and must specify the designated Risk Phrases (R-Phrases) of each substance in accordance with Schedule 2 of the Regulations Tables G.1(i) and G.1(ii) must be completed. Copy as required. Supporting information should be given in Attachment N o G. G.2 Energy Efficiency A description of the energy used in or generated by the activity must be provided. Outline the measures taken to ensure that energy is used efficiently and where appropriate, an energy audit with reference to the EPA Guidance document on Energy Audits should be carried out. SECTION H: MATERIALS HANDLING H.1 Raw Materials, Intermediates and Product Handling All materials should be listed in Tables G.1(i) and G.(ii) of Section G. Details of the storage conditions, location within the site, segregation system used and transport systems within the site should be outlined here. In addition, information relating to the integrity, impermeability and recent testing of pipes, tanks and bund areas should be outlined. H.2 Describe the arrangements for the recovery or disposal of solid and liquid wastes accepted into or generated by the installation/facility. For each waste material, give full particulars of: (a) Name (b) Description & nature of waste (c) Source (d) Where stored and integrity/impermeability of storage areas (e) Amount (m 3 ) and tonnage (f) Period or Periods of generation Page 13 of 80 EPA Export :16:44:20

16 IPPC Application Form V1/07 (g) Analysis ( include test methods and Q.C. ) (h) European Waste Catalogue Code (i) Waste Category per EC Reg 1774/2002/EC where relevant Where any waste would be classified as Hazardous Waste as defined in the Waste Management Acts, 1996 to 2003, this should be made clear in the information provided. Summary Tables H.1(i) and H.1(ii) should also be completed, as appropriate, for each waste. The licence/permit register number of the waste collection agent or disposal/recovery operator should be supplied as well as the expiry date of the relevant permits. Supporting information should form Attachment N o H.2 H.3 Waste disposal by on-site landfilling For wastes to be disposed of by landfilling on-site, full details of the disposal site should be submitted (to include inter alia, site selection procedures, location maps, (no larger than A3) geology, hydrogeology, operational plan, containment, gas and leachate management, post-closure care). Supporting information should form Attachment N o H.3. SECTION I: EXISTING ENVIRONMENT & IMPACT OF THE ACTIVITY Describe the conditions of the site of the installation. Provide an assessment of the effects of any emissions on the environment, including on an environmental medium other than that into which the emissions are made. Describe, where appropriate, measures for minimising pollution over long distances or in the territory of other states. I.1.Assessment of atmospheric emissions Describe the existing environment in terms of air quality with particular reference to ambient air quality standards. Provide a statement whether or not emissions of main polluting substances (as defined in the Schedule of S.I. 394 of 2004) to the atmosphere are likely to impair the environment. Give summary details and an assessment of the impacts of any existing or proposed emissions on the environment, including environmental media other than those into which the emissions are to be made. Attachment N o I.1 should also contain full details of any dispersion modelling of atmospheric emissions from the activity, where required. When carrying out dispersion modelling, regard should be had to the "Guidelines for the Preparation of Dispersion Modelling Assessments for Compliance with Regulatory Requirements an Update to Royal Meteorological Society Guidance" or similar guidelines from a recognised authority. I.2. Assessment of Impact on Receiving Surface Water Page 14 of 80 EPA Export :16:44:20

17 IPPC Application Form V1/07 Describe the existing environment in terms of water quality with particular reference to environmental quality standards or other legislative standards. Table I.2(i) should be completed Provide a statement whether or not emissions of main polluting substances (as defined in the Schedule of S.I. 394 of 2004) to water are likely to impair the environment. Give summary details and an assessment of the impacts of any existing or proposed emissions on the environment, including environmental media other than those into which the emissions are to be made. Full details of the assessment and any other relevant information on the receiving environment should be submitted as Attachment N o I.2. I.3. Assessment of Impact of Sewage Discharge. Give summary details and an assessment of the impacts of any existing or proposed emissions on the environment, including environmental media other than those into which the emissions are to be made. Full details of the assessment and any other supporting information should form Attachment N o I.3. I.4 Assessment of Impact of Ground/Groundwater Emissions Describe the existing groundwater quality. Tables I.4(i) should be completed. Give summary details and an assessment of the impacts of any existing or proposed emissions on the ground (aquifers, soils, sub-soils and rock environment), including any impact on environmental media other than those into which the emissions are to be made. This includes landspreading, land injection etc. Land on which material may be landspread shall be identified on a suitable scaled map (1:10,560 and 1:50,000) and submitted as no greater than A3 size. All vulnerable (as a result of ground emissions) surface water bodies must be identified on these maps. Additional information should be included in Attachment N o I.4. Landspreading of Agricultural/Non Agricultural Wastes Tables I.4(ii) and I.4.(iii) should be complete where applicable. Further information is available in the Application Guidance Document. I.5 Ground and/or Groundwater Contamination Summary details of known ground and/or groundwater contamination, historical or current, on or under the site must be given. Full details including all relevant investigative studies, assessments, or reports, monitoring results, location and design of monitoring installations, plans, drawings, documentation, including containment engineering, remedial works, and any other supporting information should be included in Attachment N o I.5. I.6 Assessment of the Environmental Impact of On-site Waste Recovery and/or Disposal. Describe the arrangements for the prevention and recovery of waste generated by the activity. Page 15 of 80 EPA Export :16:44:20

18 IPPC Application Form V1/07 Give details, and an assessment of the impact of any existing or proposed on-site waste recovery/disposal on the environment, including environmental media other than those into which the emissions are to be made. This information should form Attachment N o I.6. I.7 Noise Impact Give details and an assessment of the impacts of any existing or proposed emissions on the environment, including environmental media other than those into which the emissions are to be made. Ambient noise measurements Complete Table I.7(i) in relation to the information required below: (i) (ii) State the maximum Sound Pressure Levels which will be experienced at typical points on the boundary of the operation. (State sampling interval and duration) State the maximum Sound Pressure Levels which will be experienced at typical noise sensitive locations, outside the boundary of the operation. (iii) Give details of the background noise levels experienced at the site in the absence of noise from this operation. Prediction models, maps (no larger than A3), diagrams and supporting documents, including details of noise attenuation and noise proposed control measures to be employed, should form Attachment N o I.7. I.8 Environmental Considerations and BAT Describe in outline the main alternatives, if any, to the proposals contained in the application. Describe any environmental considerations which have been made with respect to the use of cleaner technologies, waste minimisation and raw material substitution. Describe the measures proposed or in place to ensure that: (a) The best available techniques are or will be used to prevent or eliminate or, where that is not practicable, generally reduce an emission from the activity; (b) no significant pollution is caused; (c) waste production is avoided in accordance with Council Directive 75/442/EEC of 15 July 1975 on waste; where waste is produced, it is recovered or, where that is technically and economically impossible, it is disposed of while avoiding or reducing any impact on the environment; (d) energy and other resources are used efficiently; (e) the necessary measures are taken to prevent accidents and limit their consequences; (f) the necessary measures are taken upon definitive cessation of activities to avoid any pollution risk and return the site of operation to a satisfactory state. Supporting information should form Attachment N o I.8. Page 16 of 80 EPA Export :16:44:20

19 IPPC Application Form V1/07 SECTION J: ACCIDENT PREVENTION & EMERGENCY RESPONSE Describe the existing or proposed measures, including emergency procedures, to minimise the impact on the environment of an accidental emission or spillage. Also outline what provisions have been made for response to emergency situations outside of normal working hours, i.e. during night-time, weekends and holiday periods. Describe the arrangements for abnormal operating conditions including start-up, leaks, malfunctions or momentary stoppages. Supporting information should form Attachment N o J. SECTION K: REMEDIATION, DECOMMISSIONING, RESTORATION & AFTERCARE Describe the existing or proposed measures to minimise the impact on the environment after the activity or part of the activity ceases operation, including provision for postclosure care of any potentially polluting residuals. Supporting information should be included as Attachment No. K. SECTION L: STATUTORY REQUIREMENTS Indicate how the requirements of Section 83(5)(a)(i) to (v) and (vii) to (x) of the EPA Acts, 1992 and 2003 shall be met, having regard, where appropriate, to any relevant specification issued by the Agency under section 5 (3) of the Act and the reasons for the selection of the arrangements proposed. Indicate whether or not the activity is carried out, or may be carried out, or is located such that it is liable to have an adverse effect on - (a) a site placed on a list in accordance with Chapter 1 of SI 94 of 1997, or (b) a site where consultation has been initiated in accordance with Article 5 of the EU Habitats Directive (92/43/EEC), or Indicate whether or not the activity is liable to have an adverse effect on water quality in light of S.I. No. 258 of 1998 (Local Government (Water Pollution) Act, 1977 (Water Quality Standards for Phosphorus) Regulations, 1998). Indicate whether any of the substances specified in the Schedule of the EPA (Licensing)(Amendment) 2004, S.I. 394 of 2004, are discharged by the activity to the relevant medium. Fit and Proper Person The PoE Act in Section 83(5)(xi) specifies that the Agency shall not grant a licence unless it is satisfied that the applicant or licensee or transferee as the case may be is a fit and proper person. Section 84(4) of the PoE Act specifies the information required to enable a determination to be made by the Agency. Indicate whether the applicant or other relevant person has been convicted under the PoE Act, the Waste Management Act 1996, the Local Government (Water pollution) Acts 1977 and 1990 or the Air Pollution Act Page 17 of 80 EPA Export :16:44:21

20 IPPC Application Form V1/07 Provide details of the applicant s technical knowledge and/or qualifications, along with that of other relevant employees. Provide information to show that the person is likely to be in a position to meet any financial commitments or liabilities that may have been or will be entered into or incurred in carrying on the activity to which the application relates or in consequence of ceasing to carry out that activity. Supporting information should be included as Attachment N o L with reference to where the information can be found in the application. SECTION M: DECLARATION Declaration I hereby make application for a licence / revised licence, pursuant to the provisions of the Environmental Protection Agency Acts, 1992 and 2003 and Regulations made thereunder. I certify that the information given in this application is truthful, accurate and complete. I give consent to the EPA to copy this application for its own use and to make it available for inspection and copying by the public, both in the form of paper files available for inspection at EPA and local authority offices, and via the EPA's website. This consent relates to this application itself and to any further information, submission, objection, or submission to an objection whether provided by me as Applicant, any person acting on the Applicant s behalf, or any other person. Signed by: (on behalf of the organisation) Print signature name: Date: Position in organisation: Company stamp or seal: Page 18 of 80 EPA Export :16:44:21

21 IPPC Application Form V1/07 ANNEX 1: TABLES/ATTACHMENTS Page 19 of 80 EPA Export :16:44:21

22 IPPC Application Form V1/07 Table E.1 (i) BOILER EMISSIONS TO ATMOSPHERE (1 Page for each emission point) Emission Point: Emission Point Ref. N o : N/A boilers are rated lower than 250kW and, therefore, are included as minor emissions in accordance with IPPC Application Guidance. Location: Grid Ref. (12 digit, 6E,6N): Vent Details Diameter: Height above Ground(m): Date of commencement of emission: Characteristics of Emission: Boiler rating Steam Output: Thermal Input: Boiler fuel Type: Maximum rate at which fuel is burned % sulphur content: NOx Maximum volume* of emission Temperature o C(max) o C(min) kg/hr MW kg/hr mg/nm 3 0 o C. 3% O 2 (Liquid or Gas), 6% O 2 (Solid Fuel) m 3 /hr 0 o C, 3 % O 2 (liquid or gas), 6 % O 2 (solid fuel) o C(avg) * Volume flow limits for emissions to atmosphere shall be based on Normal conditions of temperature and pressure, (i.e. 0 o C,101.3kPa), dry gas; 3% oxygen for liquid and gas fuels; 6% oxygen for solid fuels. (i) Period or periods during which emissions are made, or are to be made, including daily or seasonal variations (start-up/shutdown to be included): Periods of Emission (avg) min/hr hr/day day/yr Page 20 of 80 EPA Export :16:44:21

23 IPPC Application Form V1/07 TABLE E.1(ii) MAIN EMISSIONS TO ATMOSPHERE (1 Page for each emission point) Emission Point Ref. N o : A2-01 Source of Emission: Location: ESP Exhaust from raw mill, cement kiln and bypass East Side of Building 421, next to preheater Grid Ref. (12 digit, 6E,6N): , Vent Details Diameter: Height above Ground(m): 3.5 m 118 Date of commencement: Characteristics of Emission: (i) Volume to be emitted: Average/day 9,120,000 m 3 /d Maximum/day 11, Nm 3 /d Maximum rate/hour 472,500 Nm 3 /h Min efflux velocity 13.0 m/sec (ii) Other factors Temperature C (max) 120 o C(min) 150 o C(avg) For Combustion Sources: Volume terms expressed as : wet. dry. 10 %O 2 (iii) Period or periods during which emissions are made, or are to be made, including daily or seasonal variations (start-up /shutdown to be included): Periods of Emission (avg) 60 min/hr 24 hr/day 330 day/yr Page 21 of 80 EPA Export :16:44:21

24 IPPC Application Form V1/07 TABLE E.1(ii) MAIN EMISSIONS TO ATMOSPHERE (1 Page for each emission point) Emission Point Ref. N o : A2-02 Source of Emission: Location: Clinker Cooler South of Building 441, next to preheater Grid Ref. (12 digit, 6E,6N): , Vent Details Diameter: Height above Ground(m): 3m Date of commencement: Characteristics of Emission: (i) Volume to be emitted: Average/day 4,573,000Nm 3 /d Maximum/day 5,488,000Nm 3 /d Maximum rate/hour 228,700Nm 3 /h Min efflux velocity 13.4 m/sec (ii) Other factors Temperature 300 o C(max) 200 o C (min) 260 o C (avg) For Combustion Sources: Volume terms expressed as : wet. dry %O 2 (iii) Period or periods during which emissions are made, or are to be made, including daily or seasonal variations (start-up /shutdown to be included): Periods of Emission (avg) 60 min/hr 24 hr/day 330 day/yr Page 22 of 80 EPA Export :16:44:21

25 IPPC Application Form V1/07 TABLE E.1(ii) MAIN EMISSIONS TO ATMOSPHERE (1 Page for each emission point) Emission Point Ref. N o : A2-03 Source of Emission: Coal Mill Location: East of Building 461 Grid Ref. (12 digit, 6E,6N): , Vent Details Diameter: Height above Ground(m): 1m 47.5 Date of commencement: Characteristics of Emission: (i) Volume to be emitted: Average/day 720,000 Nm 3 /d Maximum/day 860,000 Nm 3 /d Maximum rate/hour 70,100 Nm 3 /h Min efflux velocity 18.0 m/sec (ii) Other factors Temperature o C (max) o C (min) 90 o C (avg) For Combustion Sources: Volume terms expressed as : wet. dry. 10 %O 2 (iii) Period or periods during which emissions are made, or are to be made, including daily or seasonal variations (start-up /shutdown to be included): Periods of Emission (avg) 60 min/hr 20 hr/day 330 day/yr Page 23 of 80 EPA Export :16:44:21

26 IPPC Application Form V1/07 TABLE E.1(ii) MAIN EMISSIONS TO ATMOSPHERE (1 Page for each emission point) Emission Point Ref. N o : A2-04 Source of Emission: Cement Mill Ventilation Location: On top of Building 541 Grid Ref. (12 digit, 6E,6N): , Vent Details Diameter: Height above Ground(m): 1.12m 38.9 Date of commencement: Characteristics of Emission: (i) Volume to be emitted: Average/day 1,260,000Nm 3 /d Maximum/day 1,512,000Nm 3 /d Maximum rate/hour 63,000Nm 3 /h Min efflux velocity 17.0m/sec (ii) Other factors Temperature o C (max) o C (min) 107 o C(avg) For Combustion Sources: Volume terms expressed as : wet. dry. 10 %O 2 (iii) Period or periods during which emissions are made, or are to be made, including daily or seasonal variations (start-up /shutdown to be included): Periods of Emission (avg) 60 min/hr 20 hr/day 330 day/yr Page 24 of 80 EPA Export :16:44:21

27 IPPC Application Form V1/07 TABLE E.1(ii) MAIN EMISSIONS TO ATMOSPHERE (1 Page for each emission point) Emission Point Ref. N o : A2-05 Source of Emission: Sepax Separator for Cement Mill Location: On top of Building 541 Grid Ref. (12 digit, 6E,6N): , Vent Details Diameter: Height above Ground(m): 2m 38.9 Date of commencement: Characteristics of Emission: (i) Volume to be emitted: Average/day 4,017,600Nm 3 /d Maximum/day 4,821,120Nm 3 /d Maximum rate/hour 200,800Nm 3 /h Min efflux velocity (ii) Other factors 17.0m.sec -1 Temperature o C (max) o C (min) 107 o C(avg) For Combustion Sources: Volume terms expressed as : wet. dry. 10 %O 2 (iii) Period or periods during which emissions are made, or are to be made, including daily or seasonal variations (start-up /shutdown to be included): Periods of Emission (avg) 60 min/hr 20 hr/day 330 day/yr Page 25 of 80 EPA Export :16:44:21

28 IPPC Application Form V1/07 TABLE E.1(iii): MAIN EMISSIONS TO ATMOSPHERE - Chemical characteristics of the emission (1 table per emission point) Emission Point Reference Number: A2-01 Parameter Prior to treatment (1) Brief As discharged (1) Oxides of Nitrogen (as NO 2 ) mg/nm 3 kg/h description mg/nm 3 kg/h. kg/year Avg Max Avg Max of treatment Avg Max Avg Max Avg Max 1,000 1, Sulphur Dioxide (SO 2 ) Particulates 58,700 61,385 35,200 36,381 Carbon Monoxide (CO) 3,000 6,000 1,800 3,600 Calciner designed to minimise emissions. SNCR system installed in calciner to remove NO x. No abatement system. Pyrite content of raw materials controlled Electrostatic precipitator 1F400/H2P/4*35* /1C/1K/2L D. The precipitator has a standard efficiency of 99.96% at 75.3 g/nm 3 dust load No abatement system. Fuel feed systems designed to ensure effective fuel burnout ,000 6,000 1,800 3,600 Carbon Dioxide (CO 2 ) 288, , , , , , ,22 0 Page 26 of ,140 EPA Export :16:44:21

29 IPPC Application Form V1/07 Parameter Hydrogen Chloride (HCl) Hydrogen Fluoride (HF) Total Organic Carbon (TOC) Prior to treatment (1) Brief As discharged (1) mg/nm 3 kg/h description mg/nm 3 kg/h. kg/year Avg Max Avg Max of treatment Avg Max Avg Max Avg Max - <10 - <6 Naturally abated through contact - <10 - <6 with dust in kiln system within an appropriate temperature interval. Emissions controlled through adjustment of filter temperatures Dioxins and Furans - 1x x10-8 Cadmium (Cd) and Thallium (Tl) <0.03 No abatement system. Fuel feed systems designed to ensure effective burnout. Organic carbon content of raw materials controlled through selective quarrying No abatement system. Exit gases will be rapidly cooled thus ensuring negligible dioxin and furan formation Cd emissions abated by the bypass bag filter. Tl abated by the ESP. Also maintain low levels of Tl input in fuel and raw materials x x < <0.03 Page 27 of 80 EPA Export :16:44:21

30 IPPC Application Form V1/07 Parameter Prior to treatment (1) Brief As discharged (1) mg/nm 3 kg/h description mg/nm 3 kg/h. kg/year Avg Max Avg Max of treatment Avg Max Avg Max Avg Max Mercury (Hg) - < <0.03 Metals (Sb, As, Pb, Cr, Co, Cu, Mn, Ni, V) No abatement system - < < <0.5 - <0.3 Dust filters - <0.5 - <0.3 Page 28 of 80 EPA Export :16:44:21

31 IPPC Application Form V1/07 TABLE E.1(iii): MAIN EMISSIONS TO ATMOSPHERE - Chemical characteristics of the emission (1 table per emission point) Emission Point Reference Number: A2-02 Parameter Prior to treatment (1) Brief As discharged (1) mg/nm 3 kg/h description mg/nm 3 kg/h. kg/year Avg Max Avg Max of treatment Avg Max Avg Max Avg Max Particulates 21,865 25,715 4,900 5,000 Emission Point Reference Number: A2-03 Electrostatic precipitator 1F400/H2P/3*45* /1S/1K/P6A Standard Efficiency % at 28.7 g/nm 3 dust load Parameter Prior to treatment (1) Brief As discharged (1) mg/nm 3 kg/h description mg/nm 3 kg/h. kg/year Avg Max Avg Max of treatment Avg Max Avg Max Avg Max Particulates 401, ,200 29,040 41,818 Jet pulse filter CEC SHH-D Emission Point Reference Number: A2-04 Parameter Prior to treatment (1) Brief As discharged (1) mg/nm 3 kg/h description mg/nm 3 kg/h. kg/year Avg Max Avg Max of treatment Avg Max Avg Max Avg Max Particulates 445, ,000 26,914 38,756 Filtax Filter D CD-B Page 29 of 80 EPA Export :16:44:21

32 IPPC Application Form V1/07 Emission Point Reference Number: A2-05 Parameter Prior to treatment (1) Brief As discharged (1) mg/nm 3 kg/h description mg/nm 3 kg/h. kg/year Avg Max Avg Max of treatment Avg Max Avg Max Avg Max Particulates 834,000 1,000, , ,628 Jet Pulse Filter CEH SHHRL-B Concentrations should be based on Normal conditions of temperature and pressure, (i.e. 0 o C,101.3kPa). Wet/dry should be the same as given in Table E.1(ii) unless clearly stated otherwise. Page 30 of 80 EPA Export :16:44:21

33 IPPC Application Form V1/07 TABLE E.1(iv): EMISSIONS TO ATMOSPHERE - Minor atmospheric emissions (Sheet 1 of 4) Emission point Description Emission details 1 Abatement system employed Reference Numbers material mg/nm 3(2) kg/h kg/year A3-01 Crusher Dust 50 Bag Filter A3-02 Crusher Dust 50 Bag Filter A3-03 Preblending Shed Dust 50 Bag Filter A3-04 Raw Materials Conveyor Dust 50 Bag Filter A3-05 Raw Mill Dust 50 Bag Filter A3-06 Preheater (1 st Floor) Dust 50 Bag Filter A3-07 Preheater (6 th Floor) Dust 50 Bag Filter A3-08 CF Silo 1 st Floor Dust 50 Bag Filter A3-09 Preheater (1 st Floor) Dust 50 Bag Filter A3-10 Coal Mill Filter Dust 50 Bag Filter A3-11 Clinker Store Top Dust 50 Bag Filter A3-12 Clinker Store Conveyor Dust 50 Bag Filter A3-13 Clinker Story Conveyor Dust 50 Bag Filter A3-14 Clinker Story Conveyor Dust 50 Bag Filter A3-15 Gypsum Belts Dust 50 Bag Filter A3-16 Gypsum Belts Dust 50 Bag Filter A3-17 Mill Conveyor Dust 50 Bag Filter A3-18 Mill Conveyor Dust 50 Bag Filter A3-19 Clinker Store Conveyor Dust 50 Bag Filter A3-20 Clinker Export Top Dust 50 Bag Filter A3-21 Cement Mill Dust 50 Bag Filter Page 31 of 80 EPA Export :16:44:21

34 IPPC Application Form V1/07 Emissions to Atmosphere Minor atmospheric emissions (Sheet 2 of 4) Emission point Description Emission details 1 Abatement system employed Reference Numbers material mg/nm 3(2) kg/h kg/year A3-22 Mill Conveyor to Silo Dust 50 Bag Filter A3-23 Silo 1 Vent Dust 50 Bag Filter A3-24 Silo 2 Vent Dust 50 Bag Filter A3-25 Silo1 Dust 50 Bag Filter A3-26 Silo1 Dust 50 Bag Filter A3-27 Silo1 Dust 50 Bag Filter A3-28 Silo 2 Dust 50 Bag Filter A3-29 Silo 2 Dust 50 Bag Filter A3-30 Silo 2 Dust 50 Bag Filter A3-31 Silo 3 Dust 50 Bag Filter A3-32 Silo 3 Dust 50 Bag Filter A3-33 Silo 3 Dust 50 Bag Filter A3-34 Silo 3 Dust 50 Bag Filter A3-35 Silo 3 Filter above Bagging Plant Screw Pump Dust 50 Bag Filter A3-36 PFA at Z1U01 screw Dust 50 Bag Filter A3-37 PFA on top of silo Dust 50 Bag Filter A3-38 PFA on top of silo Dust 50 Bag Filter A3-39 PFA at Z1U01 screw Dust 50 Bag Filter A3-40 Bagging Plant (main bin) Dust 50 Bag Filter A3-41 Bagging Plant (Packer 1) Dust 50 Bag Filter A3-42 Bagging Plant (Packer 2) Dust 50 Bag Filter Page 32 of 80 EPA Export :16:44:21

35 IPPC Application Form V1/07 Emissions to Atmosphere Minor atmospheric emissions (Sheet 3 of 4) Emission point Description Emission details 1 Abatement system employed Reference Numbers material mg/nm 3(2) kg/h kg/year A3-43 Bagging Plant (overflow) Dust 50 Bag Filter A3-44 By-Pass Filter Dust 50 Bag Filter A3-45 Roller Press Filter Dust 50 Bag Filter A3-46 Pan Conveyor Filter Dust 50 Bag Filter 1 The maximum emission should be stated for each material emitted, the concentration should be based on the maximum 30 minute mean. 2 Concentrations should be based on Normal conditions of temperature and pressure, (i.e. 0 o C101.3kPa). Wet/dry should be clearly stated. Include reference oxygen conditions for combustion sources. Page 33 of 80 EPA Export :16:44:21

36 IPPC Application Form V1/07 TABLE E.1(v): EMISSIONS TO ATMOSPHERE Fugitive and Potential atmospheric emissions Emission point ref. no. (as per flow diagram) Description A4-01 Explosion Relief Flap A4-02 Explosion Relief Flap A4-03 Explosion Relief Flap A4-04 Explosion Relief Flap Malfunction which could cause an emission Emission details (Potential max. emissions) 1 Material mg/nm 3 kg/hour Explosion in Coal Mill Coal Dust 350, ,000 (Shut-off valves close 3.5kg/sec) Explosion in Coal Mill Coal Dust 350, ,000 (Shut-off valves close 3.5kg/sec) Explosion in Coal Mill Coal Dust 350, ,000 (Shut-off valves close 3.5kg/sec) Explosion in Bag Filter Coal Dust 350, ,000 (Shut-off valves close 3.5kg/sec) A4-05 Explosion Relief Flap Explosion in Bag Filter Coal Dust 350, ,000 (Shut-off valves close 3.5kg/sec) 1 Estimate the potential maximum emission for each malfunction identified. Page 34 of 80 EPA Export :16:44:21

37 IPPC Application Form V1/07 TABLE E.2(i): EMISSIONS TO SURFACE WATERS (One page for each emission) Emission Point: Emission Point Ref. N o : SW1 Source of Emission: Storm water drainage system Location : Balancing / Settlement Tank Grid Ref. (12 digit, 6E,6N): , Name of receiving waters: The Woodford River Flow rate in receiving waters: 8.71 m 3.sec -1 Dry Weather Flow 0.85 m 3.sec -1 95%ile flow Available waste assimilative capacity: Emission Details: (i) Volume to be emitted Normal/day 480m 3 Maximum/day 10,000m 3 Maximum rate/hour 3,000m 3 (ii) Not available kg/day Period or periods during which emissions are made, or are to be made, including daily or seasonal variations (start-up /shutdown to be included): Periods of Emission (avg) 60 min/hr 24 hr/day 365 day/yr Page 35 of 80 EPA Export :16:44:21

38 IPPC Application Form V1/07 TABLE E.2(ii): EMISSIONS TO SURFACE WATERS - Characteristics of the emission (1 table per emission point) Emission point reference number : SW1 Parameter Prior to treatment As discharged % Efficiency Max. hourly average (mg/l) Max. daily average (mg/l) kg/day kg/year Max. hourly average (mg/l) Max. daily average (mg/l) kg/day kg/year COD N/A SS N/A BOD N/A NH N/A Cr N/A Al N/A Mineral Oil <6 N/A Total Dissolved Solids N/A Organohalogens N/A Page 36 of 80 EPA Export :16:44:22

39 IPPC Application Form V1/07 TABLE E.3(i): EMISSIONS TO SEWER (One page for each emission) Emission Point: Emission Point Ref. N o : Location of connection to sewer: SE1 Manhole adjacent to works entrance Grid Ref. (12 digit, 6E,6N): , Name of sewage undertaker: Cavan County Council Emission Details: (i) Volume to be emitted Normal/day 12.76m 3 Maximum/day N/A Maximum rate/hour 1.6m 3 (ii) Period or periods during which emissions are made, or are to be made, including daily or seasonal variations (start-up /shutdown to be included): Periods of Emission (avg) N/A min/hr N/A hr/day N/A day/yr Page 37 of 80 EPA Export :16:44:22

40 IPPC Application Form V1/07 TABLE E.3(ii): EMISSIONS TO SEWER - Characteristics of the emission (1 table per emission point) Emission point reference number : SE1 Parameter Prior to treatment As discharged % Efficiency Max. hourly average (mg/l) Max. daily average (mg/l) kg/day kg/year Max. hourly average (mg/l) Max. daily average (mg/l) kg/day kg/year BOD N/A ,566 Discharge to municipal works Page 38 of 80 EPA Export :16:44:22

41 IPPC Application Form V1/07 TABLE E.4(i): EMISSIONS TO GROUND (1 Page for each emission point) Emission Point or Area: Emission Point/Area Ref. N o : Emission Pathway: (borehole, well, percolation area, soakaway, landspreading, etc.) Location : Grid Ref. (12 digit, 6E,6N): Elevation of discharge: (relative to Ordnance Datum) Aquifer classification for receiving groundwater body: Groundwater vulnerability assessment (including vulnerability rating): Identity and proximity of groundwater sources at risk (wells, springs, etc): Identity and proximity of surface water bodies at risk: Emission Details: (i) Volume to be emitted There are no emissions to ground Normal/day m 3 Maximum/day m 3 Maximum rate/hour m 3 (ii) Period or periods during which emissions are made, or are to be made, including daily or seasonal variations (start-up /shutdown to be included): Periods of Emission (avg) min/hr hr/day day/yr Page 39 of 80 EPA Export :16:44:22

42 IPPC Application Form V1/07 TABLE E.4(ii): EMISSIONS TO GROUND - Characteristics of the emission (1 table per emission point) Emission point/area reference number: Parameter Prior to treatment As discharged % Efficiency N/A Max. hourly average (mg/l) Max. daily average (mg/l) kg/day kg/year Max. hourly average (mg/l) N/A Max. daily average (mg/l) kg/day kg/year Page 40 of 80 EPA Export :16:44:22

43 IPPC Application Form V1/07 Table E.5(i): NOISE EMISSIONS - Noise sources summary sheet (Sheet 1 of 2) Source Emission point Ref. No Equipment Ref. No Sound Pressure 1 dba at reference distance Octave bands (Hz) Sound Pressure 1 Levels db(unweighted) per band K 2K 4K 8K Impulsive or tonal qualities Periods of Emission South Side Kiln Motor at 7m 90Kw Motor at High Elevation South Kiln Motor at 3m Cooling Fans Motor at 3m Hydraulic Pump House Inside at 1m Hz / 500Hz Hz Hz Hz & 400Hz Outside Damper Room at 2m Kiln Drive Motor Outside Door at 2m , Hz & 800Hz Page 41 of 80 EPA Export :16:44:22

44 IPPC Application Form V1/07 Noise sources summary sheet (Sheet 2 of 2) Source Emission point Ref. No Equipment Ref. No Sound Pressure 1 dba at reference distance Octave bands (Hz) Sound Pressure1 Levels db(unweighted) per band K 2K 4K 8K Impulsive or tonal qualities Periods of Emission Kiln Drive Motor Inside at 1m Inside Cement Mill at 1m Raw Mill Outside at 2m North Side Mill Outlet at 3m Damper Room Motor at 1m Hz and 800Hz Hz Hz For items of plant sound power levels may be used. Page 42 of 80 EPA Export :16:44:22

45 IPPC Application Form V1/07 TABLE F.1(i): ABATEMENT / TREATMENT CONTROL Emission point reference number : A2-01 (Sheet 1 of 2) Control 1 parameter Equipment 2 Equipment maintenance Equipment calibration Equipment back-up Carbon monoxide Plant Process Control System N/A N/A Kilovolts Rectifiers Manufacturer Spare in stock Milliamps Rapping Gear Manufacturer Spare in stock Temperature Drag Chain Manufacturer Spare in stock Particulate ESP Manufacturer N/A Nitrogen oxides SNCR Manufacturer N/A Sulphur dioxide Oxygen Water Hydrogen chloride Plant Process Control System Plant Process Control System Plant Process Control System Plant Process Control System Planned Maintenance and twice yearly major overhaul N/A N/A N/A N/A N/A N/A N/A N/A Hydrogen fluoride Plant Process Control System N/A N/A Total organic carbon Plant Process Control System N/A N/A Page 43 of 80 EPA Export :16:44:22

46 IPPC Application Form V1/07 Abatement/Treatment Control (Sheet 2 of 2) Control 1 parameter Monitoring to be carried out 3 Monitoring equipment Monitoring equipment calibration Carbon monoxide Continuous (in process) CO analyser Manufacturer Kilovolts Continuous kvolts meter Manufacturer Milliamps Continuous mamp meter Manufacturer Temperature Continuous Thermocouple Manufacturer Particulate Continuous Photometric Opacity Monitor Iso-Kinetic Comparison Nitrogen oxides Continuous ABB ACF-NT Manufacturer Sulphur dioxide Continuous ABB ACF-NT Manufacturer Oxygen Continuous ABB ACF-NT Manufacturer Water Continuous ABB ACF-NT Manufacturer Hydrogen chloride Quarterly Standard method Manufacturer Hydrogen fluoride Quarterly Standard method Manufacturer Total organic carbon Quarterly Standard method Manufacturer 1 List the operating parameters of the treatment / abatement system which control its function. 2 List the equipment necessary for the proper function of the abatement / treatment system. 3 List the monitoring of the control parameter to be carried out. Page 44 of 80 EPA Export :16:44:22

47 IPPC Application Form V1/07 Emission point reference number : A2-02 Control 1 parameter Equipment 2 Equipment maintenance Equipment calibration Equipment back-up Kilovolts Rectifiers Manufacturer Spare in stock Milliamps Rapping Gear Planned Maintenance Manufacturer Spare in stock and twice yearly major Temperature Drag Chain overhaul Manufacturer Spare in stock Particulate ESP Manufacturer N/A Control 1 parameter Monitoring to be carried out 3 Monitoring equipment Kilovolts Continuous kvolts meter Manufacturer Milliamps Continuous mamp meter Manufacturer Monitoring equipment calibration Temperature Continuous Thermocouple Electronic Workshop Particulate Continuous Photometric Opacity Monitor Iso-Kinetic Comparison 1 List the operating parameters of the treatment / abatement system which control its function. 2 List the equipment necessary for the proper function of the abatement / treatment system. 3 List the monitoring of the control parameter to be carried out. Page 45 of 80 EPA Export :16:44:22

48 IPPC Application Form V1/07 Emission point reference number : A2-03 Control 1 parameter Equipment 2 Equipment maintenance Equipment calibration Equipment back-up Differential Pressure Filter Fan Spare parts available Air Sluice Planned Maintenance N/A Spare parts available Temperature Screw Conveyor Spare parts available Compressed Air Pressure Compressor Standby Compressor Control 1 parameter Monitoring to be carried out 3 Monitoring equipment Differential Pressure Alarm in CCR for high differential pressure Differential Pressure Switch Monitoring equipment calibration Electronic Workshop Temperature Continuous Thermocouple Electronic Workshop Compressed Air Pressure Alarm in CCR for low pressure Pressure Switch Electronic Workshop 1 List the operating parameters of the treatment / abatement system which control its function. 2 List the equipment necessary for the proper function of the abatement / treatment system. 3 List the monitoring of the control parameter to be carried out. Page 46 of 80 EPA Export :16:44:22

49 IPPC Application Form V1/07 Emission point reference number : A2-04 Control 1 parameter Equipment 2 Equipment maintenance Equipment calibration Equipment back-up Differential Pressure Filter Fan Spare parts available Air Sluice Planned Maintenance N/A Spare parts available Temperature Screw Conveyor Spare parts available Compressed Air Pressure Compressor Standby Compressor Control 1 parameter Monitoring to be carried out 3 Monitoring equipment Differential Pressure Alarm in CCR for high differential pressure Differential Pressure Switch Monitoring equipment calibration Electronic Workshop Temperature Continuous Thermocouple Electronic Workshop Compressed Air Pressure Alarm in CCR for low pressure Pressure Switch Electronic Workshop 1 List the operating parameters of the treatment / abatement system which control its function. 2 List the equipment necessary for the proper function of the abatement / treatment system. 3 List the monitoring of the control parameter to be carried out. Page 47 of 80 EPA Export :16:44:22

50 IPPC Application Form V1/07 Emission point reference number : A2-05 Control 1 parameter Equipment 2 Equipment maintenance Equipment calibration Equipment back-up Differential Pressure Filter Fan Spare parts available Air Sluice Planned Maintenance N/A Spare parts available Temperature Screw Conveyor Spare parts available Compressed Air Pressure Compressor Standby Compressor Control 1 parameter Monitoring to be carried out 3 Monitoring equipment Differential Pressure Alarm in CCR for high differential pressure Differential Pressure Switch Monitoring equipment calibration Electronic Workshop Temperature Continuous Thermocouple Electronic Workshop Compressed Air Pressure Alarm in CCR for low pressure Pressure Switch Electronic Workshop 1 List the operating parameters of the treatment / abatement system which control its function. 2 List the equipment necessary for the proper function of the abatement / treatment system. 3 List the monitoring of the control parameter to be carried out. Page 48 of 80 EPA Export :16:44:22

51 IPPC Application Form V1/07 TABLE F.2(i) : EMISSIONS MONITORING AND SAMPLING POINTS ( 1 table per monitoring point) Emission Point Reference No. : A2-01 Parameter Monitoring frequency Accessibility of Sampling Points Particulates Continuous Continuous Sampling method Analysis method/ technique Photometric/Opacity / BS EN Particulates Quarterly Manual extractive BS EN NO x Continuous Continuous ABB ACF-NT / ISO10849 NO x Quarterly Manual extractive ISO SO 2 Continuous Continuous ABB ACF-NT / BS EN 6069 SO 2 Quarterly Manual extractive BS EN 6069 Oxygen Continuous Continuous ABB ACF-NT Water Continuous Platform accessible by Continuous ABB ACF-NT Hydrogen chloride Quarterly stairs and elevator Manual extractive BS EN 1911 Hydrogen fluoride Quarterly Manual extractive ISO Total organic carbon Quarterly Manual extractive BS EN Carbon monoxide Continuous Continuous ABB ACF-NT / ISO Carbon monoxide Quarterly Manual extractive BS EN Metals Quarterly Manual extractive BS EN Hg Quarterly Manual extractive BS EN Cd, Tl Quarterly Manual extractive BS EN Dioxins and furans Quarterly Manual extractive BS EN 1948 Page 49 of 80 EPA Export :16:44:22

52 IPPC Application Form V1/07 Emission Point Reference No. : A2-02 Parameter Monitoring frequency Accessibility of Sampling Points Sampling method Analysis method/ technique Particulates Continuous Platform accessible by Continuous Pressure differential Particulates Quarterly stairs Manual extractive ISO 9096 Emission Point Reference No. : A2-03 Parameter Monitoring frequency Accessibility of Sampling Points Sampling method Analysis method/ technique Particulates Continuous Platform accessible by Continuous Pressure differential Particulates Quarterly stairs Manual extractive ISO 9096 Emission Point Reference No. : A2-04 Parameter Monitoring frequency Accessibility of Sampling Analysis method/ Sampling method Points technique Particulates Continuous Platform accessible by Continuous Pressure differential Particulates Quarterly stairs Manual extractive ISO 9096 Emission Point Reference No. : A2-05 Parameter Monitoring frequency Accessibility of Sampling Points Sampling method Analysis method/ technique Particulates Continuous Platform accessible by Continuous Pressure differential Particulates Quarterly stairs Manual extractive ISO 9096 Page 50 of 80 EPA Export :16:44:22

53 IPPC Application Form V1/07 Emission Point Reference No. : SW1 Parameter Monitoring frequency Accessibility of Sampling Points Sampling method Analysis method/ technique BOD Weekly, Monthly Membrane electrode USEPA method 507:1985 COD Weekly, Monthly Oxidation with chromosulfuric acid, determination as chromate. EPA / ISO15705 ph SS TDS NH 2 Cr Weekly Weekly, Monthly Weekly, Monthly Weekly, Monthly Monthly Outlet point from the Grab sample settlement tank. Platinum series ph electrode calibrated daily with ph 4,7and 10 standards Gravimetric, dried at C. EPA method Gravimetric, dried at 180 C. EPA method Indophenol blue EPA350.1 / IS 7150/1 HACH ,5 diphenylcarbohydrazine method Al Monthly EM 130 IPC-MS Temperature Weekly, Monthly Calibrated temperature gauge (sensortec) Page 51 of 80 EPA Export :16:44:22

54 IPPC Application Form V1/07 Emission Point Reference No. : GW1 Parameter Monitoring frequency Accessibility of Sampling Points Sampling method Analysis method/ technique ph EW132 ph Electrometric Measurement TOC EW123 Total Organic Carbon by Combustion Oxidation Conductivity Total NH 3 Total N Cr Al Mineral Oils VOCs (Organohalogens) Bi-annual Valve on borehole pump Grab sample EW042 Conductivity measurement EW03C Ammonia by Auto Analyser Spectrophotometry EW 022 Auto analysed by spectrometry EM 130 Metals by ICPMS EM 130 Metals by ICPMS EM 130 Metals by ICPMS E0025 Determination of VOCs in Water by Purge and Trap GC/MS Page 52 of 80 EPA Export :16:44:22

55 IPPC Application Form V1/07 TABLE F.2(ii): AMBIENT ENVIRONMENT MONITORING AND SAMPLING POINTS ( 1 table per monitoring point) Monitoring Point Reference No : AA1 Parameter Monitoring frequency Accessibility of Sampling point Sampling method Analysis method / technique Dust Continuous Site 1 at north of site, work shop. Ground level, clear access Dust deposition and directional gauge Retained water volume, ph of sample, total dissolved solids, weight of sample Monitoring Point Reference No : AA2 Parameter Monitoring frequency Dust Continuous Monitoring Point Reference No : AA3 Parameter Monitoring frequency Accessibility of Sampling point Site 2 at east of site, hilltop. Ground level, clear access Accessibility of Sampling point Sampling method Dust deposition and directional gauge Sampling method Analysis method / technique Retained water volume, ph of sample, total dissolved solids, weight of sample Analysis method / technique Dust Continuous Site 3 at south of site, ESB. Ground level, clear access Dust deposition and directional gauge Retained water volume, ph of sample, total dissolved solids, weight of sample Page 53 of 80 EPA Export :16:44:22

56 IPPC Application Form V1/07 Monitoring Point Reference No : AA4 Parameter Monitoring frequency Accessibility of Sampling point Sampling method Analysis method / technique Dust Continuous Site 4 at west of site, Treacy s Field. Ground level, clear access Dust deposition and directional gauge Retained water volume, ph of sample, total dissolved solids, weight of sample Monitoring Point Reference No : AA5 Parameter Monitoring frequency Dust Continuous Monitoring Point Reference No : N1 Parameter Monitoring frequency Accessibility of Sampling point Site 5 at Crusher. Ground level, clear access Accessibility of Sampling point Sampling method Dust deposition and directional gauge Sampling method Analysis method / technique Retained water volume, ph of sample, total dissolved solids, weight of sample Analysis method / technique Noise Annual McHughs Residence 1.5m above ground Type 1 noise measurement instruments day and night ISO 1996 Acoustics Description and Measurement of Environmental Noise: Parts 1/2/3 Page 54 of 80 EPA Export :16:44:22

57 IPPC Application Form V1/07 Monitoring Point Reference No : N2 Parameter Monitoring frequency Accessibility of Sampling point Sampling method Analysis method / technique Noise Annual Doon Heights 1.5m above ground Type 1 noise measurement instruments day and night ISO 1996 Acoustics Description and Measurement of Environmental Noise: Parts 1/2/3 Monitoring Point Reference No : N3 Parameter Monitoring frequency Noise Annual Monitoring Point Reference No : N4 Accessibility of Sampling point Slieve Russell House 1.5m above ground Sampling method Type 1 noise measurement instruments day and night Analysis method / technique ISO 1996 Acoustics Description and Measurement of Environmental Noise: Parts 1/2/3 Parameter Monitoring frequency Accessibility of Sampling point Sampling method Analysis method / technique Noise Annual McKiernans Residence 1.5m above ground Type 1 noise measurement instruments day and night ISO 1996 Acoustics Description and Measurement of Environmental Noise: Parts 1/2/3 Page 55 of 80 EPA Export :16:44:22

58 IPPC Application Form V1/07 Monitoring Point Reference No : N5 Parameter Monitoring frequency Accessibility of Sampling point Sampling method Analysis method / technique Noise Annual Site centre 1.5m above ground Type 1 noise measurement instruments day and night ISO 1996 Acoustics Description and Measurement of Environmental Noise: Parts 1/2/3 Monitoring Point Reference No : N6 Parameter Monitoring frequency Noise Annual Accessibility of Sampling point Kearns Residence 1.5m above ground Sampling method Type 1 noise measurement instruments day and night Analysis method / technique ISO 1996 Acoustics Description and Measurement of Environmental Noise: Parts 1/2/3 Page 56 of 80 EPA Export :16:44:23

59 IPPC Application Form V1/07 Table G.1(i) Details of Process related Raw Materials, Intermediates, Products, etc., used or generated on the site Ref. N o or Material/ Substance (1) CAS Number Danger (2) Category Amount Stored Annual Usage Nature of Use R (3) - Phrase S (3) - Phrase Code (tonnes) (tonnes) Limestone ,273,500 Raw material, production of cement - - Clay / silt 182,000 Shale 258,800 Gypsum ,300 Iron-ore 5,240 Alkadose Corrosive 200 litres 400 litres Biodose 50 litres 50 litres Cooldose-C 50 litres 50 litres Raw material, production of cement Raw material, production of cement Raw material, production of cement Raw material, production of cement Chemical reagent for ph correction Chemical reagent for bacteriological control Chemical reagent which acts as a corrosion inhibitor , 21, 22, Argon / methane Oxygen / m 3 30m 3 Compressed gas m 3 3,500m 3 Compressed gas 8 9, 17 Propane Extremely Flammable 16m 3 16m 3 Compressed gas 12 2, 9, 16, 33 Nitrogen m 3 100m 3 Compressed gas - 9, 23 Acetylene F + Extremely Flammable 400m 3 800m 3 Compressed gas 5, 6, 12 9, 15, 33 Page 57 of 80 EPA Export :16:44:23

60 IPPC Application Form V1/07 Ref. N o or Material/ Substance (1) CAS Number Danger (2) Category Amount Stored Annual Usage Code (tonnes) (tonnes) Nature of Use R (3) - Phrase Carbon dioxide m 3 200m 3 Compressed gas - 9, 23 Alumina refractory bricks Magnesium spinal refractory bricks Lightweight refractory bricks Refractory castable Ag mortar Bricks which contain aluminium oxide Bricks which contain magnesium oxide Bricks which contain silicon dioxide Blend of aggregate / cement and castable powder form as supplied Low iron magnesia mortar S (3) - Phrase MobilGear barrel 1,456litres EP gear oil - - MobilGear barrel 5,824litres EP gear oil/iso MobilGear barrel 4,992litres EP gear oil/iso MobilGear barrel 11,856litres EP gear oil/iso Delvac Super 1 barrel 624litres Turbo Diesel (Generator) - - Mobil Almo barrel 1,500litres Airline/Airtool Oil - - Mobil DTE 25 1 barrel 5,108litres Hydraulic Oil ISO Mobil DTE 24 1 Barrel 832litres Hydraulic Oil - - Mobil DTE Medium 1 Barrel 200litres EP Grease NLGI3 - - DTE AA 2 barrels 1,200litres Mobil Hydraulic Oil 32 2 barrels 400litres Non EPA gear oil/iso 320 Flushing hyd oil ISO Page 58 of 80 EPA Export :16:44:23

61 IPPC Application Form V1/07 Ref. N o or Material/ Substance (1) CAS Number Danger (2) Category Amount Stored Annual Usage Nature of Use R (3) - Phrase S (3) - Phrase Code (tonnes) (tonnes) Mobilux EP2 Mobilux EP3 4 pails / 4 cartons 2 pails / 2 cartons 400litres EP Grease NLGI litres EP Grease NLGI Dilithium tetraborate Harmful 10kg 8kg Chemical Reagent 22, 36 24, 60 Ethylene glycol Harmful 125litres 10litres Chemical Reagent 22 2 Propanol litres 18litres Chemical Reagent 11, 36, 67 Silica gel General Laboratory Reagents Toxic 15kg 9kg Chemical Reagent 49, 52, 53 2, 7, 16, 26, 24, 25 38, 45, 53, 60 15kg 9kg Chemical Reagent - - Coal 155,000 Fuel - - Diesel Hazardous 399,849litres Fuel Kerosene , 45, 22, 38 16, 45, 53, 61, 62 3,677llitres Fuel - - Solid Recovered Fuel - Non hazardous 127,875 Fuel - 37 Grinding aid ,000litres 396,000litres Raw material - - Ferrous sulphate Harmful 100 3,000 Chemical Reagent 22, 36, 37, 38 2, 13, 46 Fly ash - Irritant 1, ,000 Raw material 41 35, 39, 51 Notes: 1. In cases where a material comprises a number of distinct and available dangerous substances, please give details for each component substance. 2. c.f. Article 2(2) of SI N o 77/94 3. c.f. Schedules 9 and 10 of SI No 62/2004 Table G.1(ii) Details of Process related Raw Materials, Intermediates, Products, etc., used or generated on the site Page 59 of 80 EPA Export :16:44:23

62 IPPC Application Form V1/07 Ref. N o or Material/ TA Luft Class 1, Code Substance (1) 2 or 3 Odourous Yes/No Odour Description Threshold µg/m 3 EU Lists I and II (Tick and specify Group/Family Number) Dangerous Groundwater Substances Directive Directive 76/464/EEC 80/68/EEC List I List II List I List II Limestone No No No No No No Clay / silt No No No No No No Shale No No No No No No Gypsum No No No No No No Iron-ore No No No No No No Alkadose No No No No No Biodose No No No No No Cooldose-C No No No No No Argon / methane No/ Class III No No No No No Oxygen No No No No No No Propane Class III No No No No No Nitrogen No No No No No No Acetylene No No No No No No Carbon dioxide No No No No No No Alumina refractory bricks Magnesium spinal refractory bricks Lightweight refractory bricks No No No No No No No No No No No No No No No No No No Refractory castable No No No No No No Ag mortar No No No No No Page 60 of 80 EPA Export :16:44:23

63 IPPC Application Form V1/07 Ref. TA Luft EU Lists I and II Odour N o or Material/ Class 1, (Tick and specify Group/Family Number) Dangerous Groundwater Odourous Threshold Code Substance (1) 2 or 3 Substances Directive Directive Yes/No Description 76/464/EEC 80/68/EEC List II µg/m 3 List I List I List II MobilGear 630 No No No No No MobilGear 632 No No No No No MobilGear 634 No No No No No MobilGear 636 No No No No No Delvac Super No No No No No Mobil Almo 527 No No No No No Mobil DTE 25 No No No No No Mobil DTE 24 No No No No No DTE Medium No No No No No DTE AA No No No No No Mobil Hydraulic Oil 32 No No No No No Mobilux EP2 No No No No No Mobilux EP3 No No No No No Dilithium tetraborate No No No Yes, 1 No Yes, 1 Ethylene glycol Class III No No Yes, 6 Yes, 7 No N-Propanol Class III Yes Alcohol Yes, 7 Yes, 3 Yes, 7 Yes, 3 Silica gel No No No No No No Coal No No Yes, 7 Yes, 3 Yes, 7 Yes, 3 Diesel Class I. II Yes Hydrocarbon Yes, 7 Yes, 3 Yes, 7 Yes, 3 Kerosene Yes, 7 Yes, 3 Yes, 7 Yes, 3 SRF No No No No No No Page 61 of 80 EPA Export :16:44:23

64 IPPC Application Form V1/07 Ref. TA Luft EU Lists I and II Odour N o or Material/ Class 1, (Tick and specify Group/Family Number) Dangerous Groundwater Odourous Threshold Code Substance (1) 2 or 3 Substances Directive Directive Yes/No Description 76/464/EEC 80/68/EEC List II µg/m 3 List I List I List II Grinding aid No No No No No No Ferrous sulphate No No No No No No Fly ash NO NO No No No No Notes (cont.): 4. The European Commission priority candidate list Page 62 of 80 EPA Export :16:44:23

65 IPPC Application Form V1/07 TABLE H.1(i): WASTE - Hazardous Waste Recovery/Disposal (Sheet 1 of 3) Waste material EWC Code Main source 1 Quantity On-site Recovery/Dispos al Off-site Recovery, reuse or recycling Off-site Disposal Oily rags Degreasing Waste containing dangerous substances Plant maintenance Plant maintenance Tonnes / year 960l m 3 / month 115l (Method & Location ) (Method, Location & Undertaker) Recovery. ENVA Ireland, Portlaoise, Co. Laois Final Destination Lindenschmidt, Kreuztal, Germany Recovery. Safety Kleen, Unit 5 Airton Road, Tallaght, Dublin (Method, Location & Undertaker) Page 63 of 80 EPA Export :16:44:23

66 IPPC Application Form V1/07 Waste Hazardous Waste Recovery/Disposal (Sheet 2 of 3) Waste material EWC Code Main source 1 Quantity On-site Recovery/Dispos al Off-site Recovery, reuse or recycling Off-site Disposal Tonnes / year m 3 / month (Method & Location ) (Method, Location & Undertaker) (Method, Location & Undertaker) Recovery. Oily Filters Waste Oil Plant maintenance Plant maintenance and general operations 240l 7000l Enva Ireland, Portlaoise Co. Laois Final Destination R.D. Recycling Houthalen, Belgium Recovery. Enva Ireland, Portlaoise Co. Laois Page 64 of 80 EPA Export :16:44:23

67 IPPC Application Form V1/07 Waste Hazardous Waste Recovery/Disposal (Sheet 3 of 3) Waste material EWC Code Main source 1 Quantity On-site Recovery/Dispos al Off-site Recovery, reuse or recycling Off-site Disposal Tonnes / year Silica Gel Fluorescent Tubes General site lighting 2x6ft coffin m 3 / month (Method & Location ) (Method, Location & Undertaker) Recovery Guardian Silver Lining, Unit 61, Cookstown Industrial Estate, Tallaght, Dublin 24 Final destination DELA GmbH Alte Landstr.4 Essen, Germany Recovery Enva Ireland, Portlaoise, Co Laois Final destination DELA GmbH Alte Landstr.4 Essen, Germany (Method, Location & Undertaker) 1 A reference should be made to the main activity / process for each waste. Page 65 of 80 EPA Export :16:44:23

68 IPPC Application Form V1/07 TABLE H.1(ii) WASTE - Other Waste Recovery/Disposal (Sheet 1 of 4) Waste material EWC Code Main source 1 Quantity On-site recovery/disposal 2 Off-site Recovery, reuse or recycling Off-site Disposal Tonnes / year m 3 / month (Method & Location) (Method, Location & Undertaker) (Method, Location & Undertaker) Recovery. Wood Waste Packaging 4.4 Wood Waste Packaging Scrap Metal Site maintenance Wilton Waste Recycling Limited., Ballyjamesduff, Co. Cavan Recovery. Pallet Supplies Ltd., Mountain Lodge, Cootehill, Co. Cavan Recovery. Wilton Waste Recycling Limited., Ballyjamesduff, Co. Cavan Final destination Galway Metal Co. Ltd., Oranmore, Co. Galway, Page 66 of 80 EPA Export :16:44:23

69 IPPC Application Form V1/07 Waste Other Waste Recovery/Disposal (Sheet 2 of 4) Waste material EWC Code Main source 1 Quantity On-site recovery/disposal 2 Off-site Recovery, reuse or recycling Off-site Disposal Tonnes / year m 3 / month (Method & Location) (Method, Location & Undertaker) (Method, Location & Undertaker) Recovery. Tyvek suits Mixed waste including the following: General- Office (Paper/Card; Wood, Plastic); Packaging (Paper/Card, Wood, Plastic; and, General Biodegradable Waste General Operations General Operations Rehab Recycling, Ballyfermot, Dublin. Final destination Gandon Enterprises Ltd., Navan, Co. Meath Recovery. Transporting Company - Cavan Waste, Co Cavan Destination of paper/card - Oxigen Environmental Ltd. Co. Dublin. Detination of wood Finsa, Co. Clare. Destination of plastic - Retech Processing Ltd., Co. Cavan. Page 67 of 80 EPA Export :16:44:23

70 IPPC Application Form V1/07 Waste Other Waste Recovery/Disposal (Sheet 3 of 4) Waste material EWC Code Main source 1 Quantity On-site recovery/disposal 2 Off-site Recovery, reuse or recycling Off-site Disposal Tonnes / year m 3 / month (Method & Location) (Method, Location & Undertaker) (Method, Location & Undertaker) Mixed waste stream including the following: General- Office Paper/Card; Wood, Plastic). Packaging Paper/Card,W ood, Plastic; and, General Biodegradable Waste) Mixed recyclable materials General Operations General Operations Wilton Waste Recycling Limited, Ballyjamesduff Co. Caven Final destination Leinster Environmental Transporting Company - Cavan Waste, Co Cavan Final destination Corranure Landfill Co. Cavan Page 68 of 80 EPA Export :16:44:23

71 IPPC Application Form V1/07 Waste Other Waste Recovery/Disposal (Sheet 4 of 4) Waste material EWC Code Main source 1 Quantity On-site recovery/disposal 2 Off-site Recovery, reuse or recycling Off-site Disposal Mixed Waste General Operations Tonnes / year 27 m 3 / month (Method & Location) 1 A reference should be made to the main activity/ process for each waste. 2 The method of disposal or recovery should be clearly described and referenced to Attachment H.2 (Method, Location & Undertaker) (Method, Location & Undertaker) Wilton Waste Recycling Limited, Ballyjamesdu ff, Co. Caven. Final Destination White Water Landfill Page 69 of 80 EPA Export :16:44:23

72 IPPC Application Form V1/07 Table I.2(i) SURFACE WATER QUALITY (Sheet 1 of 2) Monitoring Point/ Grid Reference: SW1 Parameter ph Results (mg/l) Sampling method (grab, drift etc.) Normal Analytical Range Drift 0 14 Analysis method / technique Platinum series ph electrode Temperature Electrical conductivity EC Ammoniacal nitrogen NH 4 -N Grab mg/l Chemical oxygen demand Grab mg/l Biochemical oxygen demand Grab EPA 350,1 / ISO 7150/1 EPA / ISO USEPA method 507:1985 Dissolved oxygen DO Calcium Ca Cadmium Cd Chromium Cr <0.03 Grab 1 100mg/l EM 130 Metals by ICP-MS Chloride Cl Copper Cu Iron Fe Lead Pb Magnesium Mg Manganese Mn Mercury Hg Nickel Ni Potassium K Page 70 of 80 EPA Export :16:44:23

73 IPPC Application Form V1/07 Surface Water Quality (Sheet 2 of 2) Parameter Results (mg/l) Sampling method (grab, drift etc.) Normal Analytical Range Analysis method / technique Sodium Na Sulphate SO Zinc Zn Total alkalinity (as CaCO 3 ) Total organic carbon TOC Total oxidised nitrogen TON Nitrite NO Nitrate NO Faecal coliforms ( /100mls) Total coliforms ( /100mls) Phosphate PO Page 71 of 80 EPA Export :16:44:23

74 IPPC Application Form V1/07 Table I.4(i) GROUNDWATER QUALITY (Sheet 1 of 2) Monitoring Point/ Grid Reference: GW1 Parameter Results (mg/l) Sampling method (composite etc.) Normal Analytical Range Analysis method / technique ph Drift 0 14 Platinum series ph electrode Temperature Electrical conductivity EC 400 µs/cm 352 µs/cm 361 µs/cm µs/cm Drift µS/cm Ammoniacal nitrogen NH 4 -N < Grab mg/l EW015 Sulphate by Autoanalyser Spectrometry EPA 350,1 / ISO 7150/1 Dissolved oxygen DO Residue on evaporation (180 o C) Calcium Ca Cadmium Cd Chromium Cr <0.005 <0.01 <0.02 <0.03 Grab 1 100mg/l EM 130 Metals by ICP-MS Chloride Cl Copper Cu Cyanide Cn, total Iron Fe Lead Pb Magnesium Mg Manganese Mn Mercury Hg Nickel Ni Page 72 of 80 EPA Export :16:44:23

75 IPPC Application Form V1/07 Groundwater Quality (sheet 2 of 2) Parameter Results (mg/l) Sampling method (composite etc.) Normal Analytical Range Analysis method / technique Potassium K Sodium Na Phosphate PO Sulphate SO Zinc Zn Total alkalinity (as CaCO 3 ) Total organic carbon TOC Total oxidised nitrogen TON Arsenic As Barium Ba Boron B Fluoride F Phenol Phosphorus P Selenium Se Silver Ag Nitrite NO Nitrate NO Faecal coliforms ( /100mls) Total coliforms ( /100mls) Water level (m OD) Page 73 of 80 EPA Export :16:44:23

76 IPPC Application Form V1/07 TABLE I.4(ii): LIST OF OWNERS/FARMERS OF LAND Land Owner Townlands were landspreading Map Reference Fertiliser P requirement for each farm *NMP must take account of on-farm slurry Total P requirement of the client List TABLE I.4(ii): LANDSPREADING Land Owner/Farmer Map Reference Field ID Total Area (ha) (a) Usable Area (ha) Soil P Test Mg/l Date of P test Crop P Required (kg P/ha) Volume of On-Farm Slurry Returned (m 3 /ha) Estimated P in On-Farm Slurry (kg P/ha) (b) Volume to be Applied (m 3 /ha) P Applied (kg P/ha) Total Volume of imported slurry per plot (m 3 ) TOTAL VOLUME THAT CAN BE IMPORTED ON TO THE FARM: Concentration of P in landspread material - kg P/m 3 Concentration of N in landspread material - kg N/m 3 Page 74 of 80 EPA Export :16:44:23

77 IPPC Application Form V1/07 Table I.7(i): AMBIENT NOISE ASSESSMENT Third Octave analysis for noise emissions should be used to determine tonal noises 1. SITE BOUNDARY National Grid Sound Pressure Levels Reference (6N, 6E) L(A) eq L(A) 10 L(A) 90 Location 1: N , NOISE SENSITIVE LOCATIONS Location 1: N , Location 2: N , Location 3: N , Location 4: N , Location 5: N , Day Time 57.0 Night Time 57.8 Day Time 45.7 Night Time 45.0 Day Time 47.8 Night Time 46.5 Day Time 51.6 Night Time 48.3 Day Time 50.5 Night Time 49.0 Day Time 49.3 Night Time 47. Day Time 57.3 Night Time 58.1 Day Time 46.4 Night Time 43.5 Day Time 48.4 Night Time 46.8 Day Time 53.1 Night Time 49.4 Day Time 50.9 Night Time 50.3 Day Time 48.5 Night Time 47.6 Day Time 56.1 Night Time 55.8 Day Time 37.8 Night Time 36.3 Day Time 41.6 Night Time 37.2 Day Time 44.0 Night Time 42.9 Day Time 46.8 Night Time 47.1 Day Time 47.5 Night Time 45.5 NOTE: All locations should be identified on accompanying drawings. Page 75 of 80 EPA Export :16:44:24

78 IPPC Application Form V1/07 ANNEX 2: CHECKLIST FOR ARTICLE 10 COMPLIANCE Article 10 of the Environmental Protection Agency (Licensing) Regulations, 1994 to 2004 sets out the statutory requirements for information to accompany a licence application. The Application Form is designed in such a way as to set out these questions in a structured manner and not necessarily in the order presented in Article 10. In order to ensure a legally valid application in respect of Article 10 requirements, all Applicants should complete the following checklist and submit it with the completed Application Form. Article 10(2) Section in Application (a) give the name, address and telephone number of the applicant and, if different, any address to which correspondence relating to the application should be sent and, if the applicant is a body corporate, the address of its registered or principal office, (b) give - (i) in the case of an established activity, the number of employees and other persons working or engaged in connection with the activity on the date after which a licence is required and during normal levels of operation, or (c) (d) (ii) in any other case, the gross capital cost of the activity to which the application relates, give the name of the planning authority in whose functional area the activity is or will be carried on, in the case of a discharge of any trade effluent or other matter (other than domestic sewage or storm water) to a sewer of a sanitary authority, give the name of the sanitary authority in which the sewer is vested or by which it is controlled, Checked by Applicant (e) give the location or postal address (including where appropriate, the name of the relevant townland or townlands) and the National Grid reference of the premises to which the activity relates, (f) (g) specify the relevant class or classes in the First Schedule to the Act to which the activity relates, specify the raw and ancillary materials, substances, preparations, fuels and energy which will be produced by or utilised in the activity, (h) describe the plant, methods, processes, ancillary processes, abatement, recovery and treatment systems, and operating procedures for the activity, Page 76 of 80 EPA Export :16:44:24

79 IPPC Application Form V1/07 Article 10(2) continued../ Section in Application (i) indicate how the requirements of section 83(5)(a)(i) to (v) and (vii) to (x) of the Act shall be met, having regard, where appropriate, to any relevant specification issued by the Agency under section 5(3) of the Act and the reasons for the selection of the arrangements proposed, Checked by Applicant (j) give particulars of the source, nature, composition, temperature, volume, level, rate, method of treatment and location of emissions, and the period or periods during which the emissions are made or are to be made, (k) (l) describe the arrangements for the prevention or minimisation of waste and, where waste is produced, the on and of site arrangements for the recovery or disposal of solid and liquid wastes, specify, by reference to the relevant European Waste Catalogue codes as prescribed by Commission Decision 2000/532/EC of 03 May 2000, the quantity and nature of the waste or wastes produced or to be produced by the activity, (m) provide: (i) details, and an assessment, of the impacts of any existing or proposed emissions on the environment, including on an environmental medium other than that or those into which the emissions are or are to be made, and (ii) details of the proposed measures to prevent or eliminate, or where that is not practicable, to limit, reduce or abate emissions, (n) identify monitoring and sampling points and outline proposals for monitoring emissions and the environmental consequences of any such emissions, (o) describe the condition of the site of the installation, (p) describe in outline the main alternatives, if any, to the proposals contained in the application which were studied by the applicant, (q) specify the measures to be taken to comply with an environmental quality standard where such a standard requires stricter conditions to be attached to a licence than would otherwise be determined by reference to best available techniques, Page 77 of 80 EPA Export :16:44:24

80 IPPC Application Form V1/07 Article 10(2) continued../ Section in Application (r) describe the measures to be taken for minimising pollution over long distances or in the territory of other states, Checked by Applicant (s) describe the measures to be taken under abnormal operating conditions, including start-up, shutdown, leaks, malfunctions, breakdowns and momentary stoppages, (t) describe the measures to be taken on and following the permanent cessation of the activity or part of the activity to avoid any risk of environmental pollution and to return the site of the activity to a satisfactory state, (u) describe, in the case of an activity which gives, or could give rise, to an emission containing a hazardous substance which is discharged to an aquifer and is specified in the Annex to Council Directive 80/68/EEC of 17 December 1979 on the protection of groundwater against pollution caused by certain dangerous substances, the arrangements necessary to comply with said Council Directive, (v) include any other information required under Article 6(1) of Council Directive 96/61/EC of 24 September 1996 concerning integrated pollution prevention and control, (w) include a non-technical summary of information provided in relation to the matters specified in paragraphs (f) to (v) above, (x) state whether the activity consists of, comprises, or is for the purposes an establishment to which the European Communities (Control of Major Accident Hazards involving Dangerous Substances) Regulations, 2000 apply, Page 78 of 80 EPA Export :16:44:24

81 IPPC Application Form V1/07 Article 10(3) Without prejudice to Article 12(1), an application for a licence shall be accompanied by - Section in Application Checked by Applicant (a) a copy of the relevant page of the newspaper in which the notice in accordance with article 6 has been published, (b) a copy of the text of the site notice erected or fixed on the land or structure in accordance with article 7, (c) (d) (e) a copy of the notice given to the planning authority under section 85(1)(a) of the Act, a copy of such plans, including a site plan and location map (no larger than A3), and such other particulars, reports and supporting documentation as are necessary to identify and describe - (i) the activity (ii) the position of the site notice in accordance with article 7, (iii) the point or points from which emissions are made or are to be made, and (iv) monitoring and sampling points, and a fee specified in accordance with section 94 of the Act. Page 79 of 80 EPA Export :16:44:24

82 IPPC Application Form V1/07 Article 10(4) Checked by Applicant (b) A signed original and 2 hardcopies of the application and accompanying documents/particulars in hardcopy format plus 2 copies of all files in electronic searchable PDF format on CD-Rom shall be submitted to the headquarters of the Agency. In cases where an E.I.S. is required to be submitted to the Agency in support of the application, a signed original and 2 hardcopies of the EIS plus 16* copies of all files in electronic searchable PDF format on CD-Rom shall be submitted to the headquarters of the Agency. * Energy sector applicants = 18 copies Hardcopies submitted. CD version submitted. Page 80 of 80 EPA Export :16:44:24

83 IPPC Licence Application Quinn Cement ltd IPPC Licence Application APPLICATION FORM ATTACHMENTS TABLE OF CONTENTS WYG Environment part ofthe WYG Group creative minds safe hands... EPA Export :16:44:24

84 Application Attachment A1 Application Attachment B1 Application Attachment B2 Application Attachment B5 Application Attachment B8 Application Attachment B9 Application Attachment BlO Application Attachment C Application Attachment D Application Attachment E1 Application Attachment E1.b Application Attachment E2 Application Attachment E3 Application Attachment E5 Application Attachment E6 Application Attachment F1 Application Attachment F2 Application Attachment F3 Application Attachment G Application Attachment H1 Application Attachment H2 Application Attachment 11 Application Attachment 12 Application Attachment 13 Application Attachment 14 Application Attachment IS Application Attachment 16 Application Attachment 17 Application Attachment 18 Application Attachment J Non Technical Summary Company Infonnation Location of Activity Relevant Planning Authority Site Notice, Newspaper Advertisement and Planning Authority Notice 5eveso II Regulations IPPC Directive (96/61/EC) Management of the Installation Infrastructure and Operation Point Emissions to Atmosphere Fugitive and Potential Emissions to Atmosphere Emissions to Surface Water Emissions to 5ewers Noise Emissions Tabular Data on Emission Points Treatment, Abatement and Control Systems Emissions Monitoring and Sampling Points Tabular Data on Monitoring and Sampling Points Resource Use and Energy Efficiency Materials Handling - Raw Materials, Intennediates and Product Handling Materials Handing - Waste Handling Detailed Dispersion Modelling Assessment of Impact of Surface Water Discharges on Receiving Waters Assessment of Impact on Receiving sewer Assessment of Impact of Ground Emissions Ground and/or Groundwater Contamination Assessment of the Environmental Impact of On-Site Waste Disposal Noise Impact Assessment Environmental Consideration and BAT Accident Prevention and Emergency Response EPA Export :16:44:24

85 Application Attachment K Application Attachment L Remediation, Decommissioning, Restoration, and Aftercare cessation of Activity Statutory Requirements EPA Export :16:44:24

86 IPPC Licence Application Attachment A.1 Quinn Cement Ltd IPPC Licence Application ATTACHMENT N o A.1 NON-TECHNICAL SUMMARY WYG Environment part of the WYG Group creative minds safe hands EPA Export :16:44:24

87 IPPC Licence Application Attachment A.1 Contents 1 INTRODUCTION PROCESS DESCRIPTION... 2 Raw Material Handling... 2 Raw Milling... 3 Clinker Production... 3 Cement Milling and Dispatch PROPOSED CHANGES TO EXISTING PROCESS... 6 New Process Units RAW MATERIAL USAGE EMISSIONS Emissions to Atmosphere Main Emissions to Atmosphere Minor Emissions to Atmosphere Fugitive Emissions Emissions to Surface Water Emissions to Sewer Noise Emissions WASTE MANAGEMENT AND OPERATIONAL PROCEDURES Environmental Management System Accident and Emergency Response Plant Control Quality Control Systems EMISSIONS MONITORING Atmospheric Emissions Ambient Monitoring Noise Monitoring Surface Water Monitoring Ground Water Monitoring Tables Table 1 Major Emissions to Air WYG Environment part of the WYG Group creative minds safe hands EPA Export :16:44:24

88 IPPC Licence Application Attachment A.1 1 INTRODUCTION 1.1 Quinn Cement Ltd currently operate a cement manufacturing facility located at Scotchtown, Ballyconnell, County Cavan, Republic of Ireland. The approximate Irish Grid Reference (IGR) of the site is , Reference should be made to Figure 1 for a map of the site and surrounding area. 1.2 The plant is located approximately 3km north of the town of Ballyconnell and covers an area of approximately 35-hectares. The facility is operational 24-hours per day for approximately 330- days per year, allowing time for scheduled shut-down periods The installation began operation in 2000 after significant investment had been placed in a plant that was designed by FLSmidth. The plant currently has planning permission for a production capacity of 1,400,000tonnes.year -1 and there are approximately 98-employees in total, including those in distribution. Quinn Cement is intending to modify the existing process to include substitution of coal with Solid Recovered Fuel (SRF) and associated engineering works. The categories for which a licence is being applied for, as outlined within Schedule 1 of the Protection of The Environment Act (2003) are: 10.1 The production of cement; and, 11.1 The recovery of waste. 1.5 The following document presents a non-technical summary of the existing cement production processes undertaken on-site, the proposed changes to allow co-fuelling with SRF, associated environmental impacts, management and operational procedures and emissions monitoring information. Further details on all information presented within this document are contained within the relevant IPPC Licence application attachment. WYG Environment part of the WYG Group 1 creative minds safe hands EPA Export :16:44:24

89 IPPC Licence Application Attachment A.1 2 PROCESS DESCRIPTION 2.1 The Ballyconnell facility currently produces Portland Cement (CEM1) and Portland Flyash Cement (CEMIIA/V 6-20% flyash), which are composite mixtures consisting of synthetic minerals exhibiting hydraulic properties upon mixing with water. The main raw materials used in the process are limestone (rich in calcium) and shale (rich in silica). As the chemical composition of these materials can be variable, small quantities of other materials including sand, silt, bauxite and iron ore are used as additives in order to obtain the required blend The raw materials are processed by crushing, blending and milling to produce a homogenous raw meal. This raw meal is then passed through a high temperature kiln, where a thermal process produces a synthetic clinker. The clinker and additives are then milled into a fine powder - cement. The main unit operations carried out at the plant are: Raw material handling; Raw milling; Clinker production; Cement milling; and, Cement despatch. All the process activities, with exception of cement despatch, are controlled from the Central Control Room where numerous critical plant operational parameters are monitored. The performance of the process is continuously monitored by operatives and interventions are made where necessary to ensure process stability and product quality. 2.5 A brief description of each unit operation is provided in the following sections. Reference should be made to Figure 2 for a schematic of the cement production process. Raw Material Handling 2.6 The main raw materials used within the process are limestone and shale. 2.7 Limestone is blasted from a local quarry and transported to the site by dumper trucks and emptied directly into concrete bunkers located within contained enclosures. WYG Environment part of the WYG Group 2 creative minds safe hands EPA Export :16:44:24

90 IPPC Licence Application Attachment A Crushed limestone is delivered to the site and loaded directly into hoppers, whilst the shale is loaded into crushers. There are four intake hoppers for crushed limestone and sand and one shale crushers. The shale, limestone and sand are tipped directly from dumpers into their respective hoppers for processing and transport to the pre-blending store via enclosed rubber belt conveyors. 2.9 The raw materials are mixed and blended within the pre-blending store. Carefully proportioned quantities of each raw material are fed by conveyor belt, with fine-tuning being undertaken through the addition of small amounts of other components including sand, silt and iron ore. Once an appropriate blend has been achieved it is stored prior to milling. Raw Milling The raw material is extracted from the pre-blending store and transported to an intermediary steel bin before being conveyed to the mill via a rotary sluice. The raw mill crushes and grinds the material to a very fine powder, known as raw meal. The resulting material is lifted from the mill by circulation air and passed through a rotary separator. Material that is too coarse falls from the circulation air and is returned to the mill for further grinding. Due to the moisture content of the raw material, drying is undertaken using hot circulation air from the kiln. A series of cyclones are used to separate the raw meal from the circulation air before transportation to a silo for storage and homogenisation. A gravimetric feeding system is used to feed the raw meal to the next stage of the process. Clinker Production 2.13 The clinker production plant includes the following items: Kiln feed system; Pre-heater; Calciner; Rotary kiln; Clinker cooler; Coal milling plant; and, Coal firing system. WYG Environment part of the WYG Group 3 creative minds safe hands EPA Export :16:44:24

91 IPPC Licence Application Attachment A The raw meal is extracted from the homogenisation silo and conveyed via bucket elevator to the pre-heating tower The raw meal enters the top of the cyclone pre-heater and travels down through five cyclones under the force of gravity. The cyclone pre-heater is equipped with an in-line calciner where up to 60% of the fuel is combusted. At 600 o C the limestone decomposes to produce quicklime and carbon dioxide. After a residence time of 1-minute, the material reaches the kiln inlet and is gradually moved down the coal fired rotating kiln The temperature of the raw meal is raised from 860ºC to 1,500ºC within the kiln, initiating the clinker production process. During this stage of the process, oxides of iron, aluminium and magnesium present within the material enable the reactions to take place at temperatures much lower than would normally be required. Temperatures of over 1,500ºC are reached in the lower end of the kiln and the clinker is formed. For each 100tonnes of raw meal processed within the system, 60tonnes of clinker is produced with 40% of raw meal burnt out during ignition. The clinker passes through the cooling zone before leaving through the kiln outlet, where it falls down into the grate cooler. The cooler recuperates heat from the clinker and recycles it back to the pre-heater, resulting in reduced heating costs and fuel consumption. Excess air from the cooler is passed through an electrostatic precipitator to remove particulates before release to atmosphere. Once cooled, the clinker exits the cooler via a hammer crusher and is conveyed to the clinker store. A series of bag filters are used to prevent fugitive dust emissions arising from the conveyor system Coal is transported to site by trucks and stored within enclosed concrete bunkers. The coal is extracted by a side-scraper and transported to the coal mill via rubber belt conveyors. Any metal residue present within the coal is detected and removed by a magnetic separator Coal is milled at a rate of approximately 25tonnes.hour % of the fine coal is fed to the calciner in the pre-heater tower, whilst 40% is fed to the kiln burner. The coal must be dried during the milling process due to the high moisture content. This is undertaken by circulation of hot air arising from waste gases from the kiln There are two separate Swirlax systems for firing coal into the calciner and kiln. Although the physical dimensions differ between the two, the principle of operation is the same for both WYG Environment part of the WYG Group 4 creative minds safe hands EPA Export :16:44:24

92 IPPC Licence Application Attachment A.1 systems. The pulverised coal is fed to the kiln and calciner firing systems by means of dosing systems and blowers for transporting the coal meal in steel tubes. Cement Milling and Dispatch 2.21 Clinker is mechanically extracted from the storage area and transported directly to the cement mill for grinding Within the mill, gypsum is added to control the setting time while flyash is added to make CEM II cement. CEM II A/V uses filler to reduce the clinker content of cement therefore reducing the carbon content The gypsum, clinker and fly ash are mixed to fine powder cement within the mill before transportation to three storage silos. Two of these silos are used for despatch of bulk cement, whilst the remaining silo the outer ring is used for bulk cement whilst the inner ring is fed to a bagging plant. Cement is packed at a rate of 4,000bags.hour -1. A negative pressure is maintained in the cement mill system by the circulation fan, which passes through a bag filter for the removal of particulate before release to atmosphere. WYG Environment part of the WYG Group 5 creative minds safe hands EPA Export :16:44:24

93 IPPC Licence Application Attachment A.1 3 PROPOSED CHANGES TO EXISTING PROCESS 3.1 The main source of fuel currently used at the Ballyconnell facility is coal. This is used to generate heat throughout the manufacturing process. Quinn Cement currently proposes to substitute 55% of coal with SRF. This has the following advantages: Reduction in consumption of raw resources; Reduction in carbon dioxide emissions; and, Reduction in disposal of municipal solid waste to landfill Although the cement manufacturing process will remain unchanged, some modifications will need to be made to the existing plant to facilitate use of SRF. These include the following: Installation of new fuel storage and feeding system; Installation of new calciner; Modify bypass set up (with new conditioning tower and moving existing bypass filter); Installation of new fan; Installation of new selective non catalytic reduction system for control of nitrogen oxide emissions; Modification to existing abatement systems; Installation of new silo at cement mill for bypass dust; and, Installation of new monitoring equipment. A new IPPC Licence is therefore required to reflect the above modifications. The new process units are briefly described below. New Process Units 3.4 SRF will be delivered to site by trucks equipped with walking floors and unloaded into covered receiving stations, from which the material will be transported to storage units. 3.5 Storage units 1-4 will be designed for fine SRF (<30mm), whilst storage units 5-8 will be designed for coarse SRF (<80mm). SRF will be extracted from these units by a screw conveyor and delivered to a dosing unit, which will feed the material via a hopper to a weigh feeder for transport to the calciner by an air blower or chain conveyor. WYG Environment part of the WYG Group 6 creative minds safe hands EPA Export :16:44:24

94 IPPC Licence Application Attachment A A new calciner is required to ensure complete combustion of the SRF. This will be constructed within a separate tower in front of the existing preheater. 3.7 It is proposed to install a selective non catalytic reduction system to control nitrogen oxide emissions. The system will reduce emissions by injecting an ammonia solution into the waste gases at an appropriate gas temperature. 3.8 A continuous emissions monitoring system will be modified on the main stack to include analysis in accordance with the requirements of the Waste Incineration Directive. This will monitor and analyse emissions of nitrogen oxides, particulate matter, sulphur dioxide, water, oxygen and carbon monoxide for comparison with the relevant emission limit values. 3.9 It is currently proposed to substitute 55% of coal with SRF at the plant. In order to accommodate this modification in fuel use, the following physical plant changes are proposed: Modify bypass set up (with new conditioning tower and moving existing bypass filter); Installation of new ID fan; and, Construction of a new silo for the storage of SRF. WYG Environment part of the WYG Group 7 creative minds safe hands EPA Export :16:44:24

95 IPPC Licence Application Attachment A.1 4 RAW MATERIAL USAGE 4.1 The following raw materials will be used and generated by the process: Limestone; Clay / silt; Shale; Gypsum; Iron-ore; Alkalose; Biodose; Cooldose-C; Argon / methane; Oxygen; Propane; Nitrogen; Acetylene; Carbon dioxide; Refractory bricks; Refractory castable; Mortar; Iron sulphate; Flyash; Grinding aid; Gear lubricants; Circulating oils; Hydraulic oils; Engine oils; Grease; Dilithium tetraborate; Ethylene glycol; Potassium dichromate; Hydrochloric acid (0.1M); Propanol; WYG Environment part of the WYG Group 8 creative minds safe hands EPA Export :16:44:24

96 IPPC Licence Application Attachment A.1 Silica gel; General laboratory reagents; Coal; Diesel; Kerosene; SRF; and, Ammonia solution Energy used by the facility will include: Electricity from the National Grid; Heat from the combustion of coal; Heat from the combustion of diesel; Heat from the combustion of kerosene; and, Heat from the combustion of SRF. No energy will be exported from the facility. WYG Environment part of the WYG Group 9 creative minds safe hands EPA Export :16:44:25

97 IPPC Licence Application Attachment A.1 5 EMISSIONS Emissions to Atmosphere MAIN EMISSIONS TO ATMOSPHERE 5.1 Table 1 outlines the main sources of emissions to air, the pollutants emitted and abatement systems to be used at each point. Table 1 Major Emissions to Air Identifier Source Pollutants Sulphur dioxide Oxides of nitrogen Particulate matter Total Organic Carbon Hydrogen chloride Hydrogen fluoride A2-01 Raw Mill/Kiln Cadmium and Thallium Mercury Metals (Antimony, Arsenic, Lead, Chromium, Cobalt, Copper, Manganese, Nickel and Vanadium) Dioxins and furans A2-02 Clinker Grate Cooler Particulate matter Abatement System Electrostatic precipitator Selective noncatalytic reduction system Electrostatic precipitator A2-03 Coal Mill Particulate matter Bag filter A2-04 Cement Mill Particulate matter Bag filter A2-05 Sepax Separator for Cement Mill Particulate matter Bag filter 5.2 Assessment of the main atmospheric emissions has been undertaken using detailed dispersion modelling. This indicated that there would not be any exceedences of the relevant Air Quality Standards at any location as a result of emissions from the Ballyconnell facility. It is therefore considered that the existing and proposed abatement systems are sufficient for the plant. MINOR EMISSIONS TO ATMOSPHERE 5.3 There are also 46No. minor atmospheric emission points, mainly associated with the transportation of raw and intermediate materials throughout the facility. These all emit particulate matter and are abated by bag filters. WYG Environment part of the WYG Group 10 creative minds safe hands EPA Export :16:44:25

98 IPPC Licence Application Attachment A.1 FUGITIVE EMISSIONS 5.4 Fugitive dust emissions can arise from several activities undertaken as part of the cement manufacturing process. These include the following: Unloading and loading operations; Transportation of materials between the various unit operations; Storage of raw materials in external stockpiles; and, Overfilling of storage silos Control methods in accordance with the Environmental Protection Agency Guidance Notes on Best Available Techniques for the Production of Cement 1 and Best Available Techniques in the Cement and Lime Manufacturing Industries 2 are implemented throughout the facility and will continue upon issue of the new IPPC Licence. Emissions to Surface Water Surface water emissions from the site occur as a result of routine wash-down processes and also as a result of storm water. As such, there are not considered to be any harmful or highly toxic constituents present within the effluent. There is currently one emission point for surface water emissions, which discharges effluent to the Woodford River. The entire cement plant site is covered by one catchment area and an extensive drain network diverts all surface water flow into a settlement tank which is currently Best Available Technique. All annual average discharge consents / guidance levels for the pollutants monitored during previous operational years have been achieved. The co-fuelling of the facility and associated engineering works are not considered likely to affect the content of existing surface water emissions. Emissions to Sewer 5.8 The facility has 1No. emission point to sewer. However, this is for sanitary effluent only and there are no process emissions to sewer associated with the plant. 1 2 BAT Guidance Note on Best Available Techniques for the Production of Cement and for the Production of Lime in the Kiln, Environmental Protection Agency, Integrated Pollution Prevention and Control (IPPC) Reference Document on Best Available Techniques in the Cement and Lime Manufacturing Industries, European Commission, WYG Environment part of the WYG Group 11 creative minds safe hands EPA Export :16:44:25

99 IPPC Licence Application Attachment A.1 Noise Emissions 5.9 The cement plant will operate on a continuous basis, 24-hours a day, 330-days per year. The cement plant equipment consists of heavy industrial type machinery and therefore there are a considerable number of potential noise sources The main areas of the cement plant producing significant noise emission are as follows: Cement mill; Kiln drive Motor; Raw mill; and, Cooling fans Noise emissions are constantly reviewed as part of Quinn Environmental Management System and any further abatement techniques are identified and considered as necessary. A Noise Impact Assessment was undertaken in order to quantify potential impacts as a result of the kiln co-fuelling and associated engineering works. This concluded that noise levels at sensitive receptor locations would not change and noise annoyance or nuisance as a result of the proposals was not considered to be likely. WYG Environment part of the WYG Group 12 creative minds safe hands EPA Export :16:44:25

100 IPPC Licence Application Attachment A.1 6 WASTE 6.1 Waste arises at the plant from the various unit operations, packaging, office operation and transportation. The Ballyconnell facility implements a waste disposal hierarchy through their Environmental Management System, with the preferred option being prevention and the least preferred method being disposal. 6.2 Quinn Cement is a fully fledged member of Repak and complies with all responsibilities contained within this scheme. Repak is Ireland s first voluntary initiative between industry and the Department of the Environment designed to meet industry s producer responsibility obligations under the European Union directive on packaging and packaging waste (94/62/EC) and the subsequent Waste Management (Packaging) Regulations Records are kept of all waste streams created on site and all waste transportation companies and treatment facilities used are suitably licensed. Details on the quantity, type, origin and destination of all waste streams are reported to the Environmental Protection Agency within the Annual Environmental Report. WYG Environment part of the WYG Group 13 creative minds safe hands EPA Export :16:44:25

101 IPPC Licence Application Attachment A.1 7 MANAGEMENT AND OPERATIONAL PROCEDURES Environmental Management System 7.1 Quinn Cement maintains a full Environmental Management System in accordance with the ISO:14001 standard and intend to seek formal accreditation during late 2009 or early The Environmental Management System ensures that the company complies with all applicable legislation and also achieves continuous improvement in environmental performance The Environmental Management System has been developed as a continuous improvement model that complies with the following elements: Environmental policy; Environmental planning; Operational control (including implementation and operations); Inspection and correction; and, Management review. The following documentation forms the company Environmental Management System: Environmental Management System manual; Procedure manuals; Register of environmental aspects; Register of environmental legislation; Environmental management programme; and, Monitoring and measurement records. Accident and Emergency Response 7.5 Quinn Cement has established and maintained procedures to identify the potential for accidents and emergency situations which theoretically may occur at the Ballyconnell facility. There is a detailed response procedure in place to react to such situations as part of the Environmental Management System. 7.6 It is considered that this response procedure is adequate and applicable to the change in process for co-fuelling with SRF and associated engineering works. WYG Environment part of the WYG Group 14 creative minds safe hands EPA Export :16:44:25

102 IPPC Licence Application Attachment A.1 Plant Control 7.7 The entire plant is controlled from the Central Control Room. The central process control system is based on a dualised computer system, which consists of traditional operator workstations and a distributed system with remote modules for motor control, alarm handling and loop control. The intercommunication is performed via a high speed ethernet system. 7.8 Each individual operator workstation has direct access to the plant process database. This means that the plant can be supervised and/or controlled from any workstation on site. Each workstation displays motor status, loop control, process measurements and production data A clear separation in the unit operation sections enables independent operation of each process department. In case of one department being shut down, remaining plant sections can still be fully operated, if desired. Quality Control Systems It is the policy of Quinn Cement to produce cement that fully conforms with customer s needs and expectations and to the relevant National Standards. In order to ensure that the product continually meets these requirements, the Company maintains a Quality System in accordance with BS EN ISO 9001: 2000 and currently has ISO 9001:2000 standard accreditation. WYG Environment part of the WYG Group 15 creative minds safe hands EPA Export :16:44:25

103 IPPC Licence Application Attachment A.1 8 EMISSIONS MONITORING Atmospheric Emissions 8.1 Monitoring of atmospheric emissions from each point identified within Table 1 will be undertaken at the facility on a continuous and periodic basis. 8.2 Continuous monitoring will be undertaken on A2-01 for emissions of nitrous oxide, carbon monoxide, oxygen, water, sulphur dioxide and particulate matter. Continuous monitoring of the pressure differential on A2-02, A2-03, A2-04 and A2-05 is also to be undertaken in order to ensure the abatement systems are operating efficiently Regular calibration of the continuous monitoring systems will be undertaken in order to ensure the accuracy of all results. Periodic monitoring of all pollutants stated within Table 1 will be undertaken on a quarterly basis, or as outlined within the IPPC Licence. All monitoring will be undertaken by an appropriately accredited stack testing consultancy in accordance with the relevant monitoring methodologies to ensure the accuracy of data. All monitoring results will be reported to the Environmental Protection Agency on a periodic basis, as required by the conditions of the IPPC Licence. Ambient Monitoring Monitoring of ambient particulate concentrations will be undertaken using dust deposition gauges at 5No. locations in the vicinity of the site. Results will be reported on a monthly basis and held on-site for inspection by the Environmental Protection Agency. Noise Monitoring 8.7 Noise monitoring will be undertaken annually by an external contractor at 6No. sensitive locations to be agreed by the Environmental Protection Agency. Noise monitoring will be undertaken during day-time and night-time periods for each annual assessment, with results reported within the Annual Environmental Report. WYG Environment part of the WYG Group 16 creative minds safe hands EPA Export :16:44:25

104 IPPC Licence Application Attachment A.1 Surface Water Monitoring 8.8 A surface water quality monitoring and sampling point is provided at the outlet for discharge from the settlement tank. This facilitates monitoring of water quality prior to its discharge into the Woodford River. 8.9 The discharge will be monitored for chemical oxygen demand, biological oxygen demand, suspended solids, ph, total dissolved solids, ammonium and temperature on a weekly basis and flow rate, chemical oxygen demand, biological oxygen demand, suspended solids, total dissolved solids, ammonium, temperature, chromium and aluminium on a monthly basis The results of the monitoring will be reported to the Agency and aggregated annual results will be reported within the Annual Environmental Report. Ground Water Monitoring Ground water monitoring will be undertaken on a bi-annual basis for ph, total organic carbon, conductivity, total ammonia, total nitrogen, chromium, aluminium, mineral oils and volatile organic compounds. The results of the monitoring will be reported as required by the Agency and aggregated annual results will be reported within the Annual Environmental Report. WYG Environment part of the WYG Group 17 creative minds safe hands EPA Export :16:44:25

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108 IPPC Licence Application Attachment B.1 Quinn Cement Ltd IPPC Licence Application ATTACHMENT N o B.1. COMPANY INFORMATION WYG Environment part of the WYG Group creative minds safe hands EPA Export :16:44:25

109 IPPC Licence Application Attachment B.1 Contents 1 CERTIFICATE OF INCORPORATION COMPANY INFORMATION... 3 Figures Figure 1 Certificate of Incorporation... 2 Appendices Appendix B.1 - Quinn Cement Ballyconnell Ownership Plan WYG Environment part of the WYG Group creative minds safe hands EPA Export :16:44:25

110 IPPC Licence Application Attachment B.1 1 CERTIFICATE OF INCORPORATION 1.1 The Quinn Cement Ltd (Quinn Cement) Certificate of Incorporation is presented within Figure 1. WYG Environment part of the WYG Group 1 creative minds safe hands EPA Export :16:44:25

111 IPPC Licence Application Attachment B.1 Figure 1 Certificate of Incorporation WYG Environment part of the WYG Group 2 creative minds safe hands EPA Export :16:44:25

112 IPPC Licence Application Attachment B.1 2 COMPANY INFORMATION 2.1 Company Registration Number: IE Registered Office of the Company: Quinn Cement Ltd, Scotchtown, Ballyconnell, Co. Cavan 2.3 An Ownership Plan is provided in Appendix B.1 illustrating the Quinn Cement Ballyconnell facility. The red-line boundary of the Ballyconnell facility and the blue-line land ownership boundary of the Quinn Group is clearly labelled. WYG Environment part of the WYG Group 3 creative minds safe hands EPA Export :16:44:25

113 Appendix B.1 Quinn Cement Ballyconnell Ownership Plan EPA Export :16:44:25

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115 IPPC Licence Application Attachment B.2 Quinn Cement Ltd IPPC Licence Application ATTACHMENT N o B.2. LOCATION OF ACTIVITY WYG Environment part of the WYG Group creative minds safe hands EPA Export :16:44:25

116 IPPC Licence Application Attachment B.2 Contents 1 LOCATION OF ACTIVITY... 1 Appendices Appendix B.2 - Quinn Cement Ballyconnell Site Boundary and Overall Site Plan WYG Environment part of the WYG Group creative minds safe hands EPA Export :16:44:26

117 IPPC Licence Application Attachment B.2 1 LOCATION OF ACTIVITY 1.1 The Quinn Cement Ltd Ballyconnell installation is located at: Quinn Cement Limited Scotchtown Ballyconnell County Cavan Ireland Telephone Number: Fascimile Number: The primary, secondary and tertiary contacts are as follows: Primary contact: Steve Tonry Business Manager Renewable Energy and Environmental Services Quinn Group Derrylin CO. Fermanagh BT92 9AU Secondary contact: Kevin Lunney Group Development Director Quinn Group Derrylin CO. Fermanagh BT92 9AU Tertiary Contact: Anna McNally Environmental Advisor Quinn Cement Scotchtown Ballyconnell Co. Cavan WYG Environment part of the WYG Group 1 creative minds safe hands EPA Export :16:44:26

118 IPPC Licence Application Attachment B The Irish Grid Reference, in meters, of the centre of the Ballyconnell facility is , A geo-referenced digital mapping file (in Irish grid reference coordinates) of the Quinn Cement Ballyconnell installation is included within Appendix B.2. This includes a boundary illustrating the extent of the proposed new installation under which the IPPC licence is being applied, and it s location within the existing installation. WYG Environment part of the WYG Group 2 creative minds safe hands EPA Export :16:44:26

119 Appendix B.2 Quinn Cement Ballyconnell Site Boundary and Overall Site Plan EPA Export :16:44:26

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121 IPPC Licence Application Attachment B.5 Quinn Cement Ltd IPPC Licence Application ATTACHMENT N o B.5 RELEVANT PLANNING AUTHORITY WYG Environment part of the WYG Group 1 creative minds safe hands EPA Export :16:44:26

122 IPPC Licence Application Attachment B.5 Contents 1 PLANNING PERMISSIONS EXISTING LICENCE... 4 Appendices Appendix B.5a - Appendix B.5b - Quinn Cement Ballyconnell Planning Permissions Quinn Cement Ballyconnell IPC Licences WYG Environment part of the WYG Group 2 creative minds safe hands EPA Export :16:44:26

123 IPPC Licence Application Attachment B.5 1 PLANNING PERMISSIONS 1.1 The Quinn Cement Ballyconnell facility falls within the functional area of County Cavan planning authority. The contact details for the planning authority are as follows: County Cavan Planning Authority Cavan County Council Courthouse Farnham Street Cavan County Cavan Telephone Number: Facsimile Number: The following documents show all past planning permissions granted for the site, including the following: 97/682 Planning permission original 1,000,000tonnes per annum cement facility; 00/1384 Planning permission to retain and modify buildings including existing office block; 03/213 Planning permission to construct a bagging facility at the plant; and, 08/98 Planning Permission to construct ferrous sulphate dosing tank. 1.3 The plant capacity was upgraded to 1,400,000tonnes per annum in This capacity upgrade was declared under Section 5 of the Planning and Development Act Copies of all planning permissions are contained within Appendix E.2a. 1.5 Reference should be made to the EIS accompanying this IPPC licence application for the Ballyconnell facility. WYG Environment part of the WYG Group 3 creative minds safe hands EPA Export :16:44:26

124 IPPC Licence Application Attachment B.5 2 EXISTING LICENCE 2.1 The Quinn Cement Ballyconnell facility falls currently operates under IPC licence 378 (1998) and the amendments outlined within P Copies of the existing permit and amendments are contained within Appendix B.5b. WYG Environment part of the WYG Group 4 creative minds safe hands EPA Export :16:44:26

125 Appendix B.5a Planning Permissions EPA Export :16:44:26

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134 PLANNING & DEVELOPMENT ACTS PLANNING APPLICATION: Quinn Cement Limited. REG. NO. 08/98 SCHEDULE 1 It is considered that, subject to compliance with the conditions set out below, the proposed development would not injure the amenities of the area, give rise to a traffic hazard or be prejudicial to public health and would be in accordance with the proper planning and development of the area. SCHEDULE 2 1. Development shall be in accordance with plans and particulars submitted to and received by the Planning Authority on 5 th February 2008 subject to the requirements of the following conditions. In the interest of proper planning and sustainable development. 2. No surface water from roofs or paved areas shall flow from the site (including entrance area) onto the road adjoining the site but shall be collected by a surface water drainage system and discharged direct to nearby watercourses In the interests of public health, traffic safety and amenity. Administrative Officer. EPA Export :16:44:27

135 Appendix B.5b IPC Licences EPA Export :16:44:27

136 Headquarters, Johnstown Castle Estate, County Wexford, Ireland INTEGRATED POLLUTION CONTROL LICENCE Licence Register Number: Licensee: Location of Activity: 378 Quinn Quarries Limited Scotchtown Cement Works, Scotchtown, Ballyconnell, Co. Cavan EPA Export :16:44:27

137 Environmental Protection Agency IPC Licence Reg. N o 378 Table of Contents Page No. Glossary...1 Condition 1. Scope...3 Condition 2. Management of the Activity...3 Condition 3. Interpretation...5 Condition 4. Notification...6 Condition 5. Emissions to Atmosphere...7 Condition 6. Emissions to Water...8 Condition 7. Waste Management...10 Condition 8.Noise...11 Condition 9. Non-Process Water...11 Condition 10. Monitoring...12 Condition 11. Recording and Reporting to Agency...13 Condition 12. Emergency Response...14 Condition 13. Financial Provisions...14 Schedule 1(i) Emissions to Atmosphere...15 Schedule 1(ii) Emissions to Atmosphere: Abatement/Treatment Control...17 Schedule 1(iii) Monitoring of Emissions to Atmosphere...18 Schedule 2(i) Emissions to Water...19 Schedule 2(ii) Monitoring of Emissions to Water...19 Schedule 3(i) Hazardous Wastes for Disposal/Recovery...20 Schedule 3(ii) Other Wastes for Disposal/Recovery...20 Schedule 4(i) Groundwater Monitoring...22 Schedule 5(i) Recording and Reporting to the Agency...22 EPA Export :16:44:27

138 Environmental Protection Agency IPC Licence Reg. N o 378 Glossary of Terms The Agency The Licensee Location of Activity AA AER Annually BATNEEC Biannually BOD B.S. CHP COD Daily Day Daytime db(a) P EMP EPA ESP EWC ICP IPC K Environmental Protection Agency. Quinn Quarries Limited, c/o Hotel Kilmore, Dublin Road, Cavan Scotchtown Cement Works, Scotchtown, Ballyconnell, Co. Cavan. Atomic Absorption Annual Environmental Report. All or part of a period of twelve consecutive months. Best Available Technology Not Entailing Excessive Cost. All or part of a period of six consecutive months. 5 day Biochemical Oxygen Demand. British Standard Combined Heat & Power Chemical Oxygen Demand. During all days of plant operation, and in the case of emissions, when emissions are taking place; with no more than 1 measurement on any one day. Any 24 hour period hrs to 2200 hrs. Decibels (A weighted). Pressure Differential Environmental Management Programme. Environmental Protection Agency Electrostatic Precipitator European Waste Catalogue (94/3/EEC, see also Agency Guidance Note on the EWC) Inductively Coupled Plasma Spectroscopy. Integrated Pollution Control. Kelvin. EPA Export :16:44:27

139 Environmental Protection Agency IPC Licence Reg. N o 378 kpa Leq Local Authority Monthly Night-time Noise sensitive location PER kilo Pascals. Equivalent continuous sound level. Cavan County Council. At least 12 times per year at approximately monthly intervals hrs to 0800 hrs. Any dwelling house, hotel or hostel, health building, educational establishment, place of worship or entertainment, or any other facility or area of high amenity which for its proper enjoyment requires the absence of noise at nuisance levels. Pollution Emission Register. PM 2.5 Particulate matter with a nominal particle diameter of 2.5 µm as determined by appropriate measurements using techniques acceptable to the Agency. PM 10 Particulate matter with a nominal particle diameter of 10 µm as determined by appropriate measurements using techniques acceptable to the Agency. Quarterly Standard Methods Waste disposal operation Waste recovery operation All or part of a period of three consecutive months beginning on the first day of January, April, July or October. As detailed in Standard Methods for the Examination of Water and Wastewater, (prepared and published jointly by A.P.H.A., A.W.W.A & W.E.F) 19th Ed. 1995, American Public Health Association, 1015 Fifteenth Street, N.W., Washington DC 20005, Means any of the operations included in the Third Schedule to the Waste Management Act Means any of the operations included in the Fourth Schedule to the Waste Management Act Weekly During all weeks of plant operation, and in the case of emissions, when emissions are taking place; with no more than one measurement in any one week. EPA Export :16:44:27

140 Environmental Protection Agency IPC Licence Reg. N o 378 Condition 1. Scope Conditions 1.1 The activity shall be controlled, operated, and maintained and emissions shall take place as set out in this Integrated Pollution Control (IPC) licence. All programmes required to be carried out under the terms of this licence, become part of this licence. 1.2 No alteration to, or reconstruction in respect of, the activity or any part thereof which would, or is likely to, result in a material change or increase in: The nature or quantity of any emission, The abatement/treatment or recovery systems, The range of processes to be carried out, The fuels, raw materials, intermediates, products or wastes generated, or any changes in: The site management and control with adverse environmental significance shall be carried out or commenced without prior notice to, and without the prior written agreement of, the Agency. 1.3 This licence is for the purposes of IPC licensing under the EPA Act, 1992 only and nothing in this licence shall be construed as negating the licensee s statutory obligations or requirements under any other enactments or regulations. 1.4 Any reference in this licence to site shall mean the plan area edged in black, shaded and identified in the key as Proposed Cement Works Site on the drawing labelled Figure 2.2 in Attachment 9 of the IPC licence application. Reason: To clarify the scope of this licence. Condition 2. Management of the Activity 2.1 The licensee shall establish and maintain an Environmental Management System (EMS) which shall fulfil the requirements of this licence. The EMS shall assess all operations and review all practicable options for the use of cleaner technology, cleaner production and the reduction and minimisation of waste, and shall include as a minimum those elements specified in the Conditions 2.2 to 2.8 below: 2.2 A schedule of Environmental Objectives and Targets The licensee shall prepare a schedule of Environmental Objectives and Targets. The schedule shall include time frames for the achievement of set targets. The schedule shall address a five year period as a minimum. The schedule shall be prepared to the satisfaction of the Agency and shall be submitted to the Agency not later than six months prior to commencement of cement manufacturing on the site. The schedule shall be reviewed annually and amendments thereto notified to the Agency for agreement as part of the Annual Environmental Report (AER) (See also Condition 2.8). EPA Export :16:44:27

141 Environmental Protection Agency IPC Licence Reg. N o The licensee shall have regard to those matters listed in Schedule 5(i) Recording & Reporting to the Agency when establishing the schedule of Objectives and Targets. 2.3 Environmental Management Programme (EMP) The licensee shall, not later than four months prior to commencement of cement manufacturing on the site, submit to the Agency for agreement an EMP, including a time schedule, for achieving objectives and targets. Once agreed the EMP shall be established and maintained by the licensee. It shall include: (i) designation of responsibility for targets; (ii) the means by which they may be achieved; (iii) the time within which they may be achieved. The EMP shall be reviewed annually and amendments thereto notified to the Agency for agreement as part of the Annual Environmental Report (AER) (Condition 2.8) A report on the programme, including the success in meeting agreed targets, shall be prepared and submitted to the Agency as part of the AER. Such reports shall be retained on-site for a period of not less than seven years and shall be available for inspection by authorised persons of the Agency. 2.4 Documentation The licensee shall establish and maintain an environmental management documentation system which shall be to the satisfaction of the Agency The licensee shall issue a copy of this licence to all relevant personnel whose duties relate to any condition of this licence. 2.5 Corrective Action The licensee shall establish procedures to ensure that corrective action is taken should the specified requirements of this licence not be fulfilled. The responsibility and authority for initiating further investigation and corrective action in the event of a reported non-conformity with this licence shall be defined. 2.6 Awareness and Training The licensee shall establish and maintain procedures for identifying training needs, and for providing appropriate training, for all personnel whose work can have a significant effect upon the environment. Appropriate records of training shall be maintained Personnel performing specifically assigned tasks shall be qualified on the basis of appropriate education, training and/or experience, as required. 2.7 Responsibilities The licensee shall ensure that a person in charge, as defined under the terms of the Environmental Protection Agency Act, 1992 shall be available on-site at all times. The person in charge shall also be available to meet with authorised persons of the Agency at all reasonable times. EPA Export :16:44:27

142 Environmental Protection Agency IPC Licence Reg. N o Communications The licensee shall put in place a programme to ensure that members of the public can obtain information concerning the environmental performance of the licensee at all reasonable times. This programme shall be submitted for agreement to the Agency not later than six months prior to the commencement of cement manufacturing on the site The licensee shall submit to the Agency, eighteen months from the date of commencement of cement production, and each calendar year thereafter, an AER which shall be to the satisfaction of the Agency. This report shall include as a minimum the information specified in Schedule 5(i) Recording & Reporting to the Agency and shall be prepared in accordance with any relevant guidelines issued by the Agency. Reason: To make provision for management of the activity on a planned basis having regard to the desirability of ongoing assessment, recording and reporting of matters affecting the environment. Condition 3. Interpretation 3.1 Emission limit values for emissions to atmosphere in this licence shall be interpreted in the following way: Continuous Monitoring: (i) No 24 hour mean value shall exceed the emission limit value. (ii) 97% of all 30 minute mean values taken continuously over an annual period shall not exceed 1.2 times the emission limit value. (iii) No 30 minute mean value shall exceed twice the emission limit value For Non-Continuous Monitoring: (i) For any parameter where, due to sampling/analytical limitations, a 30 minute sample is inappropriate, a suitable sampling period should be employed and the value obtained therein shall not exceed the emission limit value. (ii) For flow, no hourly or daily mean value, calculated on the basis of appropriate spot readings, shall exceed the relevant limit value. (iii) For all other parameters, no 30 minute mean value shall exceed the emission limit value. 3.2 The concentration limits for emissions to atmosphere specified in this licence shall be achieved without the introduction of dilution air and shall be based on gas volumes under standard conditions of : In the case of non-combustion gases: (i) Temperature 273K, Pressure kpa (no correction for oxygen or water content). EPA Export :16:44:27

143 Environmental Protection Agency IPC Licence Reg. N o In the case of combustion gases: (i) Temperature 273K, Pressure kpa, dry gas; 10% oxygen. 3.3 Emission limit values for emissions to waters in this licence shall be interpreted in the following way: Continuous monitoring: (i) No flow value shall exceed the specified limit Non-Continuous Monitoring: (i) No ph value shall deviate from the specified range. (ii) No temperature value shall exceed the limit value. (iii) For parameters other than ph, temperature and flow, eight out of ten consecutive results, calculated as daily mean concentration or mass emission values on the basis of flow proportional composite sampling, shall not exceed the emission limit value. No individual result similarly calculated shall exceed 1.2 times the emission limit value. (iv) For parameters other than ph, temperature, and flow, no grab sample value shall exceed 1.2 times the emission limit value. Reason : To clarify the interpretation of emission limit values fixed under the licence. Condition 4. Notification 4.1 The licensee shall notify the Agency by both telephone and facsimile, if available, to the Agency s Headquarters in Wexford, or to such other Agency office as may be specified by the Agency, as soon as practicable after the occurrence of any of the following: Any release to atmosphere from any potential emission point Any emission which does not comply with the requirements of this licence Any malfunction or breakdown of control equipment or monitoring equipment set out in; Schedule 1(ii) Emissions to Atmosphere: Abatement/Treatment Control, which is likely to lead to loss of control of the abatement system Any incident with the potential for environmental contamination of surface water or groundwater, or posing an environmental threat to air or land, or requiring an emergency response by the Local Authority Any ESP trip-out. The licensee shall include as part of the notification, date and time of the incident, details of the occurrence, and the steps taken to minimise the emissions and avoid recurrence. EPA Export :16:44:27

144 Environmental Protection Agency IPC Licence Reg. N o The licensee shall make a record of any incident as set out in Condition 4.1 above. The notification given to the Agency shall include details of the circumstances giving rise to the incident and all actions taken to minimise the effect on the environment and minimise wastes generated. 4.3 A summary report of reported incidents shall be submitted to the Agency as part of the AER. The information contained in this report shall be prepared in accordance with any relevant guidelines issued by the Agency. 4.4 In the case of any incident as set out in Condition above which relates to discharges to water, the licensee shall notify the Northern Regional Fisheries Board as soon as practicable after such an incident. 4.5 In the event of any incident, as set out in Condition having taken place, the licensee shall notify the Local Authority as soon as practicable, after such an incident. 4.6 The licensee shall, at least one month in advance, notify the Agency of the date of commencement of cement production. Reason : To provide for the notification of incidents and update information on the activity Condition 5. Emissions to Atmosphere 5.1 No specified emission to the atmosphere shall exceed the emission limit value set out in Schedule 1(i) Emissions to Atmosphere, subject to Condition 3 of this licence. There shall be no other emission to the atmosphere of environmental significance. 5.2 All equipment, including backup equipment, specified in Schedule 1(ii) Emissions to Atmosphere Abatement/Treatment Control of this licence shall be provided on-site. All treatment/abatement, control and monitoring equipment shall be calibrated and maintained when in use, in accordance with the information submitted in Table 12A(iv) of the IPC licence application or as otherwise approved by the Agency under the Environmental Management Programme. 5.3 Monitoring and analyses of each emission shall be carried out as specified in Schedule 1(iii) Monitoring of Emissions to Atmosphere of this licence. A report on the results of this monitoring shall be submitted to the Agency on a monthly basis following commencement of cement production. 5.4 A summary report of emissions to atmosphere shall be submitted to the Agency as part of the AER. The information contained in this report shall be prepared in accordance with any relevant guidelines issued by the Agency. 5.5 The licensee shall maintain logs of all carbon monoxide trip-out events of the electrostatic precipitators in use on the site. These logs shall contain information on the time, duration, cause and corrective action taken, in the case of each trip-out event. A separate log shall be maintained for each ESP. These logs shall be available for inspection at all times by Agency personnel. A copy of the current contents of these logs shall be submitted to the Agency quarterly following commencement of cement production. 5.6 Consistent with its safe operation, the cement kiln shall be taken off-line in the event that any carbon monoxide trip or any other circumstance, leads to a loss of operation of an electrostatic precipitator for a period in excess of 30 minutes. Details of such shutdown of the cement kiln shall be included in the log(s) referred to in Condition 5.5 above. EPA Export :16:44:27

145 Environmental Protection Agency IPC Licence Reg. N o Where it appears to the Agency that the frequency of ESP trip-out episodes is excessive, the licensee shall, at the request of the Agency, make a study of the cause and propose, consistent with BATNEEC, the means for the reduction of the frequency of ESP trip-outs to levels acceptable to the Agency. Any proposed measures agreed by the Agency shall be implemented within a timetable specified by the Agency. 5.8 The licensee shall submit a proposal to the Agency for agreement, for the establishment of a set of five permanent dust deposit gauges around the site of the operation. This proposal shall be submitted to the Agency within three months of the date of grant of this licence. Having obtained approval for the proposal, the licensee shall install and commission these permanent dust deposit gauges not later than three months prior to the commencement of cement production. 5.9 The licensee shall maintain and operate dust deposit gauges around the site to the satisfaction of the Agency. The dust gauges shall be operated in accordance with B.S Part 1 of 1969 : Methods for the Measurement of Air Pollution : Deposit Gauges (or such other method as may be agreed in advance in writing with the Agency). The results of monthly measurements from these gauges shall be retained on-site, for inspection by the Agency, for a period of seven years after the measurements are made During (dry) weather conditions which favour the dispersion of dust, the licensee shall ensure that dust from the movement of machinery and windblow on-site is controlled. A procedure for windblown dust control shall be maintained by the licensee, and this documented procedure shall be available on-site for inspection by the Agency and submitted to the Agency on request The licensee shall carry our an evaluation of the PM 10 fraction of the dust emissions from each emission point specified in Schedule 1(i) Emissions to Atmosphere in this licence. A report on this evaluation shall be submitted to the Agency within eighteen months of the date of commencement of cement production The licensee shall ensure that all operations on-site shall be carried out in a manner such that air emissions, including dust emissions, and/or odours do not result in significant impairment of, or significant interference with amenities or the environment beyond the site boundary The licensee shall submit a proposal to the Agency for agreement, for the establishment of an ambient monitoring programme for PM 10 and PM 2.5. This proposal shall include, as a minimum, details on the type of monitor(s) to be used and the location(s) of the ambient monitoring points and shall be submitted to the Agency within three months of the date of grant of this licence. Having obtained approval for the proposal, the licensee shall commence the ambient monitoring programme within three months of date of approval by the Agency of the proposal. Reason: To provide for the protection of the environment by way of control, limitation, treatment and monitoring of emissions. Condition 6. Emissions to Water 6.1 No specified emission to water shall exceed the emission limit values set out in Schedule 2(i) Emissions to Water subject to Condition 3 of this licence. There shall be no other emissions to water of environmental significance. EPA Export :16:44:27

146 Environmental Protection Agency IPC Licence Reg. N o All sanitary effluent and laboratory washings (excluding laboratory wastes) which arise on the site shall be discharged to the Sanitary Authority sewer. 6.3 All treatment/abatement, control and monitoring equipment shall be calibrated and maintained at all times when in use, in accordance with the information submitted in the IPC licence application or as otherwise approved by the Agency under the EMP. 6.4 Monitoring and analyses of each emission shall be carried out as specified in Schedule 2(ii) Monitoring of Emissions to Water of this licence. A report on the results of this monitoring shall be submitted to the Agency monthly following commencement of cement production. 6.5 In the event that any analyses or observations made on the quality or appearance of surface water runoff should indicate that contamination has taken place, the licensee shall : (i) carry out an immediate investigation to identify and isolate the source of the contamination, (ii) put in place measures to prevent further contamination and to minimise the effects of any contamination on the environment, and notify the Agency as soon as is practicable. 6.6 A summary report of emissions to water shall be submitted to the Agency as part of the AER. The information contained in this report shall be prepared in accordance with any relevant guidelines issued by the Agency. 6.7 The acute toxicity of the undiluted final effluent to at least four aquatic species from different trophic levels shall be determined by standardised and internationally accepted procedures and carried out by a competent laboratory. The name of the laboratory and the scope of testing to be undertaken shall be submitted, in writing, to the Agency, not later than six months prior to the commencement of cement manufacturing on the site of the operation. Once the testing laboratory and the scope of testing have been agreed by the Agency, the Agency shall decide when this testing is to be carried out and copies of the complete reports shall be submitted by the licensee to the Agency within six weeks of completion of the testing. 6.8 Having identified the most sensitive species outlined in Condition 6.7, subsequent compliance toxicity monitoring on the two most sensitive species shall be carried out as per Schedule 2(ii) Monitoring of Emissions to Water. The Agency shall decide when this testing is to be carried out (but not more frequently than biannually) and copies of the complete reports shall be submitted by the licensee to the Agency within six weeks of completion of the testing. 6.9 No substance shall be discharged in a manner, or at a concentration which, following initial dilution, causes tainting of fish or shellfish. Reason: To provide for the protection of the environment by way of control, limitation, treatment and monitoring of emissions. EPA Export :16:44:27

147 Environmental Protection Agency IPC Licence Reg. N o 378 Condition 7. Waste Management 7.1 The licensee shall submit a report to the Agency on an assessment of the use of energy recovery and / or combined heat and power (CHP) facilities in the process. This report shall examine the feasibility of using waste heat from the process for ancillary purposes including, but not limited to, possible electricity generation. The assessment report shall be submitted to the Agency within three months of the date of grant of this licence 7.2 The licensee shall, by agreement with the Agency, adopt energy recovery and / or CHP technologies in the development of the cement production plant subject to the requirements of Condition 1.3 of this licence. 7.3 Disposal or recovery of waste shall take place only as specified in Schedule 3(i) Hazardous Waste for Disposal/Recovery and Schedule 3(ii) Other Wastes for Disposal/Recovery of this licence and in accordance with the appropriate National and European legislation and protocols. No other waste shall be disposed of/recovered either on-site or off-site without prior notice to, and prior written agreement of, the Agency. 7.4 Waste sent off-site for recovery or disposal shall only be conveyed to a waste contractor, as agreed by the Agency, and only transported from the site of the activity to the site of recovery/disposal in a manner which will not adversely affect the environment. 7.5 A full record, which shall be open to inspection by authorised persons of the Agency at all times, shall be kept by the licensee on matters relating to the waste management operations and practices at this site. This record shall as a minimum contain details of the following: The names of the agent and transporter of the waste The name of the persons responsible for the ultimate disposal/recovery of the waste The ultimate destination of the waste Written confirmation of the acceptance and disposal/recovery of any hazardous waste consignments sent off-site The tonnages and EWC Code for the waste materials listed in Schedule 3(i) Hazardous Waste for Disposal/Recovery and Schedule 3(ii) Other Wastes for Disposal/Recovery, sent off-site for disposal/recovery Details of any rejected consignments The tonnages and EWC Code for the waste materials listed Schedule 3(i) Hazardous Waste for Disposal/Recovery and Schedule 3(ii) Other Wastes for Disposal/Recovery, recovered on-site. A copy of this Waste Management record shall be submitted to the Agency as part of the AER for the site. Reason: To provide for the disposal/recovery of waste and the protection of the environment. EPA Export :16:44:27

148 Environmental Protection Agency IPC Licence Reg. N o 378 Condition 8. Noise 8.1 The licensee shall carry out a noise survey of the site operations annually following commencement of cement production. The licensee shall consult with the Agency on the timing, nature and extent of the survey and shall develop a survey programme to the satisfaction of the Agency. The survey programme shall be submitted to the Agency in writing at least one month before the survey is to be carried out. A record of the survey results shall be available for inspection by any authorised persons of the Agency, at all reasonable times and a summary report of this record shall be included as part of the AER. 8.2 Activities on-site shall not give rise to noise levels at any noise sensitive location off site, which exceed the following sound pressure limits (Leq, 15 minute) : Daytime: 55 db(a) Night-time: 45 db(a). 8.3 There shall be no clearly audible tonal component or impulsive component in the noise emission from the activity at any noise sensitive location. Reason: To provide for the protection of the environment by control of noise. Condition 9. Non-Process Water 9.1 Groundwater Prior to the commencement of cement production, the licensee shall submit a proposal to the Agency, for agreement, for the establishment of a monitoring bore-hole adjacent to the oil storage area (reference number 751 on DWG SQG-002 in Attachment 9 of the IPC Application) The licensee shall analyse groundwater samples from the bore-hole referred to in Condition above in accordance with Schedule 4(i) Groundwater Monitoring of this licence. A report on the results of this monitoring shall be submitted to the Agency biannually following commencement of cement production and a summary report shall be submitted as part of the AER. 9.2 Facilities for the Protection of Groundwater and Surface Water All tank and drum storage areas shall be rendered impervious to the materials stored therein. In addition, tank and drum storage areas shall, as a minimum be bunded, either locally or remotely, to a volume not less than the greater of the following; (i) 110% of the capacity of the largest tank or drum within the bunded area (ii) 25% of the total volume of substance which could be stored within the bunded area. EPA Export :16:44:27

149 Environmental Protection Agency IPC Licence Reg. N o 378 Reason: Drainage from bunded areas shall be diverted for collection and safe disposal. All bunds shall be tested at least once every three years. A report on such tests shall be included in the AER The integrity and water tightness of all the bunding structures and their resistance to penetration by water or other materials stored therein shall be tested and demonstrated by the licensee to the satisfaction of the Agency and shall be reported to the Agency prior to the commencement of cement manufacturing on the site The loading and unloading of materials shall be carried out in designated areas protected against spillage and leachate run - off. While awaiting disposal, all materials shall be collected and stored in designated areas protected against spillage and leachate run - off An inspection for leaks on all flanges and valves on over-ground pipes used to transport materials other than water shall be carried out weekly The licensee shall have in storage an adequate supply of containment booms and suitable absorbent material to contain and absorb any spillage. To provide for the protection of surface waters and groundwater. Condition 10. Monitoring 10.1 The licensee shall carry out such sampling, analyses, measurements, examinations, maintenance and calibrations as set out in Schedules:- Schedule 1(ii): Emissions to Atmosphere: Abatement/Treatment Control Schedule 1(iii): Monitoring of Emissions to Atmosphere. Schedule 2(ii): Monitoring of Emissions to Water. Schedule 4(i): Groundwater Monitoring of this licence Where the ability to measure a parameter is affected by mixing before emission, then, with prior written agreement from the Agency, the parameter may be assessed before mixing takes place All automatic monitors and samplers shall be functioning at all times (except during maintenance and calibration) when the activity is being carried on unless alternative sampling or monitoring has been agreed in writing by the Agency for a limited period. In the event of the malfunction of any continuous monitor, the licensee shall contact the Agency as soon as practicable, and alternative sampling and monitoring facilities shall be put in place. Prior written agreement for the use of alternative equipment, other than in emergency situations, shall be obtained from the Agency Monitoring and analysis equipment shall be operated and maintained as necessary so that monitoring accurately reflects the emission or discharge The frequency, methods and scope of monitoring, sampling and analyses, as set out in this licence, may be amended with the written agreement of the Agency following evaluation of test results. EPA Export :16:44:27

150 Environmental Protection Agency IPC Licence Reg. N o The licensee shall install on all emission points such sampling points or equipment, including any data-logging or other electronic communication equipment, as may be required by the Agency. All such equipment shall be consistent with the safe operation of all sampling and monitoring systems The licensee shall provide safe and permanent access to the following sampling and monitoring points: Final effluent / surface waters as discharged from the site Emission to atmosphere sampling points Noise sources on-site Waste storage areas on-site On-site ground-water monitoring wells. and safe access to any other sampling and monitoring points required by the Agency The licensee shall, prior to the commencement of cement manufacturing operations, install in a prominent location on the site a wind sock, or other wind direction indicator, which shall be visible from the public roadway outside the site. Reason: To ensure compliance with the requirements of other conditions of this licence by provision of a satisfactory system of measurement and monitoring of emissions. Condition 11. Recording and Reporting to Agency 11.1 The licensee shall record all sampling, analyses, measurements, examinations, calibrations and maintenance carried out in accordance with the requirements of this licence The licensee shall record all incidents which affect the normal operation of the activity and which may create an environmental risk The licensee shall record all complaints of an environmental nature related to the operation of the activity. Each such record shall give details of the date and time of the complaint, the name of the complainant and give details of the nature of the complaint. A record shall also be kept of the response made in the case of each complaint. The licensee shall submit a report to the Agency, during the month following such complaints, giving details of any complaints which arise. A summary of the number and nature of complaints received shall be included in the AER The format of all records required by this licence shall be to the satisfaction of the Agency. Records shall be retained on-site for a period of not less than seven years and shall be available for inspection by the Agency at all reasonable times Reports of all recording, sampling, analyses, measurements, examinations, calibrations and maintenance as set out in Schedule 5(i) Recording and Reporting to the Agency of this licence, shall be submitted to the Agency Headquarters as specified in this licence. The format of these reports shall be to the satisfaction of the Agency. One original and three copies shall be submitted as and when specified Provision shall also be made for the transfer of environmental information, in relation to this licence, to the Agency s computer system, as may be requested by the Agency. EPA Export :16:44:27

151 Environmental Protection Agency IPC Licence Reg. N o All reports shall be certified accurate and representative by the licensee's Plant Manager or other senior officer designated by the Plant Manager All written procedures controlling operations affecting this licence shall be available onsite for inspection by the Agency at all reasonable times The frequency and scope of reporting, as set out in this licence, may be amended with the written agreement of the Agency following evaluation of test results. Reason: To provide for the collection and reporting of adequate information on the activity. Condition 12. Emergency Response 12.1 The licensee shall, prior to the commencement of cement manufacturing operations, ensure that a documented Emergency Response Procedure is in place, which shall address any emergency situation which may originate on-site. This Procedure shall include provision for minimising the effects of any emergency on the environment. Reason: To provide for the protection of the environment. Condition 13. Financial Provisions 13.1 Agency Charges The licensee shall pay to the Agency an annual contribution of 12,926 or such sum as the Agency from time to time determines, towards the cost of monitoring the activity as the Agency considers necessary for the performance of its functions under the Environmental Protection Agency Act, The licensee shall in 1999 and subsequent years, not later than January 31 of each year, pay to the Agency this amount updated in accordance with changes in the Consumer Price Index from the date of the licence to the renewal date. The updated amount shall be notified to the licensee by the Agency. For 1998, the licensee shall pay a pro rata amount from the date of this licence to December This amount shall be paid to the Agency within one month of the date of grant of this licence. Reason: To provide for adequate financing for monitoring and financial provisions for measures to protect the environment. EPA Export :16:44:27

152 Environmental Protection Agency IPC Licence Reg. N o 378 Schedule 1(i) Emissions to Atmosphere Emission Point Reference No.: A2-01 Location : ESP Exhaust (Raw Mill / Kiln) Volume to be emitted: Maximum in any one day : 8.5 x 10 6 Nm 3 Maximum rate per hour : 0.6 x 10 6 Nm 3 Minimum discharge height: 112 m above ground level Parameter Emission Limit Value Sulphur Dioxide 600 mg / Nm 3 Oxides of Nitrogen (as NO 2) 1300 mg / Nm 3 Particulates 50 mg / Nm 3 Emission Point Reference No.: A2-02 Location : ESP Exhaust (Clinker Grate Cooler) Volume to be emitted: Maximum in any one day : 4.5 x (Note 1) Nm Minimum discharge height: Parameter Maximum rate per hour : 0.35 x (Note 1) Nm 33 m above ground level Emission Limit Value Particulates 50 mg/ Nm 3 Note 1 95% of all hourly or daily mean flow values calculated on the basis of appropriate spot readings shall not exceed the relevant limit value. No individual result similarly calculated shall exceed 1.2 times the emission limit value. Emission Point Reference No.: A2-03 Location : Bag Filer Exhaust (Coal Mill) Volume to be emitted: Maximum in any one day : 1.3 x 10 6 Nm 3 Maximum rate per hour : 0.06 x 10 6 Nm 3 Minimum discharge height: 47 m above ground level Parameter Emission Limit Value Particulates 50 mg / Nm 3 EPA Export :16:44:28

153 Environmental Protection Agency IPC Licence Reg. N o 378 Emission Point Reference No.: A2-04 Location : Bag Filter Exhaust (Cement Mill) Volume to be emitted: Maximum in any one day : 1.6 x 10 6 Nm 3 Maximum rate per hour : 0.07 x 10 6 Nm 3 Minimum discharge height: 38 m above ground level Parameter Emission Limit Value Particulates 50 mg / Nm 3 Emission Point Reference No.: A2-05 Location : Bag Filter Exhaust (Sepax Separator for Cement Mill) Volume to be emitted: Maximum in any one day : 5 x 10 6 Nm 3 Maximum rate per hour : 0.3 x 10 6 Nm 3 Minimum discharge height: 38 m above ground Parameter Emission Limit Value Particulates 50 mg/ Nm 3 Emission Point Reference No.: Location : A3-01 to A3-29 (inclusive) Bag Filter Exhausts throughout process as indicated on Drawing No a-SQG-002, Attachment 12 A of IPC Application Parameter Emission Limit Value Particulates 50 mg / Nm 3 EPA Export :16:44:28

154 Environmental Protection Agency IPC Licence Reg. N o 378 Schedule 1(ii) Emissions to Atmosphere: Abatement/Treatment Control Emission Point Reference No s.: A2-01 and A2-02 Description of Treatment: Electrostatic Precipitators Monitoring : Control Parameter Carbon monoxide Kilovolts Milliamps Temperature Particulate removal efficiency Monitoring to be Carried Out Continuous monitor (in process) Continuous monitor Continuous monitor Continuous monitor Continuous monitor Monitoring Equipment CO analyser kvolt meter mamp meter Thermocouple Photometric Opacity monitor Equipment: Control Parameter Equipment calibration Backup Equipment Carbon monoxide Kilovolts Milliamps Temperature Particulate removal efficiency Annual by manufacturer Note 1 Spares in stock Annual by manufacturer Note 1 Spares in stock Annual by manufacturer Note 1 Annual by manufacturer Note 1 Quarterly (by iso-kinetic comparison) Note 2 Spares in stock Spares in stock Spares in stock Note 1 : Or alternative contractor by agreement with the Agency. Note 2 : Frequency may be reduced to bi-annually after one year of operation, by agreement with the Agency Emission Point Reference No s.: A2-03, A2-04, A2-05 Description of Treatment: Bag Filters Monitoring : Control Parameter Monitoring to be Carried Out Monitoring Equipment Pressure Differential Continuous monitor P detector and control room alarm Temperature Continuous monitor Thermocouple and control room alarm Equipment: Control Parameter Equipment Calibration Backup Equipment Pressure Differential Annual by manufacturer Note 1 Spares in stock Temperature Annual by manufacturer Note 1 Spares in stock Note 1 : Or alternative contractor by agreement with the Agency. EPA Export :16:44:28

155 Environmental Protection Agency IPC Licence Reg. N o 378 Emission Point Reference No s.: A3-01 to A3-29 (inclusive) Description of Treatment: Bag Filters Monitoring : Control Parameter Monitoring to be Carried Out Monitoring Frequency Filter Integrity Full Visual Inspection ( as an element of Process Preventative Maintenance Programme) Weekly Schedule 1(iii) Monitoring of Emissions to Atmosphere Emission Point Reference No s.: A2-01 and A2-02 (Electrostatic Precipitators) Parameter Monitoring Frequency Analysis Method/Technique Sulphur Dioxide Continuous In-line monitor & readout Sulphur Dioxide Quarterly Flue gas analyser Oxides of Nitrogen (NOx) Continuous In-line monitor & readout Oxides of Nitrogen (NOx) Quarterly Flue gas analyser Particulates Continuous Photometric opacity & readout Particulates Quarterly Iso -kinetic / gravimetric Heavy Metal in Dust Once-off Note 1 Iso -kinetic / digestion / AA or ICP Note 1 : To be carried out within one year of commencement of cement manufacturing on-site. The licensee may be required to repeat this analysis if deemed appropriate by the Agency. Emission Point Reference No s.: A2-03, A2-04 and A2-05 (Bag Filters) Parameter Monitoring Frequency Analysis Method/Technique Particulates Continuous Photometric opacity & readout Particulates Quarterly Iso-kinetic and gravimetric EPA Export :16:44:28

156 Environmental Protection Agency IPC Licence Reg. N o 378 Schedule 2(i) Emissions to Water Emission Point Reference No.: SW-1 Name of Receiving Waters: Woodford River Location : Discharge from the Surface Water Settlement Tank Refer to Drawing No. 250EPA101 in IPC Application Volume to be emitted: (see Note 1) Maximum in any one day : 10,000 m 3 Maximum rate per hour : 3000 m 3 Parameter Emission Limit Value Temperature 25 C (max.) ph 6-9 Toxicity 5 TU BOD 10 Suspended Solids 35 mg/l Aluminium 0.2 Chromium (Cr VI) 0.05 Note 1: Where the flow limits are exceeded due to extreme meteorological conditions, the licensee shall notify the Agency in accordance with the provisions of Condition 4 of this licence. Schedule 2(ii) Monitoring of Emissions to Water Emission Point Reference No.: Description : SW-1 Treated Surface water discharged to the Woodford River Parameter Monitoring Frequency Note 1 Analysis Method/Technique Flow Continuous On-line flow meter with recorder ph Continuous On-line ph probe, meter and recorder ph Daily Laboratory ph electrode & meter Chemical Oxygen Demand Daily Standard Method Suspended Solids Daily Gravimetric Total Dissolved Solids Daily Standard Method Temperature Weekly Thermometer Biochemical Oxygen Demand Weekly Standard Method Ammonia (as N) Weekly Ion selective electrode Chromium (Cr VI) Monthly Atomic Absorption / ICP Aluminium Monthly Atomic Absorption / ICP Mineral Oil Monthly Standard Method Organohalogens Annually CG-MS Toxicity Note 2 As required by the Agency but not more frequently than biannually. To be agreed with the Agency Note 1: Note 2: Non - continuous samples (except those for temperature and ph) are to be collected using a flow proportional composite sampler, capable of hourly, daily or weekly composition. The number of toxic units (Tu) = 100/x hour EC/LC 50 in percentage vol/vol so that higher Tu values reflect greater levels of toxicity. For test regimes where species death is not easily detected, immobilisation is considered equivalent to death. EPA Export :16:44:28

157 Environmental Protection Agency IPC Licence Reg. N o 378 Schedule 3(i) Hazardous Wastes for Disposal/Recovery Waste Materials Method of Disposal/Recovery Note 1 X - Ray Tubes Fluorescent lighting tubes Degreasing materials Radioactive wastes (from detectors) Oils Grease Batteries Laboratory waste Other Note 2 Agreed hazardous waste disposal/recovery contractor. Agreed hazardous waste disposal/recovery contractor. Agreed hazardous waste disposal/recovery contractor. By agreement with Radiological Protection Institute Agreed hazardous waste disposal/recovery contractor. Agreed hazardous waste disposal/recovery contractor. Agreed hazardous waste disposal/recovery contractor. Agreed hazardous waste disposal contractor. Note 1: Note 2: Prior to the removal off-site of hazardous wastes, the licensee shall provide the Agency, to its satisfaction, with details of the hazardous waste disposal contractor to be used. The Agency may at any time instruct a licensee to stop using any specific hazardous waste disposal contractor. No other hazardous waste shall be disposed of / recovered off-site without prior notice to, and prior written agreement of the Agency. EPA Export :16:44:28

158 Environmental Protection Agency IPC Licence Reg. N o 378 Schedule 3(ii) Other Wastes for Disposal/Recovery Limestone Shale Overburden Raw meal Waste Materials On-Site Reuse Note1 Method of Disposal Note 2 By-pass dust Kiln coatings / refractories Clinker Cement Silt from surface water settlement tank Process samples Returned to the process where possible Returned to the process where possible Returned to the process where possible Returned to the process where possible Returned to the process where possible Returned to the process where possible Returned to the process where possible Returned to the process where possible Returned to the process where possible Returned to the process where possible Off-site disposal/recovery by agreed method Off-site disposal/recovery by agreed method Off-site disposal/recovery by agreed method Off-site disposal/recovery by agreed method Off-site disposal/recovery by agreed method Off-site disposal/recovery by agreed method Off-site disposal/recovery by agreed method Off-site disposal/recovery by agreed method Off-site disposal/recovery by agreed method Off-site disposal/recovery by agreed method Pallets None Agreed disposal / recovery contractor. Paper sacks None Agreed disposal / recovery contractor. Canteen waste None Agreed disposal / recovery contractor. Office Waste None Agreed disposal / recovery contractor. Filter Bags None Agreed disposal / recovery contractor. Scrap metal None Agreed disposal / recovery contractor. Other Note 3 Note 1: Note 2: Note 3: The licensee may treat, reuse, recycle or recover waste subject to the prior written agreement of the Agency. Any variation from those contractors named in the IPC Licence application, or subsequent agreements, must have the prior written agreement of the Agency. In such cases where a previously agreed waste contractor is proven not to exercise due care in respect of the transport and disposal of the licensees waste, the Agency may at any time instruct a licensee to stop using this contractor. No other waste shall be disposed of / recovered off-site without prior notice to, and prior written agreement of the Agency. EPA Export :16:44:28

159 Environmental Protection Agency IPC Licence Reg. N o 378 Schedule 4(i) Groundwater Monitoring Emission Point Reference No.: Bore-Hole established under Condition Parameter Monitoring Frequency Analysis Method/Technique ph Biannually ph electrode/meter TOC Biannually Standard Method Conductivity Biannually Standard Method Total Ammonia Biannually Standard Method Total Nitrogen Biannually Standard Method Chromium (Cr VI) Biannually Standard Method Aluminium Biannually Standard Method Hydrocarbons Biannually Standard Method Organohalogens Note 1 Annually GC-MS Note 1: Screening for priority pollutant list substances (such as CLP 40, US EPA volatile and/or semi-volatile). Schedule 5(i) Recording and Reporting to the Agency Completed reports shall be submitted to: The Environmental Protection Agency P.O. Box 3000 Johnstown Castle Estate County Wexford or Any other address as may be specified by the Agency Reports are required to be forwarded as set out below: Recurring Reports: Report Monitoring of emissions to atmosphere Reporting Frequency Monthly Report Submission Date Ten days after end of the month being reported on. Monitoring of emissions to water Monthly Ten days after end of the month being reported on. Complaints (where these arise) Monthly Ten days after end of the month being reported on. ESP trip-outs Quarterly Ten days after end of the quarter being reported on. Groundwater monitoring Biannually One month after end of half year being reported on. Compliance toxicity reports To be decided by the Agency but not more frequent than biannually Within six months of completion of testing Noise monitoring programme Annually One month prior to survey. Annual Environment Report(AER) Annually Eighteen months from the date of commencement of cement production and each year thereafter. EPA Export :16:44:28

160 Environmental Protection Agency IPC Licence Reg. N o 378 Annual Environmental Report Content Emissions to atmosphere summary. Emissions to water summary. Waste management report. Resource consumption summary. Complaints summary. Schedule of Environmental Objectives and Targets Environmental management programme - proposal Environmental management programme - report Items to be Addressed in the Schedule of Objectives & Targets Minimisation of fugitive dust emissions Minimisation of suspended solids content of surface waters being discharged from the site Minimisation of ESP trip-outs Minimisation in noise emissions from the site Waste heat recovery / reuse Solid & liquid waste recovery / reuse initiatives. Monitoring programme for sulphur content of shale. Noise monitoring report Groundwater monitoring summary Reported incidents summary Bund testing report (every three years) Dust Gauges Once-off Reports: Report Proposal for Dust Deposit Gauges PM 10 assessment of dust emissions Heavy metals in dust emissions from Kiln ESP Report Submission Date Three months of date of grant of licence. Within eighteen months of the commencement of cement manufacturing on site. Within one year of the commencement of cement manufacturing on site. Waste heat reuse / CHP assessment Programme for public information. Groundwater bore-hole proposal Bund integrity assessment. Schedule of Environmental Objectives and Targets Environmental management programme proposal. Acute Toxicity Proposal Acute Toxicity Report Ambient Monitoring Proposal Within three months of date of grant of licence. Six months prior to commencement of cement manufacturing on site. Prior to commencement of cement manufacturing on site. Prior to commencement of cement manufacturing on-site. Six months prior to commencement of cement manufacturing on site. Four months prior to commencement of cement manufacturing on site. Six months prior to commencement of cement manufacturing on site. Within six weeks of completion of testing. Within three months of date of grant of licence. Signed by Iain Maclean 13 th November 1998 EPA Export :16:44:28

161 IPPC Licence Application Attachment B.8 Quinn Cement Ltd IPPC Licence Application ATTACHMENT N o B.8 SITE NOTICE, NEWSPAPER ADVERTISEMENT AND PLANNING AUTHORITY NOTICE WYG Environment part of the WYG Group creative minds safe hands EPA Export :16:44:28

162 IPPC Licence Application Attachment B.8 Contents 1 SITE NOTICE NEWSPAPER ARTICLE PLANNING AUTHORITY NOTICE... 3 WYG Environment part of the WYG Group creative minds safe hands EPA Export :16:44:28

163 IPPC Licence Application Attachment B.8 1 SITE NOTICE 1.1 The following document contains a copy of the text from the site notice with an accompanying map showing the location of this notice on the site. WYG Environment part of the WYG Group 1 creative minds safe hands EPA Export :16:44:28

164 IPPC Licence Application Attachment B.8 2 NEWSPAPER ARTICLE 2.1 The following document is a copy of the newspaper advertisement for the proposed IPPC Licence application. WYG Environment part of the WYG Group 2 creative minds safe hands EPA Export :16:44:28

165 IPPC Licence Application Attachment B.8 3 PLANNING AUTHORITY NOTICE 3.1 The following document is a copy of the notice given to County Cavan Planning Authority. WYG Environment part of the WYG Group 3 creative minds safe hands EPA Export :16:44:29

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169 26 th October 2009 Administrative Officer Planning Department Cavan County Council Courthouse Farnham Street Cavan County Cavan Ireland Dear Sir / Madam, Re: Application to the Environmental Protection Agency by Quinn Cement Limited for an Integrated Pollution Prevention and Control licence for the Quinn Cement Limited facility at Ballyconnell, Scotchtown, County Cavan Introduction Quinn Cement Limited, Ballyconnell, Scotchtown, County Cavan has applied to the Environmental Protection Agency for an Integrated Pollution Prevention and Control (IPPC) Licence application. This IPPC Licence application is submitted in relation to the activities undertaken at the Ballyconnell facility under Class 10.1 The Production of Cement and Class 11.1 The recovery or disposal of waste in a facility, within the meaning of the Act of 1996, which facility is connected or associated with another activity specified in this Schedule in respect of which a licence or revised licence under Part IV is in force or in respect of which a licence under the said Part is or will be required of the First Schedule of the Protection of the Environment Act This letter has been prepared to meet the notification requirements of section 87(1)(a) of the Environmental Protection Agency Act 1992 (as amended). The letter details the documentation submitted as part of the Licence Application, and copies of the Newspaper Notice and Site Notice required by the Regulations are attached for information. The newspaper article was placed in the Anglo Celt on 21 st October The Licence Application has been prepared in accordance with the requirements of the Environmental Protection Agency Acts 1992 and 2003 and the Environmental Protection Agency (Licensing) Regulations 1994 to Consideration has also been afforded to the Integrated Pollution, Prevention and Control Licensing Application Guidance Notes, published by the Environmental Protection Agency, the Best Available Technique (BAT) Guidance Notes for Cement and Lime published by the EPA and the BAT Reference Document on the Cement and Lime Manufacturing Industries. The requirements of the Environmental Protection Agency were also established during a number of inception meetings and detailed scoping which were conducted with technical representatives of the Environmental Protection Agency. Planning permission is currently being sought for the proposed developments at the Ballyconnell facility and an Environmental Impact Statement is being submitted by Quarryplan on behalf of Quinn Cement. Overview of the proposed development Quinn Cement Limited currently operate a cement production process at the Ballyconnell facility, Scotchtown. This operation commenced in 2000 and currently licensed for the production of 1.4milllion tonnes of cement per annum. The plant is located approximately 3km north of the town of Ballyconnell and covers an area of approximately 35-hectares. The facility is operational 24-hours per day for approximately 330-days per year, allowing time for scheduled shut-down periods. The main source of fuel currently used at the Ballyconnell facility is coal. This is used to generate heat throughout the manufacturing process. Quinn Cement currently proposes to substitute 55% of coal with Regatta House, Clippers Quay, Salford Quays, Manchester, M50 3XP Tel: +44 (0) Fax: +44 (0) enviro.manchester@wyg.com EPA Export :16:44:29

170 Page 2 solid recovered fuel (SRF), which has the advantage of reducing consumption of natural resources, reducing emissions of carbon dioxide and the reduction in disposal of municipal solid waste to landfill. Although the cement manufacturing process will remain unchanged, some modifications will need to be made to the existing plant to facilitate use of SRF. These include the following: Installation of new fuel storage and feeding system; Installation of new calciner; Modify bypass set up (with new conditioning tower and moving existing bypass filter); Installation of new fan; Installation of new selective non catalytic reduction system for control of nitrogen oxide emissions; Modification to existing abatement systems; Installation of new silo at cement mill for bypass dust; and, Installation of new monitoring equipment. A new IPPC Licence is therefore required to reflect the above modifications. Documentation submitted as part of the licence application The following documents have been submitted as part of the Application for an IPPC Licence: 1No. signed and stamped original and 1No. copy of the IPPC Licence Application; 2No. electronic (CD ROM) copies of the IPPC Licence Application, including all digital drawing files in the appropriate format; A cheque for 22,854 being the relevant fee for this application made payable to the Environmental Protection Agency as set out in the Environmental Protection Agency (Licensing Fees) Regulations 1994 to 2004; 1No. signed original and 2No. copies of the Environmental Impact Statement produced by Quarryplan on behalf of Quinn Cement Limited; and, 15No. electronic copies of the Environmental Impact Statement produced by Quarryplan on behalf of Quinn Cement Limited. A copy of the Environmental Impact Statement has been submitted to Cavan County Council s planning department with the Planning Application by Quarryplan on behalf of Quinn Cement Limited. The Environmental Impact Statement and any further information relating to the potential effects on the environment of emissions from the activity which may occur, can be furnished from the Environmental Protection Agency head office in the course of the Agency s consideration of the application. A copy of the application for the licence may be inspected at, or obtained from the headquarters of the Agency as soon as practicable after the receipt by the Agency of the application for the licence. Conclusion The IPPC Licence Application has been prepared and submitted in accordance with the requirements of the Regulations governing such applications. If you have any queries relating to the Application for an IPPC Licence, I will be please to address them following receipt at this office. Yours faithfully for WYG ENVIRONMENT Graeme Blacklock Senior Environmental Consultant Encs. EPA Export :16:44:29

171 IPPC Licence Application Attachment B.9 Quinn Cement Ltd IPPC Licence Application ATTACHMENT N o B.9 SEVESO II REGULATIONS WYG Environment part of the WYG Group creative minds safe hands EPA Export :16:44:29

172 IPPC Licence Application Attachment B.9 Contents 1 SEVESO II REGULATIONS... 1 WYG Environment part of the WYG Group creative minds safe hands EPA Export :16:44:29

173 IPPC Licence Application Attachment B.9 1 SEVESO II REGULATIONS 1.1 This activity is not an establishment to which the European Commission (EC) (Control of Major Accident Hazards involving Dangerous Substances) Regulations (S.I. No. 74 of 2006) applies. WYG Environment part of the WYG Group 1 creative minds safe hands EPA Export :16:44:29

174 IPPC Licence Application Attachment B.10 Quinn Cement Ltd IPPC Licence Application ATTACHMENT N O B.10. IPPC DIRECTIVE (96/61/EC) WYG Environment part of the WYG Group creative minds safe hands EPA Export :16:44:29

175 IPPC Licence Application Attachment B.10 Contents 1 IPPC DIRECTIVE... 1 WYG Environment part of the WYG Group creative minds safe hands EPA Export :16:44:29

176 IPPC Licence Application Attachment B.10 1 IPPC DIRECTIVE (96/61/EC) 1.1 This activity is a category of industrial activity referred to in Annex I of the IPPC Directive (96/61/EC). The following categories apply: Category Installations for the production of cement clinker in rotary kilns with a production capacity exceeding 500 tonnes per day or lime in rotary kilns with a production capacity exceeding 50 tonnes per day or in other furnaces with a production capacity exceeding 50 tonnes per day. Category 5.3. Installations for the disposal of non-hazardous waste as defined in Annex II A to Directive 75/442/EEC under headings D8 and D9, with a capacity exceeding 50 tonnes per day. WYG Environment part of the WYG Group 1 creative minds safe hands EPA Export :16:44:29

177 IPPC Licence Application Attachment C Quinn Cement Ltd IPPC Licence Application ATTACHMENT N o C MANAGEMENT OF THE INSTALLATION WYG Environment part of the WYG Group creative minds safe hands EPA Export :16:44:29

178 IPPC Licence Application Attachment C Contents 1 SITE MANAGEMENT AND CONTROL... 2 Management Structure and Environmental Responsibilities... 2 Quinn Cement Division Manager... 2 Environmental Advisor... 3 Production Manager... 4 Maintenance Manager... 4 Plant Engineer... 4 Training and Qualifications... 5 Environmental Policy Statement... 5 Calibration and Maintenance Systems... 5 Waste Control Systems... 6 Quality Control Systems ENVIRONMENTAL MANAGEMENT SYSTEM... 7 EMS System Manual... 7 Procedures Manuals... 8 Register of Environmental Aspects... 8 Register of Environmental Legislation... 8 Environmental Management Programme... 8 Monitoring and Measurement Records... 8 EMS Auditing...9 Environmental Performance Reports HOURS OF OPERATION Figures Figure 1 Management Structure at Ballyconnell Cement Plant... 2 Tables Table 1 Qualifications and Experience of Personnel Responsible for Abatement Systems... 5 Table 2 Quinn Cement Ballyconnell Hours of Operation Appendices Appendix C.a - Environmental Management Policy Statement Appendix C.b - Calibration and Maintenance Procedures Appendix C.c - Quinn Cement Waste Control Written Procedures Appendix C.d - Quinn Cement ISO 9001:2000 Accreditation Certificate WYG Environment part of the WYG Group 1 creative minds safe hands EPA Export :16:44:29

179 IPPC Licence Application Attachment C 1 SITE MANAGEMENT AND CONTROL MANAGEMENT STRUCTURE AND ENVIRONMENTAL RESPONSIBILITIES 1.1 Figure 1 illustrates the current management structure at Quinn Cement s Ballyconnell Facility. Figure 1 Management Structure at Ballyconnell Cement Plant Tony Lunney Operations Director TP Feehan Divisional Manager Paul Carron Plant Engineer Damien Reilly Production Manager Donal Kelly Health and Safety Officer Anna McNally Environmental Advisor Dermot Smith Maintenance Manager 1.2 The following sections outline the environmental responsibilities of the various cement plant management personnel. Quinn Cement Division Manager 1.3 The divisional manager is responsible for ensuring that the company environmental policy is effectively implemented across the entire Ballyconnell facility. The divisional manager is responsible for ensuring that adequate finance is available for successful implementation of the Environmental Management System (EMS) and that these systems are reviewed whenever required. 1.4 The divisional manager ensures that any management decisions fully prioritise and consider company environmental performance. It is also their responsibility to ensure that employees are made aware of their environmental responsibilities and to ensure that all environmental and safety incidents, occurrences and near misses are investigated with preventative measures implemented to prevent their reoccurrence. WYG Environment part of the WYG Group 2 creative minds safe hands EPA Export :16:44:29

180 IPPC Licence Application Attachment C Environmental Advisor 1.5 The Environmental Advisor is a critical part of the Quinn Cement Management team. The environmental advisor have full responsibility for implementation and maintenance of the company EMS. More details of this system are provided within IPPC Licence Application Attachment No. C.2: Environmental Management System. 1.6 The Environmental Advisor at the Ballyconnell facility has the following specific responsibilities: To maintain and develop the EMS in accordance with the requirements of the ISO:14001 standard; To provide information, advice, guidance and instruction on environmental matters to management, employees, contractors and visitors on site; To maintain and keep appropriate records to ensure compliance with requirements and demonstrate conformance with the EMS; To co-ordinate the compilation and implementation of an environmental management programme that will achieve the company's objectives and targets; To assist with and facilitate the investigation and recording of environmental and safety incidents and accidents in accordance with the EMS; To monitor the company's performance in the implementation of the EMS and communicate progress to the Quinn Group Environmental Manager and Divisional Manager; To provide internal auditing of the EMS as per the defined schedule in order to ensure that the EMS is conforming to the ISO:14001 standard; To ensure that corrective actions are subsequently implemented to address any problems or issues identified during auditing; To assemble periodic environmental data reports required by management and the corporation; To establish, maintain, evaluate and update the Register of Environmental Legislation; To ensure that all documentation and data is controlled in accordance with the Quinn Group procedures; To establish and maintain measurement and recording systems for waste disposal and recycled materials; To manage community and internal relations at the Quinn Cement Ballyconnell facility and also address dissemination of information on environmental aspects; WYG Environment part of the WYG Group 3 creative minds safe hands EPA Export :16:44:29

181 IPPC Licence Application Attachment C To source, approve and employ qualified waste recycle and disposal contractors to remove waste from site in accordance with company procedures; To promote Quinn Cement s policies of reduce, reuse and recycle; To co-ordinate the introduction of new chemicals to the site with the assistance of the Divisional Management and Supervisors; To ensure compliance with the Emergency Preparedness and Response procedure and that all members of the Emergency Response Team receive training as appropriate; To ensure that projects defined in the Environmental Management Programme are implemented and that it's objectives and targets are met; To ensure that all waste, both hazardous and non-hazardous is controlled, stored and disposed of in accordance with company procedures; To ensure that only approved disposal contractors are employed to dispose of waste on behalf of the company; To ensure that a maintenance programme is in place for plant and equipment that has environmental impacts site-wide; To monitor utility usage and to initiate conservation measures; To take corrective action upon any operations that deviate from environmental or safety operating procedures; and To notify the Group Environmental Manager of any environment incidents as soon as they occur. Production Manager 1.7 The Production Manager reports to the Division Manager and is responsible for operation of the cement plant abatement systems to ensure compliance with Emission Limit Values (ELV) in addition to the company environmental policy. Maintenance Manager 1.8 The maintenance manager reports to the division manager and is directly responsible for the electrical maintenance of abatement and treatment systems. Plant Engineer 1.9 The plant engineer reports to the division manager and is responsible for the mechanical maintenance of abatement and treatment systems. WYG Environment part of the WYG Group 4 creative minds safe hands EPA Export :16:44:29

182 IPPC Licence Application Attachment C TRAINING AND QUALIFICATIONS 1.10 Table 1 contains information on qualifications held by personnel responsible for operation, maintenance and management of treatment and abatement systems on site. Table 1 Employee Division Manager Production Manager Maintenance Manager Mechanical Engineering Manager Environmental Advisor Health and Safety Advisor Qualifications and Experience of Personnel Responsible for Abatement Systems Academic Qualifications - NTEC Diploma in Construction Cert Precision Engineering National Cert Mech Eng BEng Hons Degree in Mechanical Engineering MSc Hons Degree in Manufacturing Engineering AMIMECHE BSc Honours in Environmental Health MSc Honours in Sustainable Development No. of Years Working at Quinn Cement No. of years Relevant Work Experience Cert Health & Safety As is shown within Table 1, the management staff at the Quinn Cement Ballyconnell facility has extensive work experience both at Quinn Cement and within the wider cement production sector. ENVIRONMENTAL POLICY STATEMENT 1.12 The company has an environmental policy statement, a copy of which is included in Appendix C.a. CALIBRATION AND MAINTENANCE SYSTEMS 1.13 As part of the company commitment to on-going improvement in environmental performance, emission monitoring equipment is maintained and calibrated at regular intervals. As part of the WYG Environment part of the WYG Group 5 creative minds safe hands EPA Export :16:44:29

183 IPPC Licence Application Attachment C company EMS, these written procedures are documented. A copy of these is included within Appendix C.b. WASTE CONTROL SYSTEMS 1.14 Quinn Cement have written procedures for waste management which are contained within the company EMS. A copy of these written procedures is included in Appendix C.c Quinn Cement have implemented a hierarchy of preferred waste management methods, with the most desirable option being waste prevention and the least preferred method being waste disposal. All raw materials from the process that are lost are recycled back to the beginning of the process. Quinn Cement is a fully fledged member of Repak, the Republic of Ireland s first voluntary initiative between industry and the Department of the Environment designed to meet industry s producer responsibility obligations under the EU directive on packaging and packaging waste (94/62/EC) and the subsequent Waste Management (Packaging) Regulations (1997). Quinn Cement complies with all responsibilities under this scheme. All records of waste removal and disposal are kept and the contractors chosen to remove waste are all registered waste couriers and facilities. Raw materials are substituted wherever possible to save on waste, to encourage recycling and to increase energy efficiency at the plant. QUALITY CONTROL SYSTEMS 1.16 It is the policy of Quinn Cement to produce cement that fully conforms with customer s needs and expectations and with the relevant National Standards. In order to ensure that the product continually meets these requirements, the Company maintains a Quality System in accordance with BS EN ISO 9001: 2000 and currently has ISO 9001:2000 standard accreditation. A copy of this certification is contained within Appendix C.d The company recognises that the quality awareness of personnel is essential to the efficient implementation of the quality system. Consequently, all necessary training is provided to ensure that staff can undertake their tasks effectively. Similarly, it is the obligation of all personnel to familiarise themselves with the objectives, policies and methods outlined in the manual and comply with these to the best of their ability. WYG Environment part of the WYG Group 6 creative minds safe hands EPA Export :16:44:29

184 IPPC Licence Application Attachment C 2 ENVIRONMENTAL MANAGEMENT SYSTEM 2.1 Quinn Cement do not currently have accreditation to the ISO:14001 standard. However, Quinn Cement does maintain a full Environmental Management System (EMS) in accordance with this standard. The policy is contained within Appendix C.a. However, the EMS system is continuously being developed. Quinn Cement intends to seek formal accreditation to the standard during late 2009 or early The EMS developed by Quinn Cement ensures that the company complies with all applicable legislation and also ensures a continuous improvement in environmental performance. 2.3 The EMS has been developed as a continuous improvement model that complies with the following elements: Environmental policy; Environmental planning; Operational control (including implementation & operations); Inspection and correction; and, Management review. 2.4 The following documentation forms the company EMS: EMS system manual; Procedures manuals; Register of environmental aspects; Register of environmental legislation; Environmental management programme; and, Monitoring and measurement records. EMS SYSTEM MANUAL 2.5 The EMS manual provides a comprehensive overview of the company EMS. It outlines the various mechanisms that Quinn Cement employs to maintain conformance with the standard requirements of ISO: WYG Environment part of the WYG Group 7 creative minds safe hands EPA Export :16:44:30

185 IPPC Licence Application Attachment C PROCEDURES MANUALS 2.6 The procedures manual defines the operating procedures for the EMS and, where appropriate, includes detailed work instructions for specific tasks. REGISTER OF ENVIRONMENTAL ASPECTS 2.7 The Register of Environmental Aspects details, evaluates and categorises the environmental aspects of company activities that can be controlled. Environmental impacts associated with the plant activities are calculated using the Failure Mode and Effect Analysis (FMEA). The score for each potential environmental impact is based upon frequency of occurrence, likelihood of occurrence and severity of impact. From these scores, the Environmental Advisor is able to identify operational aspects which have the most significant impact on the environment. The register is updated on a regular basis to account for any changes in operational processes. The following aspects are considered when updating the register: Any spillages that have occurred on site; Environmental incidents and near misses; Any breaches of relevant environmental legislation; Complaints or concerns arising as a result of the company operations; and, Monitoring results for discharges to air, water and noise levels. REGISTER OF ENVIRONMENTAL LEGISLATION 2.8 The Register of Environmental Legislation records all legislative, regulatory and other policy requirements and codes to which the company must comply. ENVIRONMENTAL MANAGEMENT PROGRAMME 2.9 The Environmental Management Programme describes projects and plans for the implementation of environmental improvements to achieve defined objectives and targets. MONITORING AND MEASUREMENT RECORDS 2.10 These records provide data on emissions and resource usage which facilitate the organisation in evaluating the impacts its activities have upon the wider scale environment. This data is used to monitor progress in the drive for continual improvement in environmental performance. WYG Environment part of the WYG Group 8 creative minds safe hands EPA Export :16:44:30

186 IPPC Licence Application Attachment C EMS AUDITING 2.11 The company EMS is audited on an annual basis to ensure that the system complies with the ISO:14001 standard. The scope of the audit is to verify that management activities comply with the specifications of the EMS and to determine the effectiveness of the system. Competent internal personnel who are not functionally responsible for the areas being audited may carry out the internal EMS audit. Internal audit personnel are trained sufficiently to report on environmental performance for the activities being assessed. All EMS auditors receive formal training which will be documented on the training record of each auditor. Auditing activities are co-ordinated by the Environmental Advisor who creates the audit schedule, specifies the activities and areas to be audited and nominates the auditors and audit dates. ENVIRONMENTAL PERFORMANCE REPORTS 2.12 The environmental performance of the plant is assessed on an on-going basis. Results are summarised within Annual Environmental Reports (AER) These reports present measured emissions to air and water during the report period and compare these values to Emission Limit Values (ELV) The reports also undertake an assessment of the following: Record of environmental incidents throughout the assessment period; Record of complaints received throughout the report period; Resource consumption; Waste management; and, Environmental management plan and progress report All environmental incidents which have occurred during the assessment period are contained within the AER. All complaints received during the assessment period are recorded. Each complaint is fully investigated with a report submitted to the Irish Environmental Protection Agency (EPA) for each individual complaint received. The number of complaints which the EPA receive are considered when assessing the company environmental performance The quantities of raw materials and fuels consumed during the assessment period are presented within the AER. WYG Environment part of the WYG Group 9 creative minds safe hands EPA Export :16:44:30

187 IPPC Licence Application Attachment C 2.17 The quantity of waste disposed during the assessment period are presented in the AER. For each type of waste disposed, details are reported on the quantity, disposal methods, waste transportation company and final destination of the waste The company maintains an environmental management plan which is assessed on an ongoing basis. The plan includes a set of specific environmental objectives to be achieved such as energy management improvements, abatement system improvements and waste management improvements, the action required to achieve each objective, the person responsible for implementing the required changes and a specified time frame over which such action should be achieved. These objectives are assessed on annual basis with a progress report contained within the AER for each environmental objective. WYG Environment part of the WYG Group 10 creative minds safe hands EPA Export :16:44:30

188 IPPC Licence Application Attachment C 3 HOURS OF OPERATION 3.1 The hours of operation of the Quinn Cement Ballyconnell facility under which the new licence is being applied are detailed within Table 1. Table 2 Quinn Cement Ballyconnell Hours of Operation Activity Hours of Operation Proposed Hours of Weekday 24-hour Operation Operation (1) Weekend 24-hour Operation Proposed Hours of Weekday 8am to 8pm Construction (2) Weekend 8am to 5pm (Saturdays only) NOTES: (1) Except for maintenance shutdown which will occur about 2No. times per annum. (2) Timeframe for construction period is anticipated to be 6No. months. 3.2 The Quinn Cement Ballyconnell facility is proposed to be operated 24-hours per day, for 330No. days per year. WYG Environment part of the WYG Group 11 creative minds safe hands EPA Export :16:44:30

189 Appendix C.a Environmental Management Policy Statement EPA Export :16:44:30

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191 Appendix C.b Calibration and Maintenance Procedures EPA Export :16:44:30

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196 Appendix C.c Quinn Cement Waste Control Written Procedures EPA Export :16:44:30

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200 Appendix C.d Quinn Cement ISO 9001:2000 Accreditation Certificate EPA Export :16:44:31

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204 IPPC Licence Application Attachment D Quinn Cement Ltd IPPC Licence Application ATTACHMENT N o D INFRASTRUCTURE AND OPERATION WYG Environment part of the WYG Group creative minds safe hands EPA Export :16:44:31

205 IPPC Licence Application Attachment D Contents 1 OPERATIONAL INFORMATION REQUIREMENTS... 1 Operational History... 1 Overview of Proposed Plant Modifications EXISTING PROCESSES... 3 Process Introduction... 3 Unit Operation Throughputs... 4 Raw Material Handling... 4 Process Description... 4 Process Control... 5 Process Emissions During Normal Operation... 5 Process Emissions During Malfunction... 6 Unit Operation Capacity... 6 Raw Milling... 6 Process Description... 6 Process Control... 7 Process Emissions During Normal Operation... 7 Process Emissions During Malfunction... 8 Unit Operation Capacity... 8 Clinker Production... 9 Process Description... 9 Process Control Process Emissions During Normal Operation Process Emissions During Malfunction Unit Operation Capacity Cement Milling and Despatch Process Description Process Control Process Emissions During Normal Operation Process Emissions During Malfunction Unit Operation Capacity Pollution Incidents PROPOSED ACTIVITIES Process Description SRF Material Storage and Handling Process Control Emissions During Normal Operation Emissions During Malfunction Tables Table 1 Material Input and Output for Each Unit Operation During Table 2 Material Throughput for Raw Materials Handling Unit Operation... 6 Table 3 Material Throughput for Raw Milling Unit Operation... 8 WYG Environment part of the WYG Group creative minds safe hands EPA Export :16:44:31

206 IPPC Licence Application Attachment D Table 4 SRF Fuel Properties Table 5 Design Specifications of SNCR System Appendix D.a - Site Location Maps Appendix D.b - Process Flow Diagrams Appendix D.c - New Calciner Diagram Appendix D.d - Pollution Incidents Appendices WYG Environment part of the WYG Group creative minds safe hands EPA Export :16:44:31

207 IPPC Licence Application Attachment D 1 OPERATIONAL INFORMATION REQUIREMENTS 1.1 This Integrated Pollution Prevention and Control (IPPC) Licence Application covers the proposals by Quinn Cement to use alternative fuels at the Ballyconnell plant. It is proposed to substitute 55% of coal used with Solid Recovered Fuel (SRF). OPERATIONAL HISTORY 1.2 Quinn Cement is one of many divisions of the Quinn Group, whose headquarters are located within Derrylin, County Fermanagh, Northern Ireland. Quinn Cement are a cornerstone of the Quinn Group and currently operate 2No. cement plants. The first of these plants was a 500,000tonnes.year -1 facility constructed in Gortmullan, County Fermanagh, Northern Ireland, where operations commenced in However, increased demand for cement production led to the construction of a second cement works, located near to Ballyconnell, County Cavan, Republic of Ireland, which is the subject of the current Licence Application. 1.3 Reference should be made to Appendix D.a for an illustration of the site location. 1.4 The Quinn Cement Ballyconnell plant is located approximately 3km north of the town of Ballyconnell and covers an area of approximately 35-hectares. Planning permission for the cement plant was originally granted in 1998 and an Integrated Pollution Control (IPC) Licence was granted in This covered a production capacity of 1,000,000tonnes.year -1. To meet ever increasing demands, in 2006 planning permission was granted to increase production capacity to 1,400,000tonnes.year -1 and the plant was granted an desk-top amendment in 2007 pursuant to the requirements of the IPPC Directive. 1.5 The Quinn Cement Ballyconnell facility is currently regulated under Environmental Protection Agency Acts, 1992 and 2003, Licence P The plant was originally designed by FLSmidth (FLS) who are leading experts in cement plant design. The plant design has incorporated Best Available Technique (BAT) which achieves both optimum energy efficiency and environmental performance throughout the plant and results in lower maintenance requirements and a high consistency of end product. WYG Environment part of the WYG Group 1 creative minds safe hands EPA Export :16:44:31

208 IPPC Licence Application Attachment D OVERVIEW OF PROPOSED PLANT MODIFICATIONS 1.7 The main source of fuel currently used at the Ballyconnell plant is coal. This is used to fire the kiln, a vital component of the cement manufacturing process. Quinn Cement currently proposes to substitute 55% of coal with SRF. This has the following advantages: Reduction in consumption of raw resources; Reduction in carbon dioxide (CO 2 ) emissions; and, Reduction in disposal of municipal solid waste to landfill. 1.8 Although the cement manufacturing process will remain unchanged, some modifications will need to be made to the existing plant to facilitate use of SRF, including the following: Construction of new calciner; Modification of kiln by-pass flow; Construction of fuel receiving stations and transportation system; New ID fan; Selective Non-Catalyst Reduction (SNCR) plant; and, Extended monitoring network. 1.9 Therefore a new IPPC Licence is required to reflect the above modifications. WYG Environment part of the WYG Group 2 creative minds safe hands EPA Export :16:44:31

209 IPPC Licence Application Attachment D 2 EXISTING PROCESSES 2.1 This section outlines the existing processes undertaken at the Quinn Cement Ballyconnell plant. PROCESS INTRODUCTION 2.2 The plant currently produces Portland Cement (CEMI) and Portland Flyash Cement (CEMIIA/V 6-20% flyash), which are composite mixtures consisting of synthetic minerals exhibiting hydraulic properties upon mixing with water. The main raw materials used in the process are limestone (rich in calcium) and shale (rich in silica). The raw materials are extracted from quarries both close to and remote from the cement works. As the chemical composition of these materials can be variable, small quantities of other materials including sand, silt, bauxite and iron ore are used as additives in order to obtain the required blend. 2.3 The raw materials used in the manufacture of cement are processed by crushing, blending and milling to produce a homogenous raw meal. This raw meal is then passed through a high temperature kiln, where a thermal process produces a synthetic mineral clinker. The clinker and additives are then milled into a fine powder - cement. 2.4 The main unit operations that are carried out at the plant include the following: Raw material handling; Raw milling; Clinker production; Cement milling; Bagging Plant; and, Cement despatch. 2.5 Reference should be made to the Appendix D.b for process flow diagrams illustrating the various unit operations. 2.6 All the process activities, with exception of cement despatch, are controlled from the Central Control Room (CCR) where numerous critical plant operational parameters are monitored. From the CCR, operators can monitor the performance of the process control systems and intervene where necessary to ensure process stability and product quality. WYG Environment part of the WYG Group 3 creative minds safe hands EPA Export :16:44:31

210 IPPC Licence Application Attachment D 2.7 Quinn Cement use a fully automated process control system called Robolab. This Robolab system instructs, supervises and conducts the testing of all routine samples from the various departments within the entire process. 2.8 The following sections describe the current unit activities undertaken at the Quinn Cememnt Ballyconnell cement plant. Process flow diagrams for each unit operation are contained within Appendix D.b. UNIT OPERATION THROUGHPUTS 2.9 The capacity of the Ballyconnell cement plant is currently 1,400,000tonnes cement per annum. Based upon values reported for the period from January to December 2008, Table 1 contains current material throughput values for the Ballyconnell cement plant. Table 1 Material Input and Output for Each Unit Operation During 2008 Unit Operation Input Materials (tonnes) Output Materials (tonnes) Raw Materials Handling Limestone 1,273,500 Shales 258,800 Clay and silt 182,000 Iron ore 5,240 Raw Mix 1,719,540 Raw Milling Raw Mix 1,719,540 Raw Meal - 1,719,540 Clinker Making Cement Milling Raw Meal - 1,719,540 Coal 144,396 Clinker 1,009,955 Gypsum 60,300 Flyash 81,324 Clinker 1,009,955 Cement 1,242,492 Cement Despatch Cement 1,242,492 Bulk and Bag Cement 1,242,492 RAW MATERIAL HANDLING Process Description 2.10 The main raw materials used within the process are limestone and shale, obtained from local quarries, which accounts for 85% of the raw material Limestone is blasted from local quarry sites. New technology has ensured that the resulting rock fragmentation is constant in size. All quarried materials are transported to the site by dumper trucks and emptied directly into concrete bunkers located within contained enclosures Limestone arrives at the site ready crushed and is loaded directly into hoppers, whilst the shale is loaded into specialised shale crushers. There are four intake hoppers for crushed limestone WYG Environment part of the WYG Group 4 creative minds safe hands EPA Export :16:44:31

211 IPPC Licence Application Attachment D and sand and one shale crusher. The intake hoppers are located on the high ground to the north-west of site. The shale, limestone and sand are tipped directly from dumpers into their respective hoppers for processing and transport to the pre-blending store via enclosed rubber belt conveyors Within the pre-blending store, the material is mixed and blended. Carefully proportioned quantities of each raw material are fed by conveyor belt to the pre-blending store, at a rate of 900tonnes.hour -1. This pre-blending store has a capacity of 40,000tonnes, which ensures that there is a ten day buffer stock of materials. This blend of raw material is fine-tuned with the addition of small amounts of other components including sand and silt (10%) and iron ore (1%). This process is undertaken in order to obtain the required blend of each material The circular pre-blending store consists of a concrete base 90m in diameter covered by a convex metal sheeted steel structure and has a live capacity of 40,000tonnes. Upon reaching the pre-blending store, the mixed raw material is laid out in layers by a Stacker, which is supported through the central column of the pre-blending store and a circular rail at the outer edge. Process Control 2.15 Correct chemical composition of material is achieved through the use of conveyor belt weighing equipment which controls the feed rate of each individual raw material. X-Ray Spectrometry is used to analyse the chemical composition of material leaving the raw mill on an hourly basis. In addition, spot sampling of material leaving the pre-blending store, and onstream analysers sample raw materials at 10-minute intervals. This data is fed into a proportional control system which automatically implements any necessary changes in the proportions of the various types of shale and limestone used. Process Emissions During Normal Operation Atmospheric Emissions and Abatement 2.16 The main emissions associated with the raw materials handling process are fugitive particulate emissions arising from conveyor systems used for transportation of limestone to the preblending store. The conveyor systems are enclosed and operated under negative pressure with dust collected in dedicated bag filters. The shale has a humidity of >5% even under dry weather conditions, therefore bag filters are not used on the shale transportation elevators. WYG Environment part of the WYG Group 5 creative minds safe hands EPA Export :16:44:31

212 IPPC Licence Application Attachment D Water Emissions and Abatement 2.17 Water emissions arising from this unit operation may occur as a result of storm water. Any storm water is collected within the plant surface water drainage system which leads to the water settlement tank for treatment prior to release into the Woodford River. Process Emissions During Malfunction 2.18 In the event of a power loss, the entire unit operation will shut down automatically, therefore no emissions would occur due to a loss of power Malfunction of bag-filters can occur due to wear of the filter hoses. However, due to the computerised preventative maintenance scheme currently in place, this is considered unlikely to happen. The main objective of the preventative maintenance scheme is to constantly monitor the condition of all plant equipment including bag-filters. A sufficient amount of spare parts are stocked for bag filters, therefore, in the event of a bag-filter malfunction, corrective action can be taken promptly. Unit Operation Capacity 2.20 Table 2 shows throughput capacity of raw materials handling equipment. Table 2 Material Throughput for Raw Materials Handling Unit Operation Raw Material Equipment Capacity (tonnes.hour -1 ) Crushed Limestone Vibration Feeders Shale No 1 Roller Crusher Shale/Limestone Stacker RAW MILLING Process Description 2.21 Reference should be made to Appendix D.b for a process flow diagram illustrating the raw mill unit operation The raw material from the pre-blending store is extracted by a specially designed reclaimer and transported via rubber belt conveyors to an intermediary steel bin. From the intermediary bin, the raw material is conveyed to the mill which it enters via a rotary sluice. WYG Environment part of the WYG Group 6 creative minds safe hands EPA Export :16:44:32

213 IPPC Licence Application Attachment D 2.23 The Atox type vertical Raw Mill crushes and grinds the raw material mix to a very fine powder, known as raw meal. This is carried out at a rate of 340tonnes.hour -1. The raw mill contains an air-swept vertical roller mill which grinds the raw material between a rotating grinding table and three stationary grinding rollers. The grinding pressure is generated by hydraulic cylinders which force the rollers against the rotary grinding table. The resulting grounded material is lifted from the mill by circulation air and passed through a rotary separator. Material that is too coarse falls from the circulation air by gravity and is returned to the mill for further grinding. Drying of the raw meal is required due to the moisture content. This is undertaken by hot circulation air from the kiln. In the event that the kiln is not in operation, hot air is obtained from a hot air generator A series of cyclones are used to separate the raw meal from the circulation air. The raw meal is then transported to the homogenisation silo via air slides and a belt bucket elevator. The purpose of the homogenisation silo is to store and homogenise the raw meal and to provide a controlled and programmable extraction system. A gravimetric kiln feeding system is used to feed the raw meal to the next stage of the process Process Control 2.25 The main purpose of the process control systems in the raw milling department are as follows: To ensure the correct material throughput; To ensure that the chemical composition of the material is correct; To ensure that the raw material is of the correct fineness; and, To ensure that the moisture content of the raw meal is correct The chemical composition is constantly monitored by an integrated on-stream analyser. Process Emissions During Normal Operation Atmospheric Emissions and Abatement 2.27 Materials are transported to the raw mill via an enclosed rubber conveyor belt. This is a completely enclosed material transport system which is constantly operated under negative pressure. This is achieved by a suction fan, which vents air through a bag-filter before being released to the atmosphere, therefore minimising airborne dust emissions. WYG Environment part of the WYG Group 7 creative minds safe hands EPA Export :16:44:32

214 IPPC Licence Application Attachment D 2.28 Dust laden circulation air within the raw mill is extracted through an electrostatic precipitator for cleaning before release to the atmosphere. This minimises airborne dust emissions The raw milling circuit works under negative pressure which is created by a circulation fan, therefore preventing fugitive dust emission. Water Emissions and Abatement 2.30 The raw mill plant area is paved with concrete. Any storm water accumulating within this area is collected within the dedicated plant drainage system and discharged via the water settlement tank to the Woodford River. The cooling water system is a completely enclosed system with all the water being re-circulated and cooled in a cooling unit situated in the water treatment plant. Process Emissions During Malfunction 2.31 In the event of a power loss, all parts of the cement plant will shut down simultaneously so there would be no significant emissions as a result of power loss Malfunction of bag-filters can occur due to wear of the filter hoses. However, due to the computerised preventative maintenance scheme currently in place, this is considered unlikely to happen. The main objective of the preventive maintenance scheme is to constantly monitor the condition of all plant equipment including bag-filters. A sufficient amount of spare parts are stocked for bag filters, therefore, in the event of a bag-filter malfunction, corrective action can be taken promptly. Unit Operation Capacity 2.33 Table 3 shows throughput capacities for the raw milling unit operation. Table 3 Material Throughput for Raw Milling Unit Operation Material Equipment Capacity (tonnes.hour -1 ) Raw Mix from Pre-Blending Store Weigh-Feeder Coarse High Grade Limestone Vibration-Feeder Sand Vibration-Feeder 3 30 Raw Meal Raw Mill Raw Meal Belt Bucket Elevator WYG Environment part of the WYG Group 8 creative minds safe hands EPA Export :16:44:32

215 IPPC Licence Application Attachment D CLINKER PRODUCTION Process Description 2.34 The clinker production plant includes the following items: Kiln feed system; Pre-heater; Calciner; Rotary kiln; Clinker cooler; Coal milling plant; and, Coal firing system. Kiln Feed System 2.35 The raw meal is extracted from the homogenisation silo and conveyed by bucket elevator to the top cyclones of a five stage pre-heating tower The kiln feed system controls the rate of feed by the loss-of-weight principle. The feed system consists of a closed steel tank located beneath the homogenisation silo outlets. The tank is positioned on load cells which act to constantly monitor the volume of raw meal within the tank. When pre-set volume level is reached, the silo outlets close automatically, not reopening until the volume within the tank has reduced to a pre-set level. The raw material is conveyed from the tank to the top of the pre-heater via a belt bucket elevator. The kiln feed system is operated under negative pressure by a number of suction fans and bag filters in order to prevent fugitive dust emission. Pre-Heater and Calciner 2.37 The raw meal enters the top of the cyclone pre-heater and travels down through five cyclones under the force of gravity. The cyclone pre-heater is equipped with an in-line calciner within which up to 60% of the fuel is combusted. This initiates the start of the chemical pyro-process and reduces oxides of nitrogen (NO X ) in the flue gases. At 600 o C the calcium carbonate (CaCO 3 ) in the limestone decomposes to produce quicklime (CaO) and carbon dioxide (CO 2 ). After a residence time of 1No. minute, the material reaches the kiln inlet, having reached a temperature of approximately 860ºC. The material is also 95% calcined at this point. The WYG Environment part of the WYG Group 9 creative minds safe hands EPA Export :16:44:32

216 IPPC Licence Application Attachment D heated material gradually moves down the rotating kiln, which is powered by a coal fired burner. Rotary Kiln 2.38 The kiln is the central component of the clinker production process. The kiln is relatively short at 54m in length and 4.55m in diameter but incorporates many design improvements over conventional kilns Within the kiln, the temperature of the raw meal is raised from 860ºC to 1,500ºC, which initiates the chemical reactions that are required for the clinker production process to take place. Once the temperature has reached 1,200ºC, the fusion reaction starts and calcium silicates (Ca 2 SiO 4 ), calcium aluminates and other compounds, such as calcium aluminoferrite (Ca 2 (AlFe) 2 O 5 ) are formed. During this reaction, oxides of iron, aluminium (Al) and magnesium (Mg) present within the shale assist the process by acting as a flux which enables the reactions to take place at temperatures much lower than would normally be required. At the lower end (outlet end) of the kiln, temperatures of over 1,500ºC are reached in the burning zone and the clinker is formed. For each 100tonnes of raw meal processed within the system, 60tonnes of clinker is produced as 40% of raw meal is burnt out during ignition The clinker passes through the cooling zone before leaving through the kiln outlet, where it falls down into the grate cooler. Clinker Cooler 2.41 Clinker is a hard mineral, similar to stone, and is generally between 20mm and 40mm in size. The hot clinker exits the kiln and falls into the grate cooler where it is cooled to 100ºC above ambient temperature. The clinker is passed over the grate cooler, and air is forced through the grate which acts to cool the clinker. The cooler recuperates heat from the clinker and recycles it back to the pre-heater, resulting in reduced heating costs and fuel consumption. Any excess air from the cooler is passed through an electrostatic precipitator and bag filter to remove particles before release to the atmosphere. Once cooled, the clinker exits the cooler via a hammer crusher, which acts to reduce the size of the clinker, and is conveyed via an enclosed belt bucket elevator to the clinker storage silo which has a capacity to hold 70,000tonnes of clinker. A series of bag filters are used to prevent fugitive dust emissions arising from the conveyor system. WYG Environment part of the WYG Group 10 creative minds safe hands EPA Export :16:44:32

217 IPPC Licence Application Attachment D Coal Milling Plant 2.42 Coal is transported to site by trucks and stored within enclosed concrete bunkers which have a storage capacity of 10,000tonnes. The average coal consumption is 155,000tonnes. The coal is extracted by a side-scraper and transported to the coal mill via rubber belt conveyors. Any metal residue present within the coal is detected and removed by a magnetic separator. The coal enters the mill via a rotary sluice. Dust abatement systems are not required for coal conveying systems since the raw coal has a moisture content >5% Coal is milled on site in a vertical air-swept mill capable of pulverising 25tonnes.hour % of this fine coal is fed to the calciner in the pre-heater tower whilst 40% is fed to the kiln burner The coal mill consists of a vertical roller mill comprising a built in separator and circulation fan and works in a similar way to the raw material mill. The raw coal is ground to a powder between a grinding table and three stationary fixed rollers. The grinding pressure is created by a hydraulic system which forces the rollers against the rotary table. The ground material is lifted by the circulating air, passes through the rotary separator and is extracted from the circulated air by a bag filter installation and transported to bins via screw conveyors. Only material of the required finesse leaves the separator, coarser material is returned to the mill for further grinding Due to the moisture content of the coal, the coal must be dried during the milling process, which is achieved through circulation of hot air arising from waste gases from the kiln. The coal mill installation works under negative pressure. The pressure and temperature are constantly monitored from the CCR. Various safety systems are employed to reduce the risk of explosion and fire. These are outlined in Attachment No. E.1.B. Coal Firing System 2.46 There are two separate systems for firing coal into the calciner and kiln. Although the physical dimensions differ between the two, the principle of operation is the same for both systems The kiln burner is a Swirlax combined fuel burner, which consists of a 10m long outer steel tube suspended from a carriage supported on rails. The construction allows for regulation both vertically and horizontally. The part of the burner pipe that enters into the hot kiln is protected on the outside by refractory castable. Within the outer steel tube of the burner are three annular cross sections which house an oil burner. The fine powder coal meal is injected axially WYG Environment part of the WYG Group 11 creative minds safe hands EPA Export :16:44:32

218 IPPC Licence Application Attachment D through the annular cross section. The primary combustion air is divided into two: an inner radial flow; and, an outer axial flow The calciner burner operates under the same principles as the kiln burner, but in a shorter and more compact system The primary combustion air is supplied from a medium pressure fan, with an emergency standby fan available The Swirlax combined fuel burner has the following advantages: Improved heat economy; Low NO x production; Widely adjustable flame; Easy changeover between fuels; and, Ability to utilise low grade coal The pulverised coal is fed to the kiln and calciner firing systems by means of dosing systems and blowers for transporting the coal meal in steel tubes. The outlet from the coal meal bins to the dosing system is equipped with vacuum breakers, which will close in case of fire. Process Control 2.52 The process control for the entire clinker making system is based on a computerised system, where the inputs are as follows : Kiln feed rate; Fuel firing rate; Clinker density; CaO; Kiln rotation speed; Kiln drive torque; Burning zone temperature; Preheater temperatures; Pressures (+/-) in the system; and, Concentrations of oxygen (O 2 ), carbon monoxide (CO), CO 2, NO X and sulphur dioxide (SO 2 ) in exhaust gases. WYG Environment part of the WYG Group 12 creative minds safe hands EPA Export :16:44:32

219 IPPC Licence Application Attachment D 2.53 In the control system a number of separate control loops automatically regulate damper settings, valve openings etc., whereas the main parameters such as kiln rotational speed, the fuel firing rate, the kiln feed rate and negative pressure in preheater are controlled directly by the computer In order to optimise the process control an additional control system is included. This system, known as Fuzzy Expert Kiln Control, is built-up from technical knowledge from many different cement factories and has been customised specifically for the plant The Fuzzy Expert Control System also includes an automatic kiln start-up control system, which facilitates the utilisation of the electrostatic precipitator during the start-up process A CEM-Scanner & Refractory Management for the on-line measurement of the kiln shell temperature distribution will also be included in the process control system. Process Emissions During Normal Operation Atmospheric Emissions and Abatement Systems 2.57 NO X emissions arise from the combustion of fuel in the kiln and calciner as a result of the oxidation of nitrogen (N) present in the fuel and combustion air During the design phase of the kiln and calciner emphasis was placed on the reduction of NO X in the kiln exhaust gasses by selecting the Swirlax Burner and an ILC-Preheater. The calciner is equipped with facilities for staged combustion. The secondary fuel starts the combustion in deficit of oxygen (O 2 ), thereby suppressing the formation of fuel NO X and destroying a part of the rotary kiln NO X. The process benefits not only by having a substantial lower NO X emission than a conventional kiln system but also by an improved burn-out of the secondary fuel Results from continuous NO X monitoring undertaken at the plant have continually demonstrated NO X to be well below limits outlined within the Best Available Techniques (BAT) Guidance Note 1 published by the Environmental Protection Agency (EPA) for the cement and lime sector. 1 Draft BAT Guidance Note on Best Available Techniques for the Production of Cement and for the Production of Lime in Kiln, Environmental Protection Agency, November WYG Environment part of the WYG Group 13 creative minds safe hands EPA Export :16:44:32

220 IPPC Licence Application Attachment D 2.60 SO 2 is produced by the oxidation of the sulphur (S) based components present in the raw materials and fuels in the kiln and preheater. The extent of SO 2 formation depends to a large degree on the volatility of the S and the process type. SO 2 arises as a result of S deposits within the shale used, in the form of pyrite. SO 2 formation occurs at lower temperatures than required for the calcination process and therefore takes place within the upper cyclones of the preheater. Most of the SO 2 is absorbed from kiln waste gases when passed through the raw mill as result of mixing of waste gas and limestone In order to reduce the amount of Pyrite in the raw meal, an alternative low Pyrite shale, located in Arigna, is used for mixing with the two local shale types CO 2 is released from the process as a result of the following operations: Calcination of raw meal; and, Combustion of fuel 2.63 The calcium carbonate content in the raw meal is controlled to achieve the required clinker quality. The chosen kiln with ILC-Calciner is the most energy efficient system available and there is no possibility for further reduction of the CO 2 emission related to the combustion of fuel Dust emissions arise in the kiln gases as a result of un-burnt raw materials. Continuous monitoring has demonstrated that particulate concentrations within kiln exhaust gases are well within BAT emission limits Electrostatic precipitators are used to control particulate emissions within kiln waste gases and within the clinker cooler air. Water Emissions and Abatement 2.66 Water emissions can arise as result of storm water. Any storm water generated in this area is collected in the plant drainage system, which leads to a settlement tank for treatment before discharge to the Woodford River The cooling water system used is a closed system with all the cooling water being re-circulated through a cooling unit before returning to the system reservoir. WYG Environment part of the WYG Group 14 creative minds safe hands EPA Export :16:44:32

221 IPPC Licence Application Attachment D Process Emissions During Malfunction 2.68 In the event of a power loss, the plant will shut down automatically. Therefore, no emission of any significance will occur due to a power loss Malfunction of a bag-filter can occur due to worn or defective parts. This is unlikely to happen, as a computerised preventive maintenance system is used. The main objective of the preventive maintenance scheme is a continuous inspection program for monitoring of the condition of all the plant equipment including the filter installation. Parts will be repaired or replaced before they become the cause of a plant malfunction. In the event of a bag-filter malfunction, corrective action can be taken promptly as sufficient spare-parts will be available. Unit Operation Capacity 2.70 The installed capacity for the kiln and auxiliary equipment is for the production of 4,200tonnes of clinker per day. The total annual cement production will not exceed 1.4million tonnes The kiln and auxiliary equipment operates for 24 hours per day during operational periods. Maintenance is undertaken on equipment between all operational periods. The coal mill has an installed capacity of 25tonnes.hour -1 and the kiln consumption is approximately 20tonnes.hour -1. CEMENT MILLING AND DESPATCH Process Description 2.72 Clinker is extracted mechanically from one or more of the nine bottom outlets of the clinker storage silo and transported by rubber belt conveyors directly to the cement mill for grinding. The extractor units placed at each of the nine bottom outlets are capable of dosing the exact amount of clinker, so no intermediate weighing bin is required Within the mill, the clinker is mixed with gypsum and flyash with the final quantities being approximately 89%, 5% and 6%, respectively. The purpose of adding gypsum is to control the setting time of the finished cement product. Flyash is added to make CEM II A-V cement, which contains a minimum of 6% and a maximum of 20% flyash. The production of this type of cement creates less CO 2 as clinker content is replaced by flyash. WYG Environment part of the WYG Group 15 creative minds safe hands EPA Export :16:44:32

222 IPPC Licence Application Attachment D 2.74 Gypsum is sourced from a County Cavan company and transported to the site in covered trucks and stored in enclosed concrete bunkers. The gypsum is extracted from the bunkers by vibration feeders and transported to an intermediate bin placed on load cells by a rubber belt conveying system. From the bin the gypsum is extracted by a weight-feeder and transported to the mill for grinding together with the clinker The flyash is a filler material and is used to substitute a portion of the clinker material without reducing the quality of the end cement product. This has clear environmental benefits. In 2006, approximately 6% of cement consisted of flyash. This helped reduce coal usage by 9,500tonnes. It is anticipated that the associated fuel emissions to burn this amount of clinker would have been in the region of 24,000tonnes of CO 2. The total CO 2 emissions have reduced significantly since the substitution of clinker with flyash to produce CEM II The cement mill consists of a two-chamber cylindrical ball mill which is a closed circuit grinding mill that can yield up to 170tonnes of cement during each hour. The gypsum and clinker are mixed to fine powder cement. The cement is conveyed to three cement storage silos for storage. All 3No. silos are used for despatch of bulk cement, with the inner ring of silo No.3 being automatically fed to the bagging plant for use as bag cement. Cement is packed into bags at a rate of 4,000bags.hour A negative pressure is maintained in the cement mill system by the circulation fan, which also transports an amount of finished product out of the mill. The air/cement mix passes through a bag filter installation which filters the exhaust emissions before release to atmosphere. Process Control 2.78 The objective of the cement milling is to pulverise clinker, gypsum and flyash into a fine powder. The proportions of the different constituents need to be closely monitored. The fineness of the product is measured on an hourly basis in the laboratory. The fineness can be controlled by means of altering either separator speed or airflow through the separator Gypsum is crystalline calcium sulphate (CaSO 4 ). The sulphate content of cement is measured on an hourly basis in the laboratory. Adjustments are made to the gypsum to clinker/flyash ratio to control the sulphate content to a specific target, which is related to the setting time for the product. WYG Environment part of the WYG Group 16 creative minds safe hands EPA Export :16:44:32

223 IPPC Licence Application Attachment D Process Emissions During Normal Operation Atmospheric Emissions and Abatement 2.80 The main emission arising from the cement mill and despatch process is fugitive dust during transportation of materials. Emissions are controlled using bag filters. Transportation systems operate under negative pressure to ensure dust is contained within the system. Water Emissions and Abatement 2.81 Water emissions may occur as a result of storm water. Water is collected within the plant drainage system and treated within the settlement tank prior to discharge to the Woodford River. Process Emissions During Malfunction 2.82 In the event of a power loss, the plant automatically shuts down immediately. Therefore, no emission of any significance will occur due to a power loss Malfunction of a bag filter can occur due to worn or defective parts. However, due to the computerised preventative maintenance scheme currently in place, this is considered unlikely to happen. The main objective of the preventive maintenance scheme is a continuous inspection program for monitoring the condition of all the plant equipment including all the filter installations. Parts will be repaired or replaced before they become the cause of a breakdown. In the event of a bag filter malfunction, corrective action can be taken promptly as sufficient spare parts will be available at all times. Unit Operation Capacity 2.84 The cement mill grinds cement at a rate of 170tonnes per hour. Cement that is transported to the bagging plant is bagged at a rate of 100tonnes per hour Furthermore, all three major areas of the process; the raw meal preparation, clinker burning and cement milling, are controlled by advanced Fuzzy-Logic software systems, designed with the sole purpose of continuously reacting and behaving in the same pre-programmed harmonised way during plant operation. The considerable investment in all these systems has been undertaken in order to provide even greater consistency, uniformity and therefore quality of process and product. WYG Environment part of the WYG Group 17 creative minds safe hands EPA Export :16:44:32

224 IPPC Licence Application Attachment D POLLUTION INCIDENTS 2.86 Details of all known pollution incidents since January 2005 are provided in Appendix D.e. WYG Environment part of the WYG Group 18 creative minds safe hands EPA Export :16:44:32

225 IPPC Licence Application Attachment D 3 PROPOSED ACTIVITIES PROCESS DESCRIPTION 3.1 It is currently proposed to substitute 55% of coal with SRF at the plant. In order to accommodate this modification in fuel use, the following physical plant changes are proposed: Installation of new fuel storage and feeding system; Installation of new calciner; Modify bypass set up (with new conditioning tower and moving existing bypass filter); Installation of new ID fan; Installation of new SNCR system for NO X emission reductions; Modification to existing abatement systems; Installation of new silo at cement mill for bypass dust; and, Installation of new monitoring equipment. 3.2 Reference should be made to the Appendix D.a for a proposed site layout including existing and proposed structures. 3.3 The SRF to be used will be pre-shredded to defined sizes prior to arrival on site and cleaned of impurities. Analysis of the SRF to be used has been previously undertaken. The expected properties of the SRF are shown in Table 4. Table 4 SRF Fuel Properties Parameter SRF Coarse Fraction SRF Fine Fraction 16.6MJ.kg MJ.kg -1# Calorific Value approximately 3900kcal.kg -1 approximately 3900kcal.kg -1 Bulk density (t.m - Conveying = 0,1 Conveying = 0,1 ³) Storage = 0,2 Storage = 0,2 Moisture (%) <20 <20 Particle size (mm) <80 <30 Capacity (t.h -1 ) It is proposed to create 8No. storage units, 4No. units for fine SRF (<30mm) and 4No. units for coarse SRF <80mm. WYG Environment part of the WYG Group 19 creative minds safe hands EPA Export :16:44:33

226 IPPC Licence Application Attachment D SRF Material Storage and Handling 3.5 SRF will be delivered to site by trucks equipped with walking floors and unloaded into receiving stations designed to receive at a rate of 450m 3.hr -1. Receiving units will include apron conveyors to prevent blockages and bridging and will be covered by weatherproof structures which will also cover half of the delivery truck. 3.6 Storage units will be located approximately 10m below the receiving stations. Closed drag chain conveyors will be used to transport SRF from the receiving station to the storage units. Units will be covered by weatherproof single storey steel frame buildings. Each storage unit will be designed with a live capacity of 1.05m Storage units 1-4 will be designed for fine SRF (<30mm). The SRF will be extracted from these units by a screw conveyor and delivered to a set of drag chain conveyors for transport to a dosing unit, which will then feed the material via a hopper to a weigh feeder. Material will be extracted from the feeder through a rotary sluice and transported to the calciner pneumatically by an air blower. 3.8 Storage units 5-8 will be designed for coarse SRF (<80mm). Extraction and transportation of the material will be as described for the fine SRF. The material will then be transported by a further chain conveyor to the calciner through a chute system. The chute system will be equipped with 3No. slide gates. 3.9 A new calciner is required at the plant in order to ensure complete combustion of the SRF. This will be constructed within a separate tower in front of the existing preheater. Reference should be made to Appendix D.c for graphical illustrations of the new calciner. Process Control Emissions During Normal Operation Atmospheric Emissions and Abatement 3.10 Fugitive dust emissions can arise during delivery of SRF to site and transportation of SRF to the calciner. SRF receiving stations will be operated under negative pressure to prevent dust emissions. Bag filters will be used to prevent dust emissions during transportation of SRF within conveyor systems. Within the kiln system, dust emissions will arise from solids derived from raw mineral constituents and fuel ash. A bag filter will be used to abate bypass flow dust WYG Environment part of the WYG Group 20 creative minds safe hands EPA Export :16:44:33

227 IPPC Licence Application Attachment D emissions. Electrostatic precipitators will be used to abate emissions from the kiln stack and clinker cooler NO x emissions arise from the combustion of fuel in the kiln and calciner resulting from the oxidation of N present in the fuel and combustion air It is proposed to install a SNCR system to reduce NO X emissions within flue gases. The SNCR system will reduce emissions by injecting an ammonia (NH 3 ) solution (reducing agent) into the pyro system at an appropriate gas temperature (typically ºC). The objective is to introduce the reduction chemical at the right flue gas temperature, and to assure a thorough mixing of the injected NH 3 with the flue gas The design specifications of the SNCR system are contained within Table 5. Table 5 Design Specifications of SNCR System Design Parameter Flue Gas Flow Rate Raw Gas NO x Maximum Clean Gas NO x Maximum Maximum NH 3 Slip NOTES: (A) Dry gas at 10% O 2. (B) NO x as NO 2. (C) Excluding baseline NH The SNCR plant will consists of four sub-systems: Specification 338,000Nm 3.h -1(A) 1,000mg.m -3(B) 500mg.m -3(B) <30mg.m -3(C) System for receiving, storing and distributing NH 3 solution; System for measuring and controlling the volumetric flow that corresponds to optimum operation; System for surveillance and servicing of the injectors; and, System for management and control of the process The NH 3 solution will be a % v/v aqueous solution. This will be stored within an upright double walled non-pressurised stainless steel tank, designed for filling from road tankers via a special pump module contained within the SNCR plant. The tank and auxiliary equipment will be covered by a shelter to protect from rainfall and to prevent release of vapours occurring from overheating from the direct exposure to sunlight. The containing building will be a 3-walled structure containing a concrete bund underneath the storage tanks. WYG Environment part of the WYG Group 21 creative minds safe hands EPA Export :16:44:33

228 IPPC Licence Application Attachment D This will be designed to effectively contain the content of the storage tank, in case of a leak. If a leak should occur, an alarm will be generated based on a level switch which will be placed between the storage tank and bund The NH 3 solution will be pumped to the dosing and injection equipment with a Pump Module for Reductant (PMR). Dosing will be controlled by Control and Measuring Modules (CMM) whilst injector functions are controlled by Injection Modules (IM) A Decentralised Machine Control Module (DMCM) will control the processes and communicates with the central control room computer. The DMCM will control the NH 3 injection rates, based upon monitoring of stack NO X signal. It is proposed to undertake most control of the SNCR system from the DMCM Hydrogen chloride (HCl) and Hydrogen fluoride (HF) emissions will be formed in the high temperature zones of the kiln system. There will be no dedicated abatement system for HCl and HF. These gases will be naturally abated through reacting with dust in the kiln, prior to subsequent removal by electrostatic precipitator or bag filter. HCl and HF emissions can be controlled through adjusting filter temperatures in exit gases from the bypass and preheater Chlorine (Cl) has the potential to accumulate in the kiln system and evaporates as it is heated. When gases are cooled in the preheater, the Cl will settle on the dust and returns to the kiln. The bypass extracts kiln gas containing gaseous Cl. This will be condensed as dust or absorbed by dust within the gas. The dust will be sent to the cement mill, therefore some Cl will be present within the clinker. Fluorine (F) behaves similarly to Cl in the kiln system, but will be present at much lower concentrations 3.20 SO 2 emissions will arise as described previously, resulting from pyrite in the raw materials. No dedicated abatement system is proposed for SO 2. As previously described, these emissions are to be abated through the control of the pyrite content of the raw materials. Emissions will be continuously monitored using an on-line stack analyser. Should elevated SO 2 concentrations be measured, the pyrite content of the raw materials will be lowered through selective quarrying, where possible Dioxin and furan (PCDD and PCDF) emissions can arise through the chemical reaction between organic carbon components and chlorine. The main formation risk in cement kilns is within dust filters at high temperatures. PCDDs and PCDFs will be controlled through rapid cooling of WYG Environment part of the WYG Group 22 creative minds safe hands EPA Export :16:44:33

229 IPPC Licence Application Attachment D kiln exit gases before they enter the dust filters. This will ensure negligible PCDD and PCDF formation CO emission can arise due to incomplete combustion within the calciner and kiln. CO can also arise from partly oxidised organic carbon from raw materials, leading to formation in preheater cyclone stages. No dedicated abatement system will be installed for CO. However, the calciner, fuel feed systems and process control systems have been designed to ensure effective fuel burnout, thereby ensuring minimal CO formation Emissions of toxic metals including mercury (Hg), antimony (Sb), arsenic (As), lead (Pb), chromium (Cr), cadmium (Cd), cobalt (Co), copper (Cu), manganese (Mn), thallium (Tl), nickel (Ni) and vanadium (V) can arise as a result of impurities within the raw materials and fuel Hg is highly volatile and would be expected that to exit the system within the preheater exhaust gas. It would be anticipated that a small percentage of Hg would settle on main filter dust, accumulating in a cycle over the raw meal silo. Emission levels a factor of 10 times lower would be expected when the raw mill is not in operation. No dedicated abatement is proposed for Hg emissions. Should daily average emission levels be close to emission limits, care will be taken not to operate the kiln without the raw mill in operation Most other metals (Cd, Tl, Hg, Sb, As, Cr, Co, Cu, Mn, Ni and V) will primarily exit the pyro section within the clinker. Pb and Cd will circulate between the kiln and calciner and be removed in the by-pass dust. Therefore, only traces of Pb and Cd are expected to be present within the clinker Tl will circulate within the preheater exit gas and settle on the electrostatic precipitator. Tl levels within the electrostatic precipitator dust will be periodically monitored to ensure excessively high concentrations do not build up. Should excessive Tl concentrations be observed, Tl will be removed by bleeding filter dust to the cement mill. Water Emissions and Abatement 3.27 No water is used in this process, therefore no generation of wastewater is expected. WYG Environment part of the WYG Group 23 creative minds safe hands EPA Export :16:44:33

230 IPPC Licence Application Attachment D Emissions During Malfunction 3.28 In the event of a power loss, the plant will automatically shut down immediately. Therefore, no emission of any significance will occur due to a power loss Malfunction of a bag filter can occur due to worn or defective parts. However, due to the computerised preventative maintenance scheme currently in place, this is considered unlikely to happen. The main objective of the preventive maintenance scheme is a continuous inspection program for monitoring the condition of all the plant equipment including all the filter installations. Parts will be repaired or replaced before they become the cause of a breakdown. In the event of a bag filter malfunction, corrective action can be taken promptly as sufficient spare parts will be available at all times. WYG Environment part of the WYG Group 24 creative minds safe hands EPA Export :16:44:33

231 Appendix D.a Location Maps EPA Export :16:44:33

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233 Appendix D.b Process Flow Diagrams EPA Export :16:44:33

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239 Appendix D.c New Calciner Diagram EPA Export :16:44:33

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