Quinn Cement Ltd. January December 2011

Transcription

1 Quinn Cement Ltd. January December 2011 Annual Environmental Report IPPC Licence No. P

2 Contents Contents Introduction Raw Material Processing Clinker Production Cement Manufacture Organisational Chart Summary Information Self Monitoring Data Resource consumption Summary Raw Materials Fuel usage Electricity usage (kwh) Water Consumption (m3) Emissions to Air January December Dust Gauges Assessment of Directional Dust Deposition (graphs only for January February) Emissions to water Surface Water Emissions January 2011 December Summary of Mass Emissions to Surface Water Groundwater Monitoring Summary Noise monitoring Noise monitoring Assessment Waste Management Bund Testing Report Environmental Incidents Complaints Summary Environmental Management System Report on Progress of Environmental Management Programme Schedule of Environmental Objectives and Targets Environmental Management Plan RMP and ELRA Residual Management Plan ELRA AER Returns Worksheet...29 Annex 1: Monitoring Locations:...35 Dust Deposit Gauges...36 Noise:...36 Surface water and Groundwater:...36 Annex 2: Atmospheric Emission Points

3 Air Emission Points...38 Annex 3: Quinn Cement Accreditation

4 1.0 Introduction This Annual Environmental Report relates to Quinn Cement Works (IPPC No. P ) located at Scotchtown, Ballyconnell, Co. Cavan. Scotchtown Cement Works produces Portland Cement, which is a composite of synthetic minerals exhibiting hydraulic properties on mixing with water. The main raw materials are limestone (rich in calcium) and shale (rich in silica). These are extracted from quarries both close to and remote from the cement works. The raw materials used in the manufacture of cement are processed by crushing, blending and milling to produce a homogenous raw meal, which passes through a high temperature kiln, where a thermal process produces a synthetic mineral clinker. The clinker and additives are milled into a fine powder - cement. There are three main stages in the cement manufacturing process as follows: Raw Material Processing Clinker Production Cement Manufacture 1.1 Raw Material Processing The main raw materials used in the production of cement are limestone and shale (85%). The chemical composition of these materials may vary, even within a deposit, therefore small quantities of other materials such as sand and silt (10%), bauxite and ironore (1%) are added to enable the required blend to be obtained. Limestone is blasted from a number of nearby quarry sites, the high investment in new technology ensures that the rock fragmentation is constant in size. It is then loaded onto dumpers and taken to the crushing and screening plant. Any combination of five separate crushing installations are used depending on the raw material type and source, to provide properly sized materials for feeding into the Pre-Blending Store and ultimately the Raw Mill. The limestone transported to site is almost crushed down to the required size. The shale/clay however, needs to be processed through the crushers on site. Carefully proportioned quantities of each material are fed by conveyor belt to the Pre-Blending Store, at a rate of 900 tonne per/hr. With a 40,000 tonne storage capacity, this store provides a valuable six day buffer stock of materials as well as efficiently blending the Raw Mix by its stacking and reclaiming mechanism. This blend of raw material is fine-tuned with the addition of small amounts of other components to ensure the 4

5 consistent chemical composition of the raw mix, which is then fed to the Raw Mill via weigh-feeders and conveyors. The Atox type vertical Raw Mill crushes and grinds 340 tonnes per/hr of raw materials to a very fine powder, known as raw meal. During the grinding process, the raw mix is dried by introduction of hot waste flue gases re-circulated from the kiln. The air from the Raw Mill is passed through an Electrostatic Precipitator to remove the particulate before being released to the atmosphere. The Precipitator is used to purify exhaust gases; the dust particles become electrically charged and attach themselves to plates inside the precipitator. The plates are cyclically rapped and the discharged dust is collected. The raw meal is thus separated out of the air stream by a system of cyclones before it is brought to the C.F. Homogenisation Silo. This C.F. Silo with its 16,000 tonne capacity stores and homogenises the raw meal, while also providing a controlled and programmable extraction system in conjunction with a loss-of-weight Kiln feeding system in order to feed the raw meal on to the next stage of the process. 1.2 Clinker Production 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 via the kiln feed system which controls the rate of feed by the Loss-of-Weight principle. The raw meal enters the cyclone preheater in the top and travels through the five cyclones by the force of gravity. The cyclone preheater is equipped with an In-Line-Calciner; where up to 60% of the total amount of fuel is combusted. This creates the conditions for the beginning of the chemical pyro-process and reduces 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 ). The material reaches the Kiln Inlet one minute later having reached a temperature of 860 degrees Celsius approx., the material is also 95% calcined at this point. The heated material gradually moves down the rotating kiln, which has energy supplied by a coal heated fuelled burner. Coal is milled on site in a vertical air-swept mill capable of pulverising 25 tonnes per/hr. The fine coal is then fed to the Calciner in the Pre-Heater Tower and to the Kiln Burner at a 60/40 ratio respectively. The Kiln is really the heart of the whole process, because here the raw meal temperature is raised from 860 to 1500 degrees Celsius, thereby enabling the chemical reactions, which allow the formation of Clinker to take place. This relatively short 54 M Kiln offers many design improvements on previous conventional kilns, such as its two-pier support system, tyre attachments by tangential suspension and self-aligning kiln supports. At 1200 O C, the fusion reaction 5

6 starts and calcium silicates, calcium aluminates and other compounds, such as calcium aluminoferrite are formed. During the fusion, oxides of iron, aluminium and magnesium from the shale assist the process by acting as a flux, enabling the reactions to take place at temperatures much lower than would occur normally. At the lower end (outlet end) of the kiln, temperatures of over 1500 O C are reached in the Burning Zone and the clinker is formed. Some 36% of the raw meal is burnt out (Loss On Ignition), such that for each 100 tonnes of raw meal, approximately 60 tonnes of clinker are produced. Clinker is a hard mineral, similar to stone, and is generally between 20mm and 40mm in size. The clinker leaves the kiln and enters the clinker grate cooler, where they are cooled down to 100 O C above ambient temperature by passing over grates with a forced airflow passing through the hot clinker. The purpose of the Grate Cooler is to cool the Clinker after it exits the Kiln. While cooling the Clinker the Cooler recuperates as much heat as possible and returns it to the Pre- Heater/Calciner, thereby reducing overall heating costs and fuel consumption. The excess air from the cooler is passed through another electrostatic precipitator for removal of particulate before being released to the atmosphere. The clinker is then conveyed to the clinker storage silo. This concrete storage shed has the capacity to hold 70,000 tonnes of clinker. Any combination of nine extraction points can be used to extract Clinker to feed the Cement Mill. 1.3 Cement Manufacture The clinker is finally conveyed to the Cement Mill from the Clinker Storage Shed. Within the Mill the Clinker is mixed together with approximately 5% of gypsum and is ground into a fine powder Cement. The gypsum controls the setting time of the finished product Cement. The Cement Mill itself is a two-chamber cylindrical ball mill; this closed circuit grinding mill can yield up to 170 tonnes of cement per/hr. The cement is then conveyed to three cement storage silos for storage. Two of these Silos are used for the despatch of Bulk Cement via Bulk Loader Tankers. The third Silo is used to supply the Bagging and Packaging Plant; the cement is fed from Silo 3 to the highly automated Bagging Plant via a system of Blowers. The cement is packed at a rate of 2,000 bags per hour in 25Kg sacks; the sacks are stacked on pallets and shrink wrapped ready for despatch. The entire operation is carefully monitored in the Central Control Room, where several thousand parameters affecting the plant are monitored. From here operators can monitor the performance of the process control systems and intervene where necessary to ensure process stability and product quality. Quality of product is of utmost importance to Quinn Cement there is a completely automated quality control 6

7 laboratory, known as the Robolab. This Robolab system instructs, supervises and conducts the testing of all routine samples from the various departments within the entire process. 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 done in order to provide even greater consistency, uniformity and therefore quality of process and product. 7

8 1.4 Organisational Chart 8

9 2.0 Summary Information Self Monitoring Data 2.1 Resource consumption Summary Raw Materials Raw material Usage (Tonnes/year) Raw Material January 2011 December 2011 Limestone/Silt/Shale 871,960 Gypsum/Iron-ore 30, Fuel usage Fuel usage (per year) Fuel January 2011 December 2011 Coal 82,353 tonne Diesel 321,974 litres Kerosene 1,500 litres Electricity usage (kwh) Electricity usage (kwh) January 2011 December ,017, Water Consumption (m3) Source Consumption (m3) Use Mains 5,063 Welfare Groundwater 160,240 Process 9

10 2.2 Emissions to Air January December 2011 Emission reference Point Parameter Average emission (mg/nm 3 ) Total No. of operational hours Average Flow Rate (Nm 3 /hr) 1 Calculated Mass Emission (Tonnes) Emission limit (mg/nm3) A kiln Sulphur dioxide , A2-01 kiln Nitrogen Oxide , A2-01 Kiln Particulates , A Grate cooler Particulates , A Coal mill Particulates , A2-04 Cement mill Particulates , A2-05 Sepax Filter Particulate , An average figure taken from Air Assessment Reports Carried out by QED

11 2.2.2 Dust Gauges In accordance with section 5.8 of the IPPC licence, five set of dust gauges are located around the cement manufacturing plant at locations agreed with the Agency. The dust gauges are operated in accordance with BS1747-5:1972. The results of monthly measurements from these gauges are retained on site for inspection by the Agency. The directional dust gauges were replaced at the beginning of March with single jar gauges. The directional dust gauges contain 4 deposit chambers directed in opposite directions. Sampling jar 1 is North, 2 is East, 3 is South and 4 is West for all the sample Sites except at the Crushers. At the Crushers 3 is North, 4 is East, 1 is South and 2 is West. The following results table provides averages for the five gauges on site from January to February Sample Site No Mg/m 2 /day Site 1 Work shop Site 2 Hilltop Site 3 ESB Site 4 Treacy s Field Site 5 Crusher * Note collection area = cm 2. (Samples collected and analysed by Biolabs, Scotstown, Co. Monaghan). 11

12 The following results table provides averages for the five single jar gauges on site from March to December Sample Site Total Retained Water Measured (ml) Total Dried Undissolved Matter Total Solids mg/m2/day Workshop DG Hilltop DG ESB DG Treacy s Field DG Crusher DG Assessment of Directional Dust Deposition (graphs only for January February). Site 1 Workshop - Directional Deposition Data 200 mg/m2/day North East South West Series Dust is predominantly originating from a southerly direction at the workshop dust gauge. The Plant is located to the Southwest of this gauge. This would suggest the majority of the dust is coming from the direction of the Plant or the transport network to the Plant. 12

13 Site 2 Hill-top - Directional Deposition Data 80 mg/m2/day North East South West Series The Plant is located to the east and south east of the monitor. The majority of the dust is emanating from the south which is equivalent to the haul road which connects the cement plant to the raw material reserves. The majority is likely to be transport related at this spot. Site 3 ESB - Directional Deposition Data 80 mg/m2/day North East South West Series The Plant is located to the north and northeast of this monitoring location. The dust seems to be predominantly southerly and easterly, this would suggest influence from nearby vegetation rather than the activity of the plant. 13

14 Site 4 Treacy's Field - Directional Deposition Data 100 mg/m2/day North East South West Series The Plant is to the south east of this location. The majority of dust is coming from an easterly direction which would suggest results are influenced by traffic movements around the plant, in particular in the Bagging Plant area. Site 5 Crusher - Directional Deposition Data mg/m2/day North East South West Series The Plant is located at the south of this location. The dust gauge at the Crusher is located at the northern fringe of the site. The influence on the northern gauge is likely to be localised from the crusher. 14

15 2.3 Emissions to water Surface Water Emissions January 2011 December 2011 Year Flow rate (m3/hr) PH COD mg/l SS mg/l BOD Mg/l NH 4 mg/l Cr mg/l Al mg/l Mineral Oil Limits Summary of Mass Emissions to Surface Water 2011 Year Flow (m3) PH COD (Kg) SS (kg) BOD (kg) NH 4 (kg) Cr (kg) Al (kg) Mineral Oil (kg) Note: Figures contained within Tables and are based on yearly average taken from weekly (Biolabs, Scotstown, Co. Monaghan) and monthly Surface water results (QED, Monaghan / Environmental Laboratory Services, Blackrock, Cork). Where results were represented by a < figure e.g. <0.01 the highest possible figure i.e was used to calculate the average Groundwater Monitoring Summary QED Engineering (Monaghan) took ground water samples on the 25 th October 2011 and the 9 th November The sample was analysed by Environmental Laboratory Services, Acorn Business Campus, Mahon Industrial Park, Blackrock, Co. Cork. An average of the groundwater analysis performed is tabled below. The results are as follows: Parameter Result EPA Interim Guide Value ph < x > 9.5 TOC mg/l 1.03 No abnormal change Conductivity μs/cm Total Ammonia mg/l Total Nitrogen mg/l 1.55 Chromium (Cr VI) mg/l < Aluminium mg/l Mineral Oil mg/l <10 Volatile Organic Compounds mg/l ND 15

16 2.4 Noise monitoring Section 8.1 of the IPPC license states that, the licensee shall carry out a noise survey of the site operations annually following commencement of cement production. A noise survey was carried out on the 18 th and 19 th November 2011 during daytime and night time hours respectively by N and V Consultants, Navan, Co. Meath. The noise surveys were carried out at six noise sensitive locations previously agreed upon with the Agency. The table immediately below indicates the location of the NSL measurement points NSL No. NSL 1 NSL 2 NSL 3 NSL 4 NSL 5 + NSL 6 Location McHughs Residence Doon Heights Slieve Russell House McKiernans Residence Site Centre Kearns Residence The following results were achieved: Recorded day time noise levels db(a) 18 th November Location Date Time Leq L10 L90 Comments NSL1 18 th Nov Plant inaudible at 36dBA NSL2 18 th Nov Audible at 40dBA NSL3 18 th Nov Mainly road traffic NSL4 18 th Nov Audible at 45.5dBA, also road traffic NSL th Nov Mid site (truck idling nearby) NSL6 18 th Nov Plant audible Note + Not a noise sensitive location Recorded night time noise levels db(a) 19 th November Location Date Time Leq L10 L90 Comments NSL1 19 th Nov Plant inaudible, road traffic NSL2 19 th Nov Road traffic from town NSL3 18 th Nov Road traffic and plant noise at 43.0dBA NSL4 19 th Nov Plant noise at 46.2 dba NSL th Nov Mid site beside mill NSL6 19 th Nov Plant noise audible at 44.8dBA and mountain stream audible at 41dBA 16

17 2.4.1 Noise monitoring Assessment From the results of the above survey, noise levels were above the recommended daytime level of 55dB(A) at NSL 5, however this is not a noise sensitive location, this reading is taken from the middle of the site. The night-time noise limit of Leq (15min) of 45 dba was exceeded at locations NSL 3, 4, 5 and NSL 6, however the exceedence was only attributed to plant noise in NSL 4 at 46.2 dba, slightly in excess of the limit at this location. However this house has been vacant for the past two years. There were no tonal or impulsive noise emissions from the works audible at any residence. Noise reduction actions are ongoing. The next noise survey is due to take place in

18 2.5 Waste Management Date/ Period Waste Type mixed municipal waste Mixed C&D waste Recyclable waste EWC CODE , , Quantity (tonnes) , Haulage Contractor Wilton Waste Recycling Ltd. Wilton Waste Recycling Ltd. Wilton Waste Recycling Ltd. Waste Collection Permit No. WCP/MH/08/ WCP/MH/08/ WCP/MH/08/ Waste Disposal / Recovery Contractor Wilton Waste Recycling Ltd. Wilton Waste Recycling Ltd. Wilton Waste Recycling Ltd. Waste License W.F.P-CN W.F.P-CN W.F.P-CN Disposal / Recovery Disposal Disposal Recovery Location of Disposal / Recovery Midland Waste Disposal Company Limited (131-2) Midland Waste Disposal Company Limited (131-2) Midland Waste Disposal Company Limited (131-2) Consignment Note (C1 form) Reference N/a N/a N/a 2011 Fluorescent Lamps Timber /03/2011 Solid oily waste (6 barrels solid oily waste) Irish Lamp recycling Pallet Supplies Limited Enva WCP MH/2001/101C WCP/MH/2001/53D Irish Lamp Recycling Co. Ltd. Pallet Supplies Ltd., Mountain Lodge, Cootehill, Co. Cavan WL02/2000B Recovery Mercury contaminated filters and sludge; (EWC ): Claushuis Metaals, 3899AH Zeewolde, Holland for recycling. Permit MB/ /A (GS van Flevoland) WFP-CN Recovery Pallet Supplies Ltd., Mountain Lodge, Cootehill, Co. Cavan f WCP-DC Enva Ireland Ltd. WL184-1 Recovery Enva Ireland Ltd. B N/a B Waste Oil litres Enva WCP-DC Enva Ireland Ltd. WL184-1 Recovery Enva Ireland Ltd. N/a 18

19 29/06/2011 WEEE Irish Lamp recycling WCP MH/2001/101C Irish Lamp Recycling Co. Ltd. WL02/2000B Recovery Irish Lamp Recycling Co. Ltd. B /06/2011 Mixed metals MSM Recycling WCP-DC MSM Recycling WL79-1 Recovery MSM Recycling N/a 25/08/ /09/ /10/ /12/2011 Oily rags Scrap Metal (media balls) Hazardous waste (Sylobead, empty drums and lab waste) *240l bins Enva , , Hegarty Metal Recycling 4* oily rags 1* aerosols 1* grease cartridges Enva WCP-DC Enva Ireland Ltd. WL184-1 Recovery Enva Ireland Ltd. Hegarty Metal Processors(International) Ltd., Ballysimon Road, Limerick WCP-LK Waste packaging Sylobead Potassium Dichromate SRCL WCP/DC/09/1178/01 SRCL WL 55-2 WFP-LKC Recovery Disposal Hegarty Metal Processors(International) Ltd., Ballysimon Road, Limerick Lindenschmidt, Germany O'Toole Composting, Carlow WCP-DC Enva Ireland Ltd. WL184-1 Recovery Enva Ireland Ltd. B N/a B B

20 2.6 Bund Testing Report Section of the IPPC license requires that.all bunds shall be tested at least once every three years. A report on such tests shall be included in the AER. An assessment of the integrity of : a. Gas Oil Bund b. Grinding Aid Bund c. Waste Segregation Area d. Raw Mill Hydraulic Pump Sump e. Mobile Oil and Chemical Bunds. Was carried out in December 2010 and was completed in February Testing was completed in February 2011 as severe weather conditions hampering tests in December, the Agency were informed on the 20/12/2010. This assessment was carried out in accordance with the guidelines of BS 8007:1997 and the IPC Guidance Note on Storage and Transfer of Materials for Scheduled Activities. The inspection and testing of the bunded tanks involved both visual and hydraulic testing; all bunding was pass as fit for purpose. The next bund integrity test is scheduled for Quarter 4 of

21 2.7 Environmental Incidents The following is a list of environmental incidents experienced at Quinn Cement during the period January 2011 to December Date Nature of Incident Action Taken Authorities Contacted September Fitz Environmental high SO2 on Main Stack Reported by the EPA to QC, QC Commented EPA December High Al Reported to EPA by phone and fax. EPA November High SS weekly 30/11, high monthly Al Reported to EPA by phone and fax. EPA October High SS and Al, high EPA result for Al Reported to EPA by phone and fax. EPA October High SS in weekly SW 12/10, 19/10, 27/10/2011, monthly 25/10 Reported to EPA by phone and fax. EPA September High Aluminium 27/09 Reported to EPA by phone and fax. EPA 05/09/2011 ESP trip for 48 minutes due to a power dip. Reported to EPA by phone and fax. EPA August High Aluminium 04/08, 16/08 Reported to EPA by phone and fax, to be investigated in conjunction with ongoing investigation. EPA July High Aluminium 06/07 Reported to EPA by phone and fax, to be investigated in conjunction with ongoing investigation. EPA June High Chromium in June Reported to EPA (08/07/2011) by phone voic left to be investigated in conjunction with ongoing investigation. Reported by Fax 20/07/2011. EPA 21

22 24/05/2011 ESP Trip caused by fluctuations in incoming power. 20/01/2011 EPA sample 20/01/2011 was non compliant with the Aluminium limit Precip restarted when possible Investigation into causes and report EPA EPA 2.8 Complaints Summary There were no complaints received by Quinn Cement during the period January 2011 to December

23 2.9 Environmental Management System Section 2.1 of the License states that The licensee shall establish and maintain an Environmental Management System (EMS) which shall fulfil the requirements of this license. In September 2010, the Quinn Cement EMS became accredited to the ISO standard for the first time. 23

24 2.9.1 Report on Progress of Environmental Management Programme Licence objectives 1. Noise 2. Fuel Substitution (55% of coal with SRF) 3. New IPPC License (P ) Licensee Targets Review and update the noise improvement programme with a view to achieving the night time noise level at NSL 4 and maintain compliance at other locations. Quinn Cement hope to commence construction of a new calciner, fuel storage bunker and feed system, SNCR system and silo and modify existing abatement systems and bypass set up to allow substitution of coal for Solid recovered fuel. This project will reduce use of non-renewable fuel, reduce transport CO2 of fuel as SRF will be sourced in Ireland and reduce CO2 emission from combustion. For the operation of the proposed Alternative Fuels project discussed under Objective 2 a new IPPC licence is required. Application for a new licence was submitted in Progress The majority of items on the Noise Improvement Programme have been completed or are in progress. Items which have not been fully closed out have been transferred to 2012 Objectives and Targets. This is a long term Objective and is still being progressed. This Objective has been transferred to 2012 Objectives and Targets Numerous requests for information were submitted and a Proposed Determination was issued early This is a long term Objective and is still being progressed. This Objective has been transferred to 2012 Objectives and Targets. 4. ISO To maintain and develop the EMS to the standards achieved in 2010 with accreditation to To maintain accreditation. Accreditation has been maintained. 5. ISO To continue development of the energy management system. To develop achievable goals on energy efficiency, roll out of staff training and integration with environmental management system. This Objective has been progressed, Integration with the EMS has commenced. Energy Efficiency projects and investigations are ongoing and training for management staff has been undertaken. 24

25 6. BES 6001 To achieve accreditation to BES 6001 sustainability standard across the supply chain. Certification audit scheduled for March Waste Management To establish a baseline on waste to landfill and to set in place a target for reduction that is achievable through the hierarchy of waste management options. Completed 8. Aluminium and Chromium in SW1 To carry out further investigation in spot high level findings in Al and Cr in the surface water discharge through SW1 with an ultimate goal of eliminating such occurrences. Completed 25

26 2.9.2 Schedule of Environmental Objectives and Targets 2012 Licence Objectives Licensee Targets Noise Continued implementation of Noise Improvement Programme Fuel Substitution (55% of coal with SRF) Quinn Cement hope to commence construction of a new calciner, fuel storage bunker and feed system, SNCR system and silo and modify existing abatement systems and bypass set up to allow substitution of coal for Solid recovered fuel. This project will reduce use of non-renewable fuel, reduce transport CO2 of fuel as SRF will be sourced in Ireland and reduce CO2 emission from combustion. New IPPC License (P ) For the operation of the proposed Alternative Fuels project a new IPPC licence is required. Application for a new licence was submitted in BES 6001 To achieve accreditation to BES 6001 sustainability standard across the supply chain. P IPPC Licence Implement new conditions within PO and incorporate into ISO system. Implement infrastructural and operational changes as required by the Licence ISO To continue development of the energy management system 26

27 2.9.3 Environmental Management Plan Objectives & Targets Means of Achievement/Action Necessary Person Responsible Time frame for Achievement Noise Continued implementation of Noise Improvement Programme Plant Engineer, Maintenance Manager, Environmental Advisor December 2012 Fuel Substitution (55% of coal with SRF) Quinn Cement hope to commence construction of a new calciner, fuel storage bunker and feed system, SNCR system and silo and modify existing abatement systems and bypass set up to allow substitution of coal for Solid recovered fuel. This project will reduce use of non-renewable fuel, reduce transport CO2 of fuel as SRF will be sourced in Ireland and reduce CO2 emission from combustion. Project Manager 2015 New IPPC License (P ) For the operation of the proposed Alternative Fuels project discussed above, a new IPPC licence is required. Application for a new licence was submitted in Environmental Advisor, Project Management June 2012 BES 6001 P IPPC Licence To achieve accreditation to BES 6001 sustainability standard across the supply chain. Implement new conditions within PO and incorporate into ISO system. Implement infrastructural and operational changes as required by the Licence Environmental Advisor and Cement Management Team Environmental Advisor and Cement Management Team March 2012 Within 1 year of granting of the Licence ISO To continue development of the energy management system. Environmental Advisor and Cement Management Team

28 2.10 RMP and ELRA Residual Management Plan The residual management plan is kept on file at Quinn Cement Ltd. No significant changes have been made to this document ELRA The ELRA is kept on file at Quinn Cement Limited. No significant changes have been made to this document. 28

29 2.11 AER Returns Worksheet PRTR# : P0378 Facility Name : Quinn Cement Limited Filename : P0378_2011.xls Return Year : /03/ :30 REFERENCE YEAR FACILITY IDENTIFICATION Parent Company Name Quinn Cement Limited Facility Name Quinn Cement Limited PRTR Identification Number P0378 Licence Number P Guidance to completing the PRTR workbook Waste or IPPC Classes of Activity No. class_name 10.1 The production of cement. AER Returns Workbook Version Address 1 Quinn Cement Address 2 Scotchtown Address 3 Ballyconnell Address 4 Co Cavan Cavan Country Ireland Coordinates of Location River Basin District GBNIIENW NACE Code 2351 Main Economic Activity Manufacture of cement AER Returns Contact Name Anna McNally AER Returns Contact Address Anna.McNally@quinn-group.com AER Returns Contact Position Environmentak Advisor AER Returns Contact Telephone Number AER Returns Contact Mobile Phone Number AER Returns Contact Fax Number Production Volume 0.0 Production Volume Units Number of Installations 0 Number of Operating Hours in Year 0 Number of Employees 0 User Feedback/Comments Web Address 2. PRTR CLASS ACTIVITIES Activity Number 3(c)(i) Activity Name Cement clinker in rotary kilns 3. SOLVENTS REGULATIONS (S.I. No. 543 of 2002) Is it applicable? No Have you been granted an exemption? No If applicable which activity class applies (as per Schedule 2 of the regulations)? Is the reduction scheme compliance route being used? 29

30 4.1 RELEASES TO AIR Link to previous years emissions data PRTR# : P0378 Facility Name : Quinn Cement Limited Filename : P0378_2011.xls Return Year : /03/ : SECTION A : SECTOR SPECIFIC PRTR POLLUTANTS RELEASES TO AIR Please enter all quantities in this section in KGs POLLUTANT METHOD QUANTITY Method Used No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 Emission Point 2 Emission Point 3 Emission Point 4 A (Accidental) Emission Point 5 T (Total) KG/Year KG/Year F (Fugitive) KG/Year 03 Carbon dioxide (CO2) C ETS Nitrogen oxides (NOx/NO2) M PER IS EN Sulphur oxides (SOx/SO2) M PER IS EN Particulate matter (PM10) M ALT ISO * Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button SECTION B : REMAINING PRTR POLLUTANTS RELEASES TO AIR Please enter all quantities in this section in KGs POLLUTANT METHOD QUANTITY Method Used No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year * Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button SECTION C : REMAINING POLLUTANT EMISSIONS (As required in your Licence) RELEASES TO AIR Please enter all quantities in this section in KGs POLLUTANT METHOD QUANTITY Method Used Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year * Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button 30

31 4.2 RELEASES TO WATERS Link to previous years emissions data PRTR# : P0378 Facility Name : Quinn Cement Limited Filename : P0378_2011.xls Return Year : /03/ : SECTION A : SECTOR SPECIFIC PRTR POLLUTANTS Data on ambient monitoring of storm/surface water or groundwater, conducted as part of your licence requirements, should NOT be submitted under AER / PRTR Reporting as this only co RELEASES TO WATERS Please enter all quantities in this section in KGs POLLUTANT QUANTITY Method Used No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year 19 Chromium and compounds (as Cr) M ALT ISO * Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button SECTION B : REMAINING PRTR POLLUTANTS RELEASES TO WATERS Please enter all quantities in this section in KGs POLLUTANT QUANTITY Method Used No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year * Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button SECTION C : REMAINING POLLUTANT EMISSIONS (as required in your Licence) RELEASES TO WATERS POLLUTANT Please enter all quantities in this section in KGs QUANTITY Method Used Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year 355 Aluminium M ALT ISO Ammonia (as N) M ALT ISO BOD M ALT ISO COD M ALT ISO Mineral oils M ALT ISO Organohalogens M ALT ISO Suspended Solids M ALT ISO Total Dissolved Solids M ALT ISO

32 4.3 RELEASES TO WASTEWATER OR SEWER Link to previous years emissions data PRTR# : P0378 Facility Name : Quinn Cement Limited Filename : P0378_2011.xls Return Year : 20 30/03/ : SECTION A : PRTR POLLUTANTS OFFSITE TRANSFER OF POLLUTANTS DESTINED FOR WASTE-WATER TREATMENT OR SEWER Please enter all quantities in this section in KGs POLLUTANT METHOD QUANTITY Method Used No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year * Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button SECTION B : REMAINING POLLUTANT EMISSIONS (as required in your Licence) OFFSITE TRANSFER OF POLLUTANTS DESTINED FOR WASTE-WATER TREATMENT OR SEWER Please enter all quantities in this section in KGs POLLUTANT METHOD QUANTITY Method Used Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year

33 4.4 RELEASES TO LAND Link to previous years emissions data PRTR# : P0378 Facility Name : Quinn Cement Limited Filename : P0378_2011.xls Return Year : /03/ : SECTION A : PRTR POLLUTANTS RELEASES TO LAND Please enter all quantities in this section in KGs POLLUTANT METHOD QUANTITY Method Used No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year * Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button SECTION B : REMAINING POLLUTANT EMISSIONS (as required in your Licence) RELEASES TO LAND Please enter all quantities in this section in KGs POLLUTANT METHOD QUANTITY Method Used Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year

34 ty T/Year Description and Licence / P ermi t No. of Recoverer / Di sposer / B roker A ddress of Recoverer / Disposer / B roker Name and Address of Final Destination i.e. Final Recovery / Disposal Site (HAZARDOUS WASTE ONLY) Li cence / P ermit No. of Final Destination i.e. Fi nal Recovery / Disposal Site (HA ZA RDOUS WA S TE ONLY) 5. ONSITE TREATMENT & OFFSITE TRANSFERS OF WASTE PRTR# : P0378 Facility Name : Quinn Cement Limited Filename : P0378_2011.xls Return Year : /03/ : Please enter all quantities on this sheet in Tonnes 13 European Waste Code Hazardous Quanti Quantity (Tonnes per Year) Method Used Waste Treatment Operation M/C/E Method Used Location of Treatment Name Haz Waste : Name and Licence/Permit No of Next Destination Facility Non Haz Waste: Name and Licence/Permit No of Recover/Disposer Transfer Destination of Waste absorbents, filter materials (including oil filters not otherwise specified), wiping cloths, protective clothing contaminated by To Other Countries Yes 0.38 dangerous substances R13 M Weighed Abroad ENVA Ireland,WL184-1 Haz Waste : Address of Next Destination Facility Non Haz Waste: Address of Recover/Disposer Clonminam Ind. Est., Portlaoise,Co. Laois,.,Ireland Name and License / Permit No. and Address of Final Recoverer / Disposer (HAZARDOUS WASTE ONLY) Actual Address of Final Destination i.e. Final Recovery / Disposal Site (HAZARDOUS WASTE ONLY) Lindenschmidt,Reg.no. E ,Kreuztal,.,.,.,Ger many Kreuztal,.,.,.,Germany Within the Country Yes 1.35 other engine, gear and lubricating oils R9 M Weighed Offsite in Ireland ENVA Ireland,WL184-1 absorbents, filter materials (including oil filters not otherwise specified), wiping cloths, protective clothing contaminated by To Other Countries Yes 0.6 dangerous substances R13 E Volume Calculation Abroad ENVA Ireland,WL184-1 Clonminam Ind. Est., Portlaoise,Co. Laois,.,Ireland Clonminam Ind. Est., Portlaoise,Co. Laois,.,Ireland Enva Ireland,WL184-1,Clonminam Industrial Estate Clonminam Industrial Estate,Portlaoise,Co.,Portlaoise,Co. Laois,.,Ireland Laois,.,Ireland Lindenschmidt,Reg.no. E ,Kreuztal,.,.,.,Ger many Kreuztal,.,.,.,Germany packaging containing residues of or To Other Countries Yes contaminated by dangerous substances D15 M Weighed Abroad Eco Safe Systems,54-2 To Other Countries Yes chemicals consisting of or containing 0.98 dangerous substances D15 M Weighed Abroad Eco Safe Systems,54-2 laboratory chemicals, consisting of or containing dangerous substances, including To Other Countries Yes 0.2 mixtures of laboratory chemicals R13 M Weighed Abroad ENVA Ireland,WL184-1 fluorescent tubes and other mercurycontaining To Other Countries Yes waste R4 M Weighed Abroad Irish Lamp Recycling,WL02/2000B 1A Allied Industrial Estate,Kylemore Road,Dublin 10,.,Ireland 1A Allied Industrial Estate,Kylemore Road,Dublin 10,.,Ireland Clonminam Ind. Est., Portlaoise,Co. Laois,.,Ireland Woodstock Industrial Estate,Kilkenny Road,Athy,Co. Kildare,Ireland Lindenschmidt,Reg.no. E ,Kreuztal,.,.,.,Ger many Kreuztal,.,.,.,Germany Lindenschmidt,Reg.no. E ,Kreuztal,.,.,.,Ger many Kreuztal,.,.,.,Germany SBH,D-74238,Austrasse 5,Krautheim,.,.,Germany Claushuis Metaals for recycling. Permit,MB/ /A,3899AH Zeewolde,.,.,.,Netherlands Austrasse 5,Krautheim,.,.,Germany 3899AH Zeewolde,.,.,.,Netherlands 34

35 Annex 1: Monitoring Locations: 35

36 Dust Deposit Gauges D1 D2 D3 D4 D5 Site 1 Work shop Site 2 Hilltop Site 3 ESB Site 4 Treacy s Field Site 5 Crusher Noise: **N1 **N2 N3 N4 N5 N6 NSL1 McHugh s Residence NSL2 Doon Heights NSL3 Slieve Russell House NSL4 McKiernan s Residence NSL5 Site Centre NSL6 Kearns Residence **NSL 1 and 2 outside the scope of the above drawing. Surface water and Groundwater: SW1 GW1 Discharge Point Onsite Borehole

37 Annex 2: Atmospheric Emission Points

38 Air Emission Points A2-01 Kiln A2-02 Grate Cooler A2-03 Coal Mill A2-04 Cement Mill A2-05 Sepax Filter

39 Annex 3: Quinn Cement Accreditation