Quinn Cement Ltd. January December 2010

Transcription

1 Quinn Cement Ltd. January December 20 Annual Environmental Report IPPC Licence No. P0378-1

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 20 - December Dust Gauges Assessment of Directional Dust Deposition Emissions to water Surface Water Emissions January 20 December Summary of Mass Emissions to Surface Water Groundwater Monitoring Summary Toxicity Testing: Noise monitoring Noise monitoring Assessment Waste Management

3 2.6 Bund Testing Report Environmental Incidents Complaints Summary Environmental Management System Environmental Policy 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...35 Annex 1: Monitoring Locations:...41 Dust Deposit Gauges...42 Noise:...42 Surface water and Groundwater:...42 Annex 2: Atmospheric Emission Points...43 Air Emission Points...44 Annex 3: Quinn Cement 140 Accreditation

4 1.0 Introduction This Annual Environmental Report relates to Quinn Cement Works (IPPC No. P0378-) 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 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 20 December 20 Limestone 945,070 Clay/silt 50,000 Shale 178,621 Gypsum 36,931 Iron-ore 3, Fuel usage Fuel usage (per year) Fuel January 20 December 20 Coal 99,455 tonne Diesel 411,521 litres Kerosene 4,918 litres Electricity usage (kwh) Electricity usage (kwh) January 20 December 20 82,161, Water Consumption (m3) Source Consumption (m3) Use Mains 5,600 Welfare Groundwater 154,030 Process 9

10 2.2 Emissions to Air January 20 - December 20 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) A2- - kiln Sulphur dioxide , , A2- kiln Nitrogen Oxide , , A2- Kiln Particulates , , A Grate cooler Particulates 5.5 4, , A Coal mill Particulates ,978 35, A2-04 Cement mill Particulates ,348 30, A2-05 Sepax Filter Particulate 8.6 5, , 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 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 of 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 December 20. Sample Site Site 1 Work shop No Total Retained Water measured (ml) ph Total Undissolved Matter (mg/l) Total Dissolved Matter (mg/l) Total Solids (mg) Mg/m 2 /day 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 Assessment of Directional Dust Deposition Site 1 Workshop - Directional Deposition Data 150 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. 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 north and 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. 12

13 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 in composition which would suggest influence from the road network to the weighbridge area, transport related localised dust Site 4 Treacy's Field - Directional Deposition Data 150 mg/m2/day North East South West Series The Plant is to the south east of this location. There is an even distribution of dust in all directions with slightly higher from the east. This would not be related to the Plant, but more likely to have influence from the main Ballyconnell to Derrylin Road. 13

14 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 north pot of the directional gauge is likely to be localised from the crusher. The results from the south and east are likely to have been influenced by the cement plant but also localised dust from the Crushers. 14

15 2.3 Emissions to water Surface Water Emissions January 20 December 20 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 < <0. Limits Summary of Mass Emissions to Surface Water 20 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. the highest possible figure i.e. 0. was used to calculate the average Groundwater Monitoring Summary QED Engineering (Monaghan) took ground water samples on the 6 th May 20 and the 13 th October 20. 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 0.56 No abnormal change Conductivity μs/cm Total Ammonia mg/l < Total Nitrogen mg/l 1.5 Chromium (Cr VI) mg/l < Aluminium mg/l < Volatile Organic Compounds mg/l ND 15

16 2.3.3 Toxicity Testing: The sample was collected by QED Engineering (Monaghan) and analysed by Aquatic Services Unit, Environmental Research Institute, Lee Road, Cork. Report was submitted to the Agency on 1 st November 20. Testing was carried out in accordance with Condition 6.7 of the License. There were four species from different trophic levels examined for toxicity against effluent discharge from SW 1. Species were rainbow trout (Onchorhynchus mykiss); waterflea (Daphnia magna); duckweed (Lemna minor) and bacteria (Vibrio fischeri). All were tested against standard methods in US EPA Whole Effluent Testing Guidelines (US EPA, 2002). The results from the 4 bioassays performed on the effluent from SW1 at Quinn Cement indicated that the sample was non toxic across all species tested. In future toxicity testing will be carried out annually and reported in the AER for analysis across bioassays for Daphnia magna and Vibrio fischeri in accordance with Condition 6.8 of the License. 16

17 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 13 th December 20 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) 13 th December 20. Location Date Time Leq L10 L90 Comments NSL1 13/12/ Barely audible at 31dBA NSL2 13/12/ Audible at 44dBA NSL3 + 13/12/ Mainly road traffic NSL4 13/12/ Plant audible at 48dBA, also road traffic NSL5 + 13/12/ Mid site beside mill NSL6 13/12/ Mainly cement plant Note + Not a noise sensitive location Recorded night time noise levels db(a) 13 th December 20 Location Date Time Leq L10 L90 Comments NSL1 13/12/ Plant inaudible, slight road traffic NSL2 13/12/ Road traffic from town NSL3 + 13/12/ Road traffic and plant noise at 44.0dBA NSL4 13/12/ Plant noise at 46 dba NSL5 + 13/12/ Mid site beside mill NSL6 13/12/ Plant noise at 44.0 dba 17

18 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 4, however the consultants comments indicate that plant noise was audible at 48 dba, there is also significant noise from road traffic at this location. The night-time noise limit of Leq (15min) of 45 dba was exceeded at locations NSL 4 and NSL 6, however the exceedence was only attributed to plant noise in NSL 4 at 46 dba, slightly in excess of the limit at this location, but there has been improvement since the previous AER. There were no tonal or impulsive noise emissions from the works audible at any residence. All staff has received Environmental training including the importance of noise reduction on site. Doors are inspected and repaired regularly. The next noise survey is due to take place in

19 2.5 Waste Management Date/ Period 14/1/20 14/1/20 Waste Type mixed municipal Mixed C&D EWC CODE 15, 1503, 2003 Quantity (tonnes) Haulage Contractor Waste Collection Permit No. Waste Disposal / Contractor Waste License Disposal / Disposal Disposal Location of Disposal / Consignment Note (C1 form) Reference 14/1/20 Recyclable , Leinster Environmental (WP 2004/30) 04/02/20 Scrap metal Felix Gormley WCP/MH/20/76D Felix Gormley 04/02/20 Scrap metal Felix Gormley WCP/MH/20/76D Felix Gormley 11/02/20 02/11/20 12/02/20 12/02/20 Mixed C&D Mixed C&D Mixed C&D Mixed C&D Clearway Disposals, Belfast Clearway Disposals, Belfast W.F.P-CN W.F.P-CN

20 18/2/20 drums RILTA Environmental Limited, Block 402, Greenogue Business Park, Rathcoole, Co. Dublin WCP-DC RILTA Environmental Limited, Block 402, Greenogue Business Park, Rathcoole, Co. Dublin WL 192/03 A1 Metal Recycling, Mountmellick, Co. Laois, WMP007d 25/2/20 recyclable , Leinster Environmental (WP 2004/30) 16/3/20 16/3/20 12/04/20 Mixed C&D Mixed C&D oily rags + filters , /4/20 oil /4/20 29/4/20 20/05/20 20/05/20 Mixed C&D Mixed C&D Mixed C&D Mixed C&D 3*205l rags 1*205 l filters 1500 litres Enva Ireland Ltd. Enva Ireland Ltd. R.D. Recycling, Houthalen, Belgium, Reg.no /1/KD Enva Ireland Ltd. WCP-DC WCP-DC Enva Ireland Ltd. Enva Ireland Ltd WL184-1 WL B

21 11/06/20 Mixed C&D 15/06/20 Pallets /6/20 19/6/20 Mixed C&D Mixed C&D pallets (2.76 t) /6/20 Oily rags *205 l 22/6/20 oil /07/20 Mixed C&D 21/7/20 oil /7/20 pallets liters liters 126 pallets Pallet Supplies Enva Ireland Ltd. Enva Ireland Ltd. Enva Ireland Ltd. Pallet Supplies WCP/MH/20/53D R.D. Recycling, Houthalen, Belgium, Reg.no /1/KD Enva Ireland Ltd. Enva Ireland Ltd. WCP-DC WCP-DC WCP-DC WCP/MH/20/53D Pallet Supplies Ltd., Mountain Lodge, Cootehill, Co. Cavan Enva Ireland Ltd. Enva Ireland Ltd. Enva Ireland Ltd. Pallet Supplies Ltd., Mountain Lodge, Cootehill, Co. Cavan W.F.P-CN WL184-1 WL WL184-1 W.F.P-CN Pallet Supplies Ltd., Mountain Lodge, Cootehill, Co. Cavan f Pallet Supplies Ltd., Mountain Lodge, Cootehill, Co. Cavan f B

22 27/7/20 Mixed C&D /08/20 oily rags *205 l 23/8/20 Mixed C&D Enva Ireland Ltd. WCP-DC R.D. Recycling, Houthalen, Belgium, Reg.no /1/KD Clearway Disposals, Belfast Enva Ireland Ltd. 25/8/20 Scrap metal Felix Gormley WCP/MH/20/76D Felix Gormley 14/09/20 23/09/20 Mixed C&D 2 x 205 l UN approved drums and 2 x 205 l UN approved drums , /10/20 Pallets /10/20 Mixed C&D 4 x 205 l drums 3.16 (86 pallets) Enva Ireland Ltd. Pallet Supplies 20/10/20 Plastic Recyco 20/10/20 Cardboard Recyco WCP-DC WCP/MH/20/53D WCP MH/10/03- WCP MH/10/03- Enva Ireland Ltd. Pallet Supplies Ltd., Mountain Lodge, Cootehill, Co. Cavan WL W.F.P-CN WL184-1 W.F.P-CN Recyco WML 25/ Recyco WML 25/ Lindenschmidth, Germany, Reg.no. E Pallet Supplies Ltd., Mountain Lodge, Cootehill, Co. Cavan 62 Gortin Road Omagh 62 Gortin Road Omagh B B

23 20/10/20 1 t bags Recyco 20/10/20 20/10/20 20/10/20 21/10/20 02/11/20 04/11/20 Recyclable Mixed C&D Mixed C&D recyclable Aerosol Cans Recyclable , , Enva Ireland Ltd. WCP MH/10/03-62 Gortin Road Omagh Leinster Environmental (WP 2004/30) WCP-DC Recyco WML 25/ Enva Ireland Ltd. 17/11/20 Scrap metal Felix Gormley WCP/MH/20/76D Felix Gormley 18/11/20 recyclable , WP No. 06/32 WL184-1 WP No. 06/32 W.F.P-CN WP No. 06/32 Leinster Environmental (WP 2004/30) Lindenschmidth, Germany, Reg.no. E Leinster Environmental (WP 2004/30) Clearway Disposals, Belfast Leinster Environmental (WP 2004/30) B /12/20 Recyclable , WP No. 06/32 Leinster Environmental (WP 2004/30) 23

24 08/12/20 08/12/20 Landfill Materials Mixed C&D Disposal 09/12/20 Recyclable , Leinster Environmental (WP 2004/30) 15/12/20 Partswasher Arven Chemicals Ltd. NSO Arven Industrial Chemicals Limited CB/JNSO17CU Lanstar, Cadishead Manchester (BS.1538.IQ) NSO /12/20 Recyclable , Leinster Environmental (WP 2004/30) See PRTR submission attached in Section 2.12 for hazardous which was above the PRTR reporting threshold. 24

25 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 Gas Oil and Grinding Aid bunded tanks used at Quinn Cement was carried out in September 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 over a period of 7 days between the September 5 th and September 11 th inclusive. Mr. Sean Feehan CEng ADCON Consultants performed the survey. All bunds were found adequate for their intended purpose. The next bund integrity test was scheduled for Quarter 4 of 20. Tests were not completed at that stage due to severe weather conditions hampering tests. The Agency was informed on the 20/12/20. Tests will be completed in Quarter 1 21 and forwarded to the Agency upon completion. Mr. Sean Feehan CEng ADCON Consultants will again perform the survey. Bunds to be integrity tested include: a. Gas Oil Bund b. Grinding Aid Bund c. Waste Segregation Area d. Raw Mill Hydraulic Pump Sump e. Mobile Oil and Chemical Bunds. 25

26 2.7 Environmental Incidents The following is a list of environmental incidents experienced at Quinn Cement during the period January 20 to December 20. Date Nature of Incident Action Taken 18//21 Aluminium exceedances in discharge Investigation including analysis from SW1 ( mg/l, limit 0.2 and report. Action ongoing. mg/l). Settlement Pond was desludged and EPA approval for recycling of January the sludge was analysed. No sludge as a raw material in cement 20 discharge during the week ending production. Informed of non 27//20 discharge. 08/02/20 Chromium exceedances in discharge Investigation including analysis from SW1 (0.12 mg/l, limit 0.05 and report. Action ongoing. mg/l). 18/03/20 Euro Environmental (on behalf of the Investigation including review of Agency) carried out stack CEMS results and QED quarterly monitoring). SOx was analysis for this period. mg/nm3, limit 600 mg/nm3. 24/05/20 SW monitored at SW1 for impact There was a small fire at the base of of fire water there was no impact the Pan Conveyor. Early detection found as foaming agent used to and implementation of the ERP. Fire quench the fire. Investigation and Services were called. report. ESP trip for 4 minutes due to raw 11/06/20 mill panel trip causing a downstream Investigation and report. trip effect on the ESP. ESP trip for 20 minutes due to a 04/07/20 problem with the air breaker in the Investigation and report. switch room. EPA test on SW1 sample found an 07/09/20 exceedance in SS (55 mg/l, limit 35 Investigation including analysis mg/l) and a exceedance in Al (0.430 and report. Action ongoing mg/l, limit o.2 mg/l) 14 th and Quarterly stack monitoring on A2- Investigation and report. 15 th Sept and A2-03 found an exceedance on 1 Subsequent monitoring. 20 of 2 runs on particulate emissions. Authorities Contacted EPA EPA EPA EPA EPA, CCC, HSA. EPA EPA. EPA EPA 26

27 Date Nature of Incident Action Taken EPA test on SW1 sample found an exceedance in Al ( mg/l, limit 18/11/20 o.2 mg/l). this sample was split and Investigation including analysis tested by QED (ELS, Blackrock, Cork) and report. Action ongoing and found an exceedance in Al (0.277 mg/l, limit 0.2 mg/l) 27/11/20 ESP trip for 5 minutes due to a power dip. Investigation and report. Jars on the Crushers and the ESB November Repaired. Application to move to station locations of dust deposit 20 Bergerhoff method. gauges broken. Bund tests not carried out due to December Rescheduled to Q 1 21, EPA adverse weather causing freezing of 20 informed. water during test procedure. Authorities Contacted EPA EPA EPA EPA 27

28 2.8 Complaints Summary The following is a list of environmental complaints received by Quinn Cement during the period January 20 to December 20. Dates Complaint Date of Complaint Complainant Type was Observed Dust Noise 08//20 07//20 Ms Barbara McHugh X This complaint was fully investigated and an investigation report was submitted to the EPA in response to the complaint as recorded above on 11//20. 28

29 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 20, the Quinn Cement EMS became accredited to the ISO 140 standard for the first time Environmental Policy 29

30 2.9.2 Report on Progress of Environmental Management Programme Licence objectives Licensee Targets Progress Noise Abatement Quinn Cement aim to complete the majority of elements of the noise improvement programme prior to completion of the 20 Noise Survey. It is hoped this will result in all emissions levels being below the licence limits for day and night. See results of the noise survey. Some of the improvements are ongoing and will be reviewed again in 21. Alternative Fuels Project 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 has not commenced, objective carried over. New IPC Licence 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 20. P application still being assessed for proposed determination. Objective carried over Environmental and Energy Management System Formal accreditation of Environmental and Energy Management System Accreditation achieved to 140, energy management system not accredited, though formal system in place. 30

31 2.9.3 Schedule of Environmental Objectives and Targets 21 Licence Objectives 1. Noise 2. Fuel Substitution (55% of coal with SRF) 3. New IPPC License (P ) 4. ISO ISO BES Waste Management 8. Aluminium and Chromium in SW1 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 20. To maintain and develop the EMS to the standards achieved in 20 with accreditation to 140. To maintain accreditation. 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. To achieve accreditation to BES 60 sustainability standard across the supply chain. To establish a baseline on to landfill and to set in place a target for reduction that is achievable through the hierarchy of management options. 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. 31

32 2.9.4 Environmental Management Plan No. Objectives & Targets Means of Achievement/Action Necessary Person Responsible Time frame for Achievement 1 Noise 2 Fuel Substitution (55% of coal with SRF) 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. Plant Engineer, Maintenance Manager, Environmental Advisor Project Manager 22 December 21 3 New IPPC License (P ) 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 20. Environmental Advisor, Project Management June 21 4 ISO ISO 160 To maintain and develop the EMS to the standards achieved in 20 with accreditation to 140. To maintain accreditation. 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. Environmental Advisor and Cement Management Team Environmental Advisor and Cement Management Team December 21 December 21, accreditation (22) 6 BES 60 To achieve accreditation to BES 60 Environmental Advisor and September 21 32

33 7 Waste Management 8 Aluminium and Chromium in SW1 sustainability standard across the supply chain. To establish a baseline on to landfill and to set in place a target for reduction that is achievable through the hierarchy of management options. 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. Cement Management Team Environmental Advisor, Maintenance Manager, Production Manager. September 21 Cement Management July 21 33

34 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. 34

35 2.11 AER Returns Worksheet PRTR# : P0378 Facility Name : Quinn Cement Limited Filename : P0378_20.xls Return Year : 20 REFERENCE YEAR FACILITY IDENTIFICATION Parent Company Name Quinn Cement Limited Facility Name Quinn Cement Limited PRTR Identification Number P0378 Licence Number P0378- 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 Country Ireland Coordinates of Location River Basin District GBNIIENW NACE Code 2351 Main Economic Activity Manufacture of cement AER Returns Contact Name Fintan Coyle AER Returns Contact Address Fintan.Coyle@quinn-group.com AER Returns Contact Position Environmental 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? Have you been granted an exemption? If applicable which activity class applies (as per Schedule 2 of the regulations)? Is the reduction scheme compliance route being used? 35

36 4.1 RELEASES TO AIR Link to previous years emissions data PRTR# : P0378 Facility Name : Quinn Cement Limited Filename : P0378_20(1).xls Return Year : 20 30/03/21 15: 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 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year 03 Carbon dioxide (CO2) C ETS Nitrogen oxides (NOx/NO2) M PER EN14792: Sulphur oxides (SOx/SO2) M PER EN14792: Particulate matter (PM10) M PER 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 Additional Data Requested from Landfill operators For the purposes of the National Inventory on Greenhouse Gases, landfill operators are requested to provide summary data on landfill gas (Methane) flared or utilised on their facilities to accompany the figures for total methane generated. Operators should only report their Net methane (CH4) emission to the environment under T(total) KG/yr for Section A: Sector specific PRTR pollutants above. Please complete the table below: Landfill: Please enter summary data on the quantities of methane flared and / or utilised Quinn Cement Limited Method Used Designation or Description Facility Total Capacity m3 per hour additional_pollutant_no T (Total) kg/year M/C/E Method Code Total estimated methane generation (as per site model) 0.0 N/A Methane flared (Total Flaring Capacity) Methane utilised in engine/s (Total Utilising Capacity) Net methane emission (as reported in Section A above) 0.0 N/A 36

37 4.2 RELEASES TO WATERS Link to previous years emissions data PRTR# : P0378 Facility Name : Quinn Cement Limited Filename : P0378_20(1).xls Return Year : 20 30/03/21 15: 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 on 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 PER EN ISO 17025: * 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 PER EN ISO 17025: Ammonia (as N) M PER EN ISO 17025: BOD M PER EN ISO 17025: COD M PER EN ISO 17025: Mineral oils M PER EN ISO 17025: Organohalogens M PER EN ISO 17025: Suspended Solids M PER EN ISO 17025: Total Dissolved Solids M PER EN ISO 17025:

38 4.3 RELEASES TO WASTEWATER OR SEWER Link to previous years emissions data PRTR# : P0378 Facility Name : Quinn Cement Limited Filename : P0378_20(1).xls Return Ye 30/03/21 12: 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 * Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button 38

39 4.4 RELEASES TO LAND Link to previous years emissions data PRTR# : P0378 Facility Name : Quinn Cement Limited Filename : P0378_20(1).xls Return Year : 20 30/03/21 12: 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 * Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button 39

40 T/Year Description and Li cence / Per mi t No. of Recoverer / Disposer / Broker Address of Recoverer / Disposer / Broker Name and Address of Final Destination i.e. Final / Disposal Site (HAZARDOUS WASTE ONLY) Licence / Permit No. of Final Destination i.e. Final / Disposal Site (HAZARDOUS WASTE ONLY) 5. ONSITE TREATMENT & OFFSITE TRANSFERS OF WASTE PRTR# : P0378 Facility Name : Quinn Cement Limited Filename : P0378_20(1).xls Return Year : 20 30/03/21 15: Please enter all quantities on this sheet in Tonnes 5 Transfer Destination European Waste Code Hazardous Quantity Quantity (Tonnes per Year) of Waste Method Used Waste Treatment Operation M/C/E Method Used Location of Treatment Name Within the Country Yes 4.0 other engine, gear and lubricating oils R9 M Weighed Offsite in Ireland Enva,184-1 absorbents, filter materials (including oil filters not otherwise specified), wiping cloths, protective clothing contaminated by To Other Countries Yes 1.23 dangerous substances R13 E Volume Calculation Abroad Enva,184-1 To Other Countries Yes 0.1 oil filters R13 E Volume Calculation Abroad Enva,184-1 gases in pressure containers (including To Other Countries Yes 0.72 halons) containing dangerous substances R13 E Volume Calculation Abroad Enva,184-1 aqueous liquid s containing dangerous To Other Countries Yes substances R13 M Weighed Abroad Haz Waste : Name and Licence/Permit No of Next Destination Facility Non Haz Waste: Name and Licence/Permit No of Recover/Disposer Arven Industrial Chemicals,CB/JNSO17CU Haz Waste : Address of Next Destination Facility Non Haz Waste: Address of Recover/Disposer Clonminam Industrial Estate,Portlaoise,Co. Laois,Co. Laois,Ireland Clonminam Industrial Estate,Portlaoise,Co. Laois,Co. Laois,Ireland Clonminam Industrial Estate,Portlaoise,Co. Laois,Co. Laois,Ireland Clonminam Industrial Estate,Portlaoise,Co. Laois,Co. Laois,Ireland 12 Goddard Road,Astmoor Industrial estate,runcorn,cheshire WA7IQF,United Kingdom Name and License / Permit No. and Address of Final Recoverer / Disposer (HAZARDOUS WASTE ONLY) Enva,184-1 Actual Address of Final Destination i.e. Final / Disposal Site (HAZARDOUS WASTE ONLY) Clonminam Industrial Estate,Portlaoise,Co. Laois,Co. Laois,Ireland RD Recycling,51727/1/KD,.,.,Hou thalen,.,belgium.,.,houthalen,.,belgium RD Recycling,51727/1/KD,.,.,Hou thalen,.,belgium.,.,houthalen,.,belgium Lindenschmidt,E ,.,.,Kreuztal,.,Germany.,.,Kreuztal,.,Germany Lanstar,BS.1538.IQ,Lanstar, Cadishead,Manchester,.,Unit Lanstar,Cadishead,Manchest ed Kingdom er,.,united Kingdom 40

41 Annex 1: Monitoring Locations: 41

42 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

43 Annex 2: Atmospheric Emission Points

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

45 Annex 3: Quinn Cement 140 Accreditation