Annual Environmental Report 2015

Transcription

1 Annual Environmental Report 2015 For Woodland Products Ltd., Drumully, Emyvale, Co. Monaghan IPPC Reg. No. P By QED Engineering Ltd., M-TEK Building 1 Armagh Road Monaghan March 2016

2 Table of Contents 1. INTRODUCTION 2 2. SUMMARY INFORMATION Water Monitoring Emissions to Atmosphere Waste Management Resource Consumption Environmental Incidents Environmental Complaints ENVIRONMENTAL MANAGEMENT Schedule of Environmental Objectives & Targets Environmental Management Programme Report on EMP Proposal EMP proposal for Pollution Emissions Register Report on PER PER Proposal for LICENCE-SPECIFIC REPORTS Noise Monitoring Report Bund Testing Report (every 3 years) Tank and Pipeline Testing & Inspection Report Dry Filter Spraybooth & Bagfilter Dust Abatement/ 16 Treatment Systems Summary Report 4.5 Package Treatment System Assessment Report 16 1

3 1. Introduction Woodland Products Ltd. manufactures furniture at Drumully, Emyvale, Co. Monaghan. Woodlands Products was issued with an IPC licence on 23 rd April 1999 as they fell under Class of IPC Licensing The use of coating materials in processes with a capacity to use at least 10 tons per year of organic solvents. Since obtaining the IPC Licence the company has decreased the volume of organic solvent coating materials used at the site. This decrease has come around predominantly as the site has changed from solvent based paints to water based paints and also due to a downturn in the level of sales for the site. Until all environmental issues at the site are resolved, it is understood that the site can t surrender the licence, although they fall outside the category requiring a licence. Condition and Schedule 4(i) of the IPC licence requires that the company submit an Annual Environmental Report (AER), to include the following content: 1. Emissions to Atmosphere Summary 2. Dry Filter Spraybooth & Bagfilter Dust Abatement/Treatment Systems Summary Report. 3. Emissions to Surface Water Summary 4. Waste Management Report 5. Resource Consumption Summary 6. Complaints Summary 7. Schedule of Environmental Objectives & Targets 8. Environmental Management Programme (EMP) Report 9. Environmental Management Programme (EMP) Proposal 10. Pollution Emission Register (PER) Report 11. Pollution Emission Register (PER) Proposal 12. Noise Monitoring Report 13. Tank and Pipeline Testing & Inspection Report 14. Reported Incidents Summary 15. Bund Testing Report (every 3 years) 16. Package Treatment System Assessment Report The following AER is submitted to the Agency for approval. This AER was drawn up following the EPA Guidance Note for Annual Environmental Report, It covers the reporting period January to December Brief description of site activities Raw materials are delivered to site and stored. Wood is cut to size, veneered and trimmed. These panels are bored/routed to specification in the machine shop. Pieces are then assembled and taken to the polish room where the furniture is sanded, stained, base-coated, shaded and lacquered. The furniture is then sent to the fitting shop where glass, hinges, etc. are attached. Finished items are packaged, stored and eventually dispatched off site. Responsibility for Environmental Management The Managing Director, Mr. Harry Gillanders has the ultimate responsibility for environmental matters related to site activities. The Maintenance Manager has responsibility for the technical element of environmental management, e.g. maintaining dust extraction systems, monitoring points (water, air, etc.). In addition the office staff is responsible for maintenance of the IPPC public file and for the up-keep of some of the environmental records e.g. waste records. 2

4 2. Summary Information 2.1 Water Monitoring Surface Water discharge points i.e. Rain water run off from roofs and yard areas to the mountain river are required to be monitored quarterly for ph, Suspended Solids and COD. A visual inspection of these points for colouration and odour is also carried out, when there is water flow. The Agency s correspondence dated 11 th January 2006, ref M198/ap07ap.doc requires that quarterly water monitoring at two wells on site, the puraflo system and the river be carried out at Woodland Products. Subsequently, the Agency s correspondence dated the 17 th of January 2013 approved the cessation of monitoring of the Mountain Water River following the submission of a Hydrogeological Risk Assessment Report and a request for cessation of this monitoring based on the findings of the report. In 2015 surface water monitoring at Woodland Products was undertaken on the 27 th of May for emission points: SW1, SW2, SW3, SW4, SW7 and SW8. Monitoring of SW5 and SW6 was not carried out as there was no flow present. Monitoring was also carried out on the 27 th of October for surface water emission points: SW1, SW2, SW3, SW4, SW5, SW6, SW7 and SW8. Sampling was not carried out in the other quarters due to the lack of discharge from emission points on a number of site visits during these quarters. Surface Water Monitoring results for 2015 are as follows: 27/5/15 27/10/15 Location COD mg/l ph Suspended Solids mg/l COD mg/l ph Suspended Solids mg/l SW1 < < SW < SW < SW SW SW SW SW All surface water discharge monitoring results; for COD, Suspended solids and ph at the site were relatively low and not problematic during the two 2015 monitoring events. 3

5 Ground Water Monitoring results for 2015 are as follows: Parameter Units Landfill Well Production Well Landfill Well Production Well Landfill Well Production Well Landfill Well Production Well EC (Groundwater) 12/17/ /17/2015 9/30/2015 9/30/2015 6/23/2015 6/23/2015 5/6/2015 5/6/2015 Regulations 4th Quarter rd Quarter nd Quarter st Quarter 2015 Depth of Water below ground level m Topographic Level m Potentiometric Surface m ph ph units Conductivity us/cm Total Oxidised Nitrogen (TON) mg/ln <0.2 <0.2 <0.2 <0.2 <0.20 < <0.20 Total Phosphorus mg/lp <0.02 <0.02 <0.02 <0.02 < <0.020 <0.020 Chloride mg/l Ammonia mg/ln Suspended Solids mg/l 140 < < <5.0 Arsenic ug/l As 1.7 <1 <1 <1 <1.0 <1.0 1 < Barium ug/l Ba Boron ug/l B Cadmium ug/l Cd <0.08 <0.08 <0.08 <0.08 <0.080 <0.080 <0.080 < Chromium ug/l Cr <1.0 <1.0 < Copper ug/l Cu <1 9.1 <1 7.3 < Iron ug/l Fe <20 < <20 <20 < <20 Lead ug/l Pb <1 <1 <1 <1 <1.0 <1.0 <1.0 < Magnesium mg/l Mg Manganese ug/l Mn Nickel ug/l Ni 3.7 <1 <1 <1 <1.0 < < Selenium ug/l Se 1.4 <1 <1 < <1.0 Potassium mg/l K Zinc ug/l Zn As there are no limits set in the IPPC licence for groundwater, results are compared to the EC Groundwater Limit Values 2010, where available. Highlighted results indicate where the limit value has been exceeded, which shows slightly elevated results for Ammonia in the Landfill well. 4

6 Puraflo Monitoring results for 2015 are as follows: Parameter Units Puraflo System Puraflo System Puraflo System 17/12/15 30/09/15 23/06/15 Puraflo System 06/05/15 Limit Schedule 4th Quarter rd Quarter nd Quarter st Quarter 2015 ph ph units Conductivity us/cm Total Oxidised Nitrogen (TON) Mg/l No 2.7 < Total Phosphorus Mg/l P Chloride Mg/l Cl Ammonia Mg/l N Suspended Solids mg/l < <5.0 <5.0 Arsenic Ug/l As <1 <1 <1.0 <1 7.5 Barium Ug/l Ba Boron Ug/l B < < Cadmium Ug/l Cd <0.08 <0.08 <0.080 < Chromium Ug/l Cr <1.0 < Copper Ug/l Cu < Iron Ug/l Fe < <20 20 Lead Ug/l Pb 1.3 <1 <1.0 < Magnesium mg/l Mg Manganese Ug/l Mn Nickel Ug/l Ni 2.1 <1 <1.0 < Selenium Ug/l Se <1 <1 5 <1.0 Potassium Mg/l K Zinc Ug/l Zn Monitoring of the Puraflo system discharge shows variable concentrations of ammonia, with the most recent sample showing relatively low concentrations. Sampling since 2011 has shown lower concentrations compared with the higher levels detected in period, as shown in the following graph. 5

7 2.2 Emissions to Atmosphere Monitoring of air emissions from the site was carried out on 18/5/2015. Emission from Oil Burning Boiler EP1: 18/5/15 Emission from Wood Boiler EP2 (corrected to 11%): 18/5/15 6

8 Emission from Wood Boiler EP2 (corrected to 6%): 18/5/15 Emission from Spray Booth EP5: 18/5/15 Emission from Spray Booth EP13: 18/5/15 7

9 Emission from Spray Booth EP19: 18/5/15 All air emissions for the oil boiler and spray booths were low and within limit values, so not problematic. Emissions from the wood waste boiler are high and measures to reduce emissions by changing the settings of the boiler are ongoing by the site. 2.3 Waste Management Details EWC Waste Carrier Destination General Skip Waste Blue Dolphin Environmental Ltd. WFP/MN Cardboard Blue Dolphin Environmental Waste Wood & Sawdust Septic Tank Sludge Waste Glue Washwater Liquid Sealer/Lacquers Ltd. WFP/MN Indaver Ireland Ltd, Carranstown, Duleek, Co. Meath W Kincorragh, Smithborough, Co. Monaghan None Recycled in Wood Burning Boiler McElvaney s Waste & Recycling NWCPO Corcaghan, County Monaghan ENVA Ireland Ltd. 41/01 Smithstown Industrial Estate, Shanon, County Clare ENVA Ireland Ltd. 41/01 Smithstown Industrial Estate, Shanon, County Clare 8

10 Skip Waste There is one main skip on the site which is sent for incineration by Blue Dolphin Environmental Ltd. Details of skip waste disposed from in 2015 and previous years is presented in the following table. Period Weight (Tonnes) Total Tonnage Total Tonnage Total Tonnage Total Tonnage Total Tonnage The amount of waste disposed to landfill has decreased dramatically in recent years, due to better waste management practices at the site, including reducing waste at source, recycling and re-using, where possible, and also changes in waste treatment with a move away from disposal due to increasing landfill levy costs. In 2015 the volume of waste decreased by 20% on 2014 figures. This was due primarily to the fact that the skip was enclosed in a cage in 2015 to prevent unauthorised fly-tipping into it, which was occurring in the previous years. Cardboard Waste Cardboard waste has been segregated from general waste since 2003 and sent for recycling to Blue Dolphin Environmental Ltd. The amount of waste recycled to date: Period Weight (Tonnes) Total Tonnage Total Tonnage Total Tonnage Total Tonnage Total Tonnage Wood Waste All wood waste offcuts and sawdust extracted via the dust extraction system are burned in the solid fuel boiler. Hazardous Waste Septic Tank Sludge The sewerage system was not emptied in Liquid Sealer/Lacquers There were no liquid sealers or lacquers removed from the site in

11 Waste Glue Washwater There was no waste glue washwater removed from the site in Waste Oil There was no waste oil removed from the site in Resource Consumption Electricity Consumption in kwh Year Electricity Consumption in kwh , , , , , , , , , , , ,480 Electricity consumption increased by 21% in 2015 from 2014 figures. This was due to the fact that in 2015 the site worked full time (5 days per week) whereas in 2014 the site predominantly worked 3 days/week. 10

12 Heating Oil Consumption Year Heating Oil Consumption litres , , , , , , , , , , , ,947 Heating oil consumption increased 27% in 2015 from 2014 figures. 11

13 2.5 Environmental Incidents There have been no environmental incidents at the site in Environmental Complaints No complaints of an environmental nature have been issued to the company in the past year. A record file exists for the recording of environmental complaints, should any arise in the future. 3. Environmental Management 3.1 Schedule of Environmental Objectives & Targets OBJECTIVE 1 TARGET 1 AND IMPLEMENTATION DETAILS Improve the Puraflo Effluent Treatment System Measures to improve effluent treatment at the site will be investigated in terms of upgrading the existing system or connecting to the nearest town effluent treatment plant. RESPONSIBILITY: Harry Gillanders TIMEFRAME: On-going OBJECTIVE 2 TARGET 2 AND IMPLEMENTATION DETAILS RESPONSIBILITY: Harry Gillanders To ensure emissions from the wood and boilers are kept below the licence limits at all times The controls available for the wood boiler will be examined to ensure that emissions are kept below the licence limits, particularly for CO and NOx. TIMEFRAME: On-going OBJECTIVE 3 TARGET 3 AND IMPLEMENTATION DETAILS Improve the Dust Extraction System The dust extraction system requires upgrading and new bags are required on the filter system. RESPONSIBILITY: Harry Gillanders TIMEFRAME: On-going 12

14 3.2 Environmental Management Programme Report on EMP Proposal of Improve the Puraflo Effluent Treatment System The company continued to monitor the Puraflo Effluent Treatment System in 2015 and results were low on some occasions and higher on others. The loading on the treatment system has reduced in recent years also due to lower numbers of workers and occupants on the site. In 2015 the company got a number of wastewater treatment specialists to examine the system and recommend design upgrades. They also investigated the possibility of joining the public sewerage system and submitted an application it Irish Water in this regard and are awaiting a response on this. When all details are known and full costs available, the company can decide on the best measure to improve the puraflo effluent treatment system. 2. To ensure emissions from the boiler are kept below the licence limits at all times The boiler was monitored in 2015 and emissions were high. Measures to reduce the oxygen emissions to near 11% on the flue gases will be examined to ensure that emissions are kept below the licence limits. Further monitoring will be conducted in Apply for the surrender of the IPPC licence The company did not apply for a surrender of the licence in They are investigating measures to improve the puraflo system and when this is implemented and when funds are available, they will consider submitting a Surrender of Licence Application that will satisfy the Agency.. 13

15 3.2.2 EMP Proposal for 2015 The Environmental Management Program for 2015 is a continuation of that in 2014, with some inclusions. Environmental Management Program for Woodland Products Ltd OBJECTIVE 1 Improve the Puraflo Effluent Treatment System TARGET 1 AND IMPLEMENTATION DETAILS The company will endeavour to improve the operation of the Puraflo system at the site to ensure that it is providing effective wastewater treatment RESPONSIBILITY: Harry Gillanders TIMEFRAME: On-going OBJECTIVE 2 TARGET 2 AND IMPLEMENTATION DETAILS RESPONSIBILITY: Harry Gillanders To ensure emissions from the wood and oil boilers are kept below the licence limits at all times The controls available for the wood boiler will be examined to ensure that emissions are kept below the licence limits, particularly for CO and NOx. TIMEFRAME: On-going OBJECTIVE 3 TARGET 3 AND IMPLEMENTATION DETAILS RESPONSIBILITY: Harry Gillanders Upgrade the dust extraction system The dust extraction system requires upgrading and new bags are required on the filter system. Up to 10,000 will be spend on this system in 2015 to ensure that it is working effectively. TIMEFRAME: On-going 14

16 3.3 Pollution Emissions Register Report on PER 2015 The statistics for usage of solvent based materials and water based materials at the site for 2015 and previous years are provided in the table below. Date No. of products used Amount of solvent based products - litres VOC total - tonnes Amount of water based products litres Jan-Dec , ,990 Jan-Dec ,663 Jan-Dec ,173 Jan-Dec , ,150 Jan-Dec , ,732 Jan-Dec , ,445 Jan-Dec , ,279 Jan-Dec , ,925 Jan-Dec , ,516 Jan-Dec , ,654 Jan-Dec , ,355 Jan-Dec , ,895 Jan-Dec , ,799 Jan- Dec , ,850 Jan- Dec , ,532 Jan-Dec , , PER Proposal for Calculate the total tonnage of VOC utilised in 2016 and compare this total with previous year s figure to see if it is increasing or decreasing, and provide explanations for the increase or decrease. 4. Licence Specific Reports 4.1 Noise Monitoring Report A noise assessment of the site was undertaken in September 2015 and reported to the EPA. The noise levels at Woodland Products Ltd. are not excessive. All background noise readings at Noise Sensitive Locations are below the IPC Daytime limit of 55dBA. The 1/3 Octave Noise Readings taken at Noise Sensitive Locations and subjective determinations made on the site during monitoring show that there was no tonal or impulsive noise from the factory audible at the Noise Sensitive Locations. No complaints relating to noise have been issued to the company in the past year. 15

17 4.2 Bund Testing Report A Bund Integrity Assessment was carried out on all bunds at Woodland Products Ltd in January Three bunds were tested and two passed and one failed. The site has planned to line this bund and this work will be complete within the next month. When this work is complete the bund will be retested and a report issued. 4.3 Tank & Pipeline Inspection Report PC Drains has inspected the drains on site in Due to the nature of drains they could not test all that was required due to access problems. The site is awaiting a report from PC to state what was done and this will be reported on EDEN when it is available. 4.4 Dry Filter Spraybooth & Bagfilter Dust Abatement / Treatment Systems Summary Report Spray Booth Maintenance Dry back spray booth filters are changed regularly and the booths are hoovered out. The level of cleaning each spray booth receives is directly related to its usage. Some spray booths that are continuously used may be cleaned out weekly and others, which receive limited usage may be cleaned out every 2-3 weeks. A log of all spray booth maintenance is kept on-site. Dust Extraction System Cades Ltd., the supplier, service the dust extraction system. Maintenance personnel on site maintain the bag filters. A record of all maintenance is kept on site. The dust extraction system is undergoing a full overhaul and upgrade in Package Treatment System Assessment Report The company has brought out a service agreement with Anua for the maintenance of the Puraflo system. The system was inspected in May

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