ATTACHMENT No. E EMISSIONS TABLE OF CONTENTS E.1. Emissions to Atmosphere...2 E.2. Emissions to Surface Waters...6 E.3. Emissions to Sewer...8 E.4. Emissions to Ground...8 E.5. Noise Emissions...8 E - 1 of 50
E.1. E.1.1 Emissions to Atmosphere Boiler Emissions There are no boiler emissions from the site associated with the cement manufacturing process. E.1.2 Main Emissions A description of the main emissions to atmosphere is given in Tables E.1(ii). The chemical characteristics of the main emissions are given in Tables E.1(iii). The current IPC licensed main emission points at Irish Cement Ltd Platin (ICL Platin) are given in Table E.1 (refer also to Figure E.1). Raw Mill 1 and Coal Mill 1 are to be ducted in 2007 into the Kiln 1 stack in accordance with the Environmental Management Plan 2007/2008, submitted to the Agency as part of the 2006 Annual Environmental Report. Table E.1 Current Main Emission Points IPPC Licence Application Label Description A2-01 Kiln 1 (including Raw Mill 1 and Coal Mill 1 outlets after ducting) A2-02 Kiln 2, Raw Mill 2 A2-03 Coal Mill 2 A2-04 Cement Mill 1 A2-05 Cement Mill 2 and Separator A2-06 Cement Mill 3 and Separator A2-07 Kiln 2 Grate Cooler Kiln 1 is to be decommissioned approximately 2 weeks before Kiln 3 is commissioned. ICL Platin will inform the Agency in 2008 of the date for commissioning of Kiln 3. ICL Platin wishes to retain emission point A2-01 as an emission point for Raw Mill 1. Exhaust gases from the new Kiln 3 line may be used to dry limestone being milled for the production of CEM II cements in the existing Raw Mill 1. In this situation, it is proposed to vent the gas through the existing Kiln 1 chimney i.e. main emission point A2-01. With commissioning of Kiln 3 in late 2008 (Cement Mill 4 will be commissioned in summer 2008), the main emission points will be (refer also to Figure E.1): Table E.2 Future Main Emission Points IPPC Licence Application Label Description A2-01 Raw Mill 1 A2-02 Kiln 2, Raw Mill 2 A2-03 Coal Mill 2 A2-04 Cement Mill 1 A2-05 Cement Mill 2 and Separator E - 2 of 50
IPPC Licence Application Label Description A2-06 Cement Mill 3 and Separator A2-07 Kiln 2 Grate Cooler A2-08 Kiln 3/Bypass/Raw Mill /Coal Mill 3 A2-09 Kiln 3 Grate Cooler A2-10 Cement Mill 4 E.1.2.1 Main Emissions - Monitoring of Emissions to Atmosphere Table E.3 lists Kiln 1 monitoring results and compares them with IPC licence limits. Table E.3 Kiln 1 Monitoring Results 2006 Parameter Average Concentration (2006) (mg/nm³@10%o 2 ) IPC Licence Limits (mg/nm³@10%o 2 ) Particulates 3.5 120 NO x 1,227 1,800 SO 2 Raw Mill on SO 2 Raw Mill off 29* 1,500 29* 4,000 * SO 2 is measured quarterly in accordance with the requirements of IPC Licence Reg. No. P0030-02. Readings of data indicate zero emissions. A conservative approach is taken to calculate maximum potential SO 2 emissions using a figure of 10 ppm SO 2 at 10% O 2 (i.e. 29mg/Nm 3 @10%O 2 ). Table E.4 lists Kiln 2 monitoring results and compares them with IPC licence limits. Table E.4 Kiln 2 Monitoring Results 2006 Parameter Average Concentration (2006) (mg/nm³@10%o 2 ) IPC Licence Limits (mg/nm³@10%o 2 ) Particulates 29 100 NO x 1,265 1,800 SO 2 Refer to Table E.3 It is planned to commission Kiln 3 in late 2008. Table E.5 lists the monitoring results for the other main emission points monitored for particulates emissions. E - 3 of 50
Table E.5 Other Particulates Monitoring Results 2006 Source Average Concentration (mg/nm³) IPC Licence Limits (mg/nm³) Raw Mill 1 10 100 Coal Mill 1 62 100 Coal Mill 2 84 100 Cement Mill 1 16 100 Kiln 2 Grate Cooler 18 100 Cement Mill 2 and Separator 6 50 Cement Mill 3 and Separator 11 50 Table E.6 details monitoring frequency and methods used to monitor emissions from Kilns 1 and 2. Table E.6 Monitoring Frequency of Kiln 1 and Kiln 2 Parameter Monitoring Frequency Analysis Method / Technique NO X (as NO 2 ) Quarterly Flue gas analysis NO X (as NO 2 ) Continuous Non destructive IR/UV SO 2 Quarterly Flue gas analysis Particulates Quarterly Iso-kinetic/gravimetric Particulates Continuous Photometric CO Quarterly Flue gas analysis Table E.7 below details monitoring frequency and methods used to monitor particulates from the other main emission points. Table E.7 Parameter Monitoring of Particulates from Other Main Emission Sources Monitoring Frequency Analysis Method / Technique Particulates Quarterly Iso-Kinetic/Gravimetric E - 4 of 50
E.1.2.2 Main Emissions Description of Abatement Systems Particulate emissions from the following sources are/will be abated using electrostatic precipitators: A2-01 Kiln1/Coal Mill 1/Raw Mill 1 A2-02 Kiln 2, Raw Mill 2 A2-04 Cement Mill 1 A2-07 Kiln 2 Grate Cooler A2-09 Kiln 3 Grate Cooler Particulates emissions from the following sources are/will be abated using bag filters: A2-03 Coal Mill 2 A2-05 Cement Mill 2 and Separator A2-06 Cement Mill 3 and Separator A2-08 Kiln 3/Bypass/Raw Mill 3/Coal Mill 3 A2-10 Cement Mill 4 NO X emissions from Kilns 2 will be abated using selective non-catalytic reduction (SNCR). SNCR involves injecting aqueous ammonia into the kiln exhaust gas to reduce NO X to N 2. SNCR technology will be used to abate NO X emissions from Kiln 3 if required. Further information on the abatement systems for emissions to atmosphere is provided in Attachment No. F. E.1.3 Minor Emissions A minor emission is an emission, which on the basis of its concentration and mass emission is not considered environmentally significant. Therefore it is not classified as a main emission. Some relevant minor emission points (e.g. extract from transfer points on materials handling systems) are abated using bag filters. Minor emission points and the abatement systems employed are detailed in Table E.1(iv). Current minor emission points are shown in Figure E.2. Minor emission points associated with Kiln 3 are shown in Figure E.3. E.1.4 Fugitive Emissions Fugitive dust emissions can occur from operations on-site. Every effort is made to minimise such emissions. Dust management measures appropriate to modern cement manufacture are applied and are continually reviewed as part of the annual Environmental Management Plan for the site. All fugitive emission points are detailed in Table E.1(v). Fugitive emission locations are shown in Figure E.4. E - 5 of 50
E.1.5 Potential Emissions A potential emission point is an emission point that is not active under normal operations. Potential emissions and the malfunctions causing the emissions are identified in Table E.1(v). Potential emission sources are shown in Figure E.5. E.2. E.2.1 Emissions to Surface Waters Source of Emissions Details of all emissions to surface water are given Tables E.2(i) and (ii). A flow diagram of the surface and process water, domestic sewage effluent and groundwater conveyance is given in Figure E.6. The surface, process and groundwater conveyance system is shown in Figure E.7. The domestic sewage effluent conveyance system is shown in Figure E.8(A) and E.8(B). Management of process and surface water run-off on-site consists of a water collection system which delivers process and surface water into storm balancing tanks followed by sedimentation/settlement tanks, both of which are used to reduce the levels of suspended solids. Deep well water from the quarry is managed through continuous pumping of groundwater from the deep well in the quarry floor. It does not require any treatment. Domestic effluent is treated in a purpose built package waste water treatment plant on-site. Treated Process and Surface water run-off discharges from the sedimentation tank and confluences with deep well water from the quarry and treated domestic effluent to form the final treated effluent which discharges to the outfall point into the River Nanny via a designated pipeline. The treated final effluent is discharged through 2,637m of 610 mm pipeline which runs underground from the cement factory to the outfall point into the receiving waters of the River Nanny. The outfall pipe runs under roads and agricultural land and outfalls into the River Nanny south of the factory, just off the R150 regional road. The current IPC licensed emission points are as follows: Emission Point W1 W3 W4 Emission Type Treated process and surface water effluent from storm balancing and settlement tanks Treated domestic sewage effluent from wastewater treatment plant Combined effluent streams from W1, treated process and surface water effluent, W3, treated domestic effluent and potable excess quarry groundwater It is envisaged that the updated IPPC Licence will contain 1 licensed emission point to surface water, SW1 i.e. current licensed emission point W4. E - 6 of 50
E.2.2 Emissions to Surface Water Monitoring Results The total mass emissions of licensed emission parameters to surface water are estimated from monitoring results and are given in Table E.8. Table E.8 SW1 (current IPC Licensed Emission Point W4) Surface Water Emissions Monitoring Results 2006 Parameter Biochemical Oxygen Demand 6,676 Suspended solids 51,497 Cu 38 Pb 76 Sn 38 Average ph 7.6 Average flowrate (m 3 /day) 10,451 Total Mass Emission (Kg) The Table E.9 below details monitoring frequency and methods used to monitor emissions from W4. Table E.9 Parameter Monitoring of Emission Parameters from SW1 (current IPC Licensed Emission Point W4) Monitoring Frequency Analysis Method / Technique Outlet flow Continuous On-line flowmeters with recorders ph Monthly ph electrode Suspended solids Monthly Gravimetric method Total Cu Biannually Atomic absorption spectroscopy Total Pb Biannually Atomic absorption spectroscopy Total Zn Biannually Atomic absorption spectroscopy Biochemical Oxygen Demand Note that: Monthly Toxicity testing is carried out on instruction from the Agency Standard methods Mineral oils are also monitored in accordance with IPC Licence requirements. E - 7 of 50
E.3. E.3.1 Emissions to Sewer Source of Emissions Foul water effluent from the facility is not discharged to the public sewer. Foul water is comprised of domestic wastewater and utilities wastewater from laboratories. Foul effluent from the works is discharged through a wastewater treatment package plant and thence to the common effluent discharge pipe for discharge to the River Nanny. E.3.2 Characteristics of Foul Water Emissions The wastewater treatment system generates approximately 38 m³ per day (average from 2006 Annual Environmental Report) with a BOD loading of approximately 23.6 mg/l. E.4. Emissions to Ground There are no direct emissions to ground from the site. E.5. Noise Emissions The details of the significant noise sources in terms of sound power level are given in the Noise Summary Sheets Tables E.5 (i). Noise sources on-site are shown in Figure E.9. E - 8 of 50
IPPC Licence Application Tables E.1(i) E.1(ii) E.1(iii) E.1(iv) E.1(v) E.2(i) E.2(ii) E.3(i) E.3(ii) E.4(i) E.4(ii) E.5(i) E - 9 of 50
Table E.1 (i) BOILER EMISSIONS TO ATMOSPHERE (1 Page for each emission point) Emission Point: Emission Point Ref. N o : Not Applicable Location: Grid Ref. (12 digit, 6E,6N): Vent Details Diameter: Height above Ground(m): Date of commencement of emission: Characteristics of Emission: Boiler rating Steam Output: Thermal Input: kg/hr MW Boiler fuel Type: Maximum rate at which fuel is burned kg/hr % sulphur content: NOx mg/nm 3 0 o C. 3% O 2 (Liquid or Gas), 6% O 2 (Solid Fuel) Maximum volume* of emission m 3 /hr 0 o C, 3 % O 2 (liquid or gas), 6 % O 2 (solid fuel) Temperature o C(max) o C(min) o C(avg) * Volume flow limits for emissions to atmosphere shall be based on Normal conditions of temperature and pressure, (i.e. 0 o C,101.3kPa), dry gas; 3% oxygen for liquid and gas fuels; 6% oxygen for solid fuels. (i) Period or periods during which emissions are made, or are to be made, including daily or seasonal variations (start-up/shutdown to be included): Periods of Emission (avg) min/hr hr/day day/yr E - 10 of 50
TABLE E.1(ii) MAIN EMISSIONS TO ATMOSPHERE (1 Page for each emission point) Emission Point Ref. N o : A2-01 Source of Emission: Kiln 1, Raw Mill 1, Coal Mill 1 (ICL Plant No. 14601). Raw Mill 1 and Coal Mill 1 are being ducted into Kiln 1. Location: Kiln 1 Stack in front of building 185 Grid Ref. (12 digit, 6E,6N): 306520E 271754N Vent Details Diameter: 2.38m Height above Ground (m): 98.01m Date of commencement: 1972 Characteristics of Emission: (i) Volume to be emitted: Average/day 2.832 x 10 6 Nm 3 /d Maximum/day 4.56 x 10 6 Nm 3 /d Maximum rate/hour 190,000 Nm 3 /h Min efflux velocity 9.0 m.sec -1 (ii) Other factors Temperature 216 o C(max) 110 o C(min) 121 o C(avg) For Combustion Sources: Volume terms expressed as: wet. dry 10%O 2 (iii) Period or periods during which emissions are made, or are to be made, including daily or seasonal variations (start-up /shutdown to be included): Periods of Emission (avg) 60 min/hr 24 hr/day 365 day/yr E - 11 of 50
TABLE E.1(ii) MAIN EMISSIONS TO ATMOSPHERE (1 Page for each emission point) Emission Point Ref. N o : A2-01 Source of Emission: Raw Mill 1. Raw Mill 1 ducted to Kiln 1 chimney. ICL Platin wishes to retain emission point A2-01 as an emission point for Raw Mill 1. Exhaust gases from the new Kiln 3 line may be used to dry limestone being milled for the production of CEM II cements in the existing Raw Mill 1. In this situation, it is proposed to vent the gas at through the existing Kiln 1 chimney i.e. main emission point A2-01. Location: Kiln 1 Stack in front of Building 185 Grid Ref. (12 digit, 6E,6N): 306520E 271754N Vent Details Diameter: 2.38m Height above Ground (m): 98.01m Date of commencement: Post 2008 Characteristics of Emission: (i) Volume to be emitted: Average/day 1.08 x 10 6 Nm 3 /d Maximum/day 1.18 x 10 6 Nm 3 /d Maximum rate/hour 49,000 Nm 3 /h Min efflux velocity Ask Una m.sec -1 (ii) Other factors Temperature 118 o C(max) 76 o C(min) 87 o C(avg) For Combustion Sources: Volume terms expressed as: wet. dry 10%O 2 (iii) Period or periods during which emissions are made, or are to be made, including daily or seasonal variations (start-up /shutdown to be included): Periods of Emission (avg) 60 min/hr 24 hr/day 365 day/yr E - 12 of 50
TABLE E.1(ii) MAIN EMISSIONS TO ATMOSPHERE (1 Page for each emission point) Emission Point Ref. N o : A2-02 Source of Emission: Kiln 2, Raw Mill 2 (ICL Plant No. 24601) Location: Grid Ref. (12 digit, 6E,6N): Kiln 2 Stack 306490E 271801N Vent Details Diameter: 3.70 Height above Ground(m): 103.04 Date of commencement: 1977 Characteristics of Emission: (i) Volume to be emitted: Average/day 7.76424 x 10 6 Nm 3 /d Maximum/day 9.6 x 10 6 Nm 3 /d Maximum rate/hour 400,000 Nm 3 /h Min efflux velocity 8.9 m.sec -1 (ii) Other factors Temperature 148 o C(max) 103 o C(min) 121 o C(avg) For Combustion Sources: Volume terms expressed as : wet. dry @ 10 %O 2 (iii) Period or periods during which emissions are made, or are to be made, including daily or seasonal variations (start-up /shutdown to be included): Periods of Emission (avg) 60 min/hr 24 hr/day 365 day/yr E - 13 of 50
TABLE E.1(ii) MAIN EMISSIONS TO ATMOSPHERE (1 Page for each emission point) Emission Point Ref. N o : A2-03 Source of Emission: Coal Mill 2 (ICL Plant No. 22676) Location: Beside building 135 Grid Ref. (12 digit, 6E,6N): 306599E 271737N Vent Details Diameter: 1.0 Height above Ground(m): 48.09 Date of commencement: 1982 Characteristics of Emission: (i) Volume to be emitted: Average/day 496,296 Nm 3 /d Maximum/day 744,000 Nm 3 /d Maximum rate/hour 31,000 Nm 3 /h Min efflux velocity 9.2 m.sec -1 (ii) Other factors Temperature 85 o C(max) 74 o C(min) 81 o C(avg) For Combustion Sources: Volume terms expressed as : wet. dry @ 10 %O 2 (iii) Period or periods during which emissions are made, or are to be made, including daily or seasonal variations (start-up /shutdown to be included): Periods of Emission (avg) 60 min/hr 24 hr/day 365 day/yr E - 14 of 50
TABLE E.1(ii) MAIN EMISSIONS TO ATMOSPHERE (1 Page for each emission point) Emission Point Ref. N o : A2-04 Source of Emission: Cement Mill 1 Electrostatic Precipitator (ICL Plant No. 15222) Location: Building No. 152 Grid Ref. (12 digit, 6E,6N): 306806E 271834N Vent Details Diameter: 0.704 Height above Ground(m): 28.64 Date of commencement: 1972 Characteristics of Emission: (i) Volume to be emitted: Average/day 376,032 Nm 3 /d Maximum/day 444,000 Nm 3 /d Maximum rate/hour 18,500 Nm 3 /h Min efflux velocity 11.1 m.sec -1 (ii) Other factors Temperature 110 o C(max) 93 o C(min) 101 o C(avg) For Combustion Sources: Volume terms expressed as : wet @ actual % O 2 dry (iii) Period or periods during which emissions are made, or are to be made, including daily or seasonal variations (start-up /shutdown to be included): Periods of Emission (avg) 60 min/hr 24 hr/day 365 day/yr E - 15 of 50
TABLE E.1(ii) MAIN EMISSIONS TO ATMOSPHERE (1 Page for each emission point) Emission Point Ref. N o : A2-05 Source of Emission: Cement Mill 2 and Separator Bag Filter (ICL Plant No. 25422) Location: Building No. 254 Grid Ref. (12 digit, 6E,6N): 306791E 271840N Vent Details Diameter: 1.90 Height above Ground(m): 34.82 Date of commencement: 1978 Characteristics of Emission: (i) Volume to be emitted: Average/day 2.02584 x 10 6 Nm 3 /d Maximum/day 2.88 x 10 6 Nm 3 /d Maximum rate/hour 120,000 Nm 3 /h Min efflux velocity 8.8 m.sec -1 (ii) Other factors Temperature 110 o C(max) 69 o C(min) 85 o C(avg) For Combustion Sources: Volume terms expressed as : : wet @ actual % O 2 dry (iii) Period or periods during which emissions are made, or are to be made, including daily or seasonal variations (start-up /shutdown to be included): Periods of Emission (avg) 60 min/hr 24 hr/day 365 day/yr E - 16 of 50
TABLE E.1(ii) MAIN EMISSIONS TO ATMOSPHERE (1 Page for each emission point) Emission Point Ref. N o : A2-06 Source of Emission: Cement Mill 3 and Separator Bag Filter (ICL Plant No. 35622) Location: Grid Ref. (12 digit, 6E,6N): Adjacent to building No. 356 (Northside) 306761E 271881N Vent Details Diameter: 1.988 Height above Ground(m): 26.35 Date of commencement: 1990 Characteristics of Emission: (i) Volume to be emitted: Average/day 2.226 x 10 6 Nm 3 /d Maximum rate/hour 135,000 Nm 3 /h (ii) Other factors Maximum/day 3.24 x 10 6 Nm 3 /d Min efflux velocity 15.5 m.sec -1 Temperature 104 o C(max) 68 o C(min) 85 o C(avg) For Combustion Sources: Volume terms expressed as : wet @ actual % O 2 dry (iii) Period or periods during which emissions are made, or are to be made, including daily or seasonal variations (start-up /shutdown to be included): Periods of Emission (avg) 60 min/hr 24 hr/day 365 day/yr E - 17 of 50
TABLE E.1(ii) MAIN EMISSIONS TO ATMOSPHERE (1 Page for each emission point) Emission Point Ref. N o : A2-07 Source of Emission: Kiln 2 Grate Cooler (ICL Plant No. 24560) Location: East of Kiln 2 Grid Ref. (12 digit, 6E,6N): 306722E 271867N Vent Details Diameter: 3.55 Height above Ground(m): 30.43 Date of commencement: 1998 Characteristics of Emission: (i) Volume to be emitted: Average/day 3.73956 x 10 6 Nm 3 /d Maximum rate/hour 210,000 Nm 3 /h (ii) Other factors Maximum/day 5.04 x 10 6 Nm 3 /d Min efflux velocity 15.9 m.sec -1 Temperature 280 o C(max) 193 o C(min) 250 o C(avg) For Combustion Sources: Volume terms expressed as : : wet @ actual % O 2 dry (iii) Period or periods during which emissions are made, or are to be made, including daily or seasonal variations (start-up /shutdown to be included): Periods of Emission (avg) 60 min/hr 24 hr/day 365 day/yr E - 18 of 50
TABLE E.1(ii) MAIN EMISSIONS TO ATMOSPHERE (1 Page for each emission point) Emission Point Ref. N o : A2-08 Source of Emission: Location: Grid Ref. (12 digit, 6E,6N): Kiln 3, Raw Mill 3, Coal Mill 3, Kiln 3 By-pass Kiln 3 stack 306603E 271675N Vent Details Diameter: 3.75 Height above Ground(m): 123 Date of commencement: Planned for late 2008 Characteristics of Emission: (i) Volume to be emitted: Average/day 9.512616x10 6 Maximum/day 9.84 x 10 6 Nm 3 /d Nm 3 /d Maximum rate/hour 410,000 Nm 3 /h Min efflux velocity 12 m.sec -1 (ii) Other factors Temperature 194 o C(max) 90 o C(min) 108 o C(avg) For Combustion Sources: Volume terms expressed as : wet. dry 10%O 2 (iii) Period or periods during which emissions are made, or are to be made, including daily or seasonal variations (start-up /shutdown to be included): Periods of Emission (avg) 60 min/hr 24 hr/day 365 day/yr E - 19 of 50
TABLE E.1(ii) MAIN EMISSIONS TO ATMOSPHERE (1 Page for each emission point) Emission Point Ref. N o : A2-09 Source of Emission: Location: Grid Ref. (12 digit, 6E,6N): Kiln 3 Grate Cooler Kiln 3 Grate Cooler stack 306707E 271707N Vent Details Diameter: 3.0 Height above Ground(m): 35.0 Date of commencement: Planned for late 2008 Characteristics of Emission: (i) Volume to be emitted: Average/day 3.816288 x10 6 Maximum/day 5.26 x 10 6 Nm 3 /d Nm 3 /d Maximum rate/hour 219,000Nm 3 /h Min efflux velocity 12.8 m.sec -1 (ii) Other factors Temperature 320 o C(max) 190 o C(min) 317 o C(avg) For Combustion Sources: Volume terms expressed as : wet @ actual % O 2 dry (iii) Period or periods during which emissions are made, or are to be made, including daily or seasonal variations (start-up /shutdown to be included): Periods of Emission (avg) 60 min/hr 24 hr/day 365 day/yr E - 20 of 50
TABLE E.1(ii) MAIN EMISSIONS TO ATMOSPHERE (1 Page for each emission point) Emission Point Ref. N o : A2-10 Source of Emission: Location: Grid Ref. (12 digit, 6E,6N): Cement Mill 4 Bag Filter Cement Mill 4 Stack 306802E 271928N Vent Details Diameter: 2.0 Height above Ground(m): 39 Date of commencement: Planned for summer 2008 Characteristics of Emission: (i) Volume to be emitted: Average/day 2.64 x10 6 Maximum/day 2.64 x 10 6 Nm 3 /d Nm 3 /d Maximum rate/hour 110,000 Nm 3 /h Min efflux velocity 11.1 m.sec -1 (ii) Other factors Temperature 130 o C(max) 70 o C(min) 105 o C(avg) For Combustion Sources: Volume terms expressed as : wet @ actual % O 2 dry (iii) Period or periods during which emissions are made, or are to be made, including daily or seasonal variations (start-up /shutdown to be included): Periods of Emission (avg) 60 min/hr 24 hr/day 365 day/yr E - 21 of 50
TABLE E.1(iii): MAIN EMISSIONS TO ATMOSPHERE - Chemical characteristics of the emission (1 table per emission point) Emission Point Reference Number: A2-01 (Current) Kiln 1 (including Raw Mill 1 and Coal Mill 1 outlets after ducting) Parameter Prior to treatment (1) Brief As discharged (1) mg/nm 3 kg/h description mg/nm 3 kg/h. kg/year Avg Max Avg Max of treatment Avg. Max Avg. Max Avg. Max Particulates 40357 40357 4762 7668 Exhaust gases are cooled by a Conditioning Tower and cleaned by an Electrostatic Precipitator. Type: F.L. Smidth 2FAA-363636-6080-1 Installed: 1971 ca Conditioning tower added in 2001. 5.9 50 0.699 9.5 6127 83,220 NO X 1233 1800 145 342 None 1233 1800 145 252 1.3 x10 6 2.2x10 6 SO X 29 750 3.4 143 Absorption occurs in the preheater / rawmill 29 750 3.4 143 29784 1.2 x10 6 1. Concentrations should be based on Normal conditions of temperature and pressure, (i.e. 0 o C,101.3kPa). Wet/dry should be the same as given in Table E.1(ii) unless clearly stated otherwise. E - 22 of 50
TABLE E.1(iii): MAIN EMISSIONS TO ATMOSPHERE - Chemical characteristics of the emission (1 table per emission point) Emission Point Reference Number: A2-01(Future) Raw Mill 1 ICL Platin wishes to retain emission point A2-01 as an emission point for Raw Mill 1. Exhaust gases from the new Kiln 3 line may be used to dry limestone being milled for the production of CEM II cements in the existing Raw Mill 1. In this situation, it is proposed to vent the gas at through the existing Kiln 1 chimney i.e. main emission point A2-01. Parameter Prior to treatment (1) Brief As discharged (1) mg/nm 3 kg/h description mg/nm 3 kg/h. kg/year Avg Max Avg Max of treatment Avg. Max Avg. Max Avg. Max Particulates 60,000 60,000 270 2940 Exhaust gases cleaned by an Electrostatic Precipitator. Type: F.L. Smidth 2FAA-363636-6080-1 Installed: 1971 ca 19 50 0.855 2.45 7,490 21,462 NO X 1267 1800 57 88 Lower NO X precalciner kiln and SNCR SO X 29 400 1.3 19.6 Absorption occurs in the preheater / rawmill 750 1300 33.8 63.7 296,088 558,012 29 400 1.3 19.6 11,388 171,696 1. Concentrations should be based on Normal conditions of temperature and pressure, (i.e. 0 o C,101.3kPa). Wet/dry should be the same as given in Table E.1(ii) unless clearly stated otherwise. E - 23 of 50
TABLE E.1(iii): MAIN EMISSIONS TO ATMOSPHERE - Chemical characteristics of the emission (1 table per emission point) Emission Point Reference Number: A2-02 - Kiln 2, Raw Mill 2 (ICL Plant No. 24601) Parameter Prior to treatment (1) Brief As discharged (1) mg/nm 3 kg/h description mg/nm 3 kg/h. kg/year Avg Max Avg Max of treatment Avg Max Avg Max Avg Max Particulates 52950 52950 17130 21180 Exhaust gases are cleaned by electrostatic precipitator. 24.2 50 7.8 20 68,489 175,200 Type: F.L. Smidth FAA-404040-15090-1 Installed: 1977 Electrostatic Precipitator extended in 2007. NO X 1267 1800 410 720 Selective Non Catalytic Reduction in the Preheater Tower Installed 2007 SO X 29 750 9.4 300 Absorption occurs in the preheater / rawmill 750 1000 243 400 2.1 x10 6 3.5x10 6 29 750 9.4 300 29784 2.6 x10 6 1. Concentrations should be based on Normal conditions of temperature and pressure, (i.e. 0 o C,101.3kPa). Wet/dry should be the same as given in Table E.1(ii) unless clearly stated otherwise. E - 24 of 50
TABLE E.1(iii): MAIN EMISSIONS TO ATMOSPHERE - Chemical characteristics of the emission (1 table per emission point) Emission Point Reference Number: A2-03 - Coal Mill 2 (ICL Plant No. 22676) Parameter Prior to treatment (1) Brief As discharged (1) mg/nm 3 kg/h description mg/nm 3 kg/h. kg/year Avg Max Avg Max of treatment Avg Max Avg Max Avg Max Particulates 60000 60000 940 1110 Exhaust gases are cleaned by a bag filter. 10 50 0.207 1.55 1,812 13,578 Type: F.L. Smidth Installed: An Electrostatic Precipitator was originally installed in 1983. This was replaced by a Bag Filter in 2007. NO X 1267 1800 26.2 55.8 Selective Non Catalytic Reduction in the Preheater Tower Installed 2007 SO X 29 750 0.6 23.3 Absorption occurs in the preheater / rawmill 750 1000 15.5 31.0 135780 271560 29 750 0.6 23.3 5256 203,670 1. Concentrations should be based on Normal conditions of temperature and pressure, (i.e. 0 o C,101.3kPa). Wet/dry should be the same as given in Table E.1(ii) unless clearly stated otherwise. E - 25 of 50
TABLE E.1(iii): MAIN EMISSIONS TO ATMOSPHERE - Chemical characteristics of the emission (1 table per emission point) Emission Point Reference Number: A2-04 - Cement Mill 1 Electrostatic Precipitator (ICL Plant No. 15222) Parameter Prior to treatment (1) Brief As discharged (1) mg/nm 3 kg/h description mg/nm 3 kg/h. kg/year Avg Max Avg Max of treatment Avg Max Avg Max Avg Max Particulates 60000 60000 940 1110 Exhaust gases are cleaned by electrostatic precipitator. 20.6 75 0.323 1 2826 12,155 Type: F.L. Smidth FAB-7100F Installed: In 1972 Cement Mill 1 Electrostatic Precipitator was installed. In 1988 a High Efficiency Separator and Bag Filter were installed. This Bag Filter is a minor emission point. 1. Concentrations should be based on Normal conditions of temperature and pressure, (i.e. 0 o C,101.3kPa). Wet/dry should be the same as given in Table E.1(ii) unless clearly stated otherwise. E - 26 of 50
TABLE E.1(iii): MAIN EMISSIONS TO ATMOSPHERE - Chemical characteristics of the emission (1 table per emission point) Emission Point Reference Number: A2-05 - Cement Mill 2 Bag Filter (ICL Plant No. 25422) Parameter Prior to treatment (1) Brief As discharged (1) mg/nm 3 kg/h description mg/nm 3 kg/h. kg/year Avg Max Avg Max of treatment Avg Max Avg Max Avg Max Particulates 60000 6000 5065 7200 Exhaust gases are cleaned by air electrostatic precipitator/bag filter. Installed: In 1978 Cement Mil 2 and an Electrostatic Precipitator were installed. In 1998 a High Efficiency Separator and Bag Filter were installed. Since then the gases from the ESP are ducted into the High Efficiency Separator and Bag Filter. 14.3 50 1.203 6 10,538 52,560 1. Concentrations should be based on Normal conditions of temperature and pressure, (i.e. 0 o C,101.3kPa). Wet/dry should be the same as given in Table E.1(ii) unless clearly stated otherwise. E - 27 of 50
TABLE E.1(iii): MAIN EMISSIONS TO ATMOSPHERE - Chemical characteristics of the emission (1 table per emission point) Emission Point Reference Number: A2-06 - Cement Mill 3 Bag Filter (ICL Plant No. 35622) Parameter Prior to treatment (1) Brief As discharged (1) mg/nm 3 kg/h description mg/nm 3 kg/h. kg/year Avg Max Avg Max of treatment Avg Max Avg Max Avg Max Particulates 60000 60000 5565 8100 Exhaust gases are cleaned by a bag filter. Type: Redacam bag filter BI-GET 2DP Installed: In 1978 Cement Mill 3 and an Electrostatic Precipitator were installed. In 1990 a High Efficiency Separator and Bag Filter were installed. Gases from the ESP are now ducted into the High Efficiency Separator and Bag Filter. 25.4 50 2.352 6.75 20,605 59,130 1. Concentrations should be based on Normal conditions of temperature and pressure, (i.e. 0 o C,101.3kPa). Wet/dry should be the same as given in Table E.1(ii) unless clearly stated otherwise. E - 28 of 50
TABLE E.1(iii): MAIN EMISSIONS TO ATMOSPHERE - Chemical characteristics of the emission (1 table per emission point) Emission Point Reference Number: A2-07 - Kiln 2 Grate Cooler (ICL Plant No. 24560) Parameter Prior to treatment (1) Brief As discharged (1) mg/nm 3 kg/h description mg/nm 3 kg/h. kg/year Avg Max Avg Max of treatment Avg Max Avg Max Avg Max Particulates 60000 60000 9349 12600 Exhaust gases are cleaned by an Electrostatic Precipitator 17.3 100 2.698 21 23,635 183,960 Installed: 1998 1. Concentrations should be based on Normal conditions of temperature and pressure, (i.e. 0 o C,101.3kPa). Wet/dry should be the same as given in Table E.1(ii) unless clearly stated otherwise. E - 29 of 50
TABLE E.1(iii): MAIN EMISSIONS TO ATMOSPHERE - Chemical characteristics of the emission (1 table per emission point) Emission Point Reference Number: A2-08 - Kiln 3, Raw Mill 3, Coal Mill 3 and Kiln 3 by-pass Parameter Prior to treatment (1) Brief As discharged (1) mg/nm 3 kg/h description mg/nm 3 kg/h. kg/year Avg Max Avg Max of treatment Avg Max Avg Max Avg Max Particulates 97561 97561 38669 40000 Exhaust gases are cleaned by a bag filter. NO X 1267 1800 502 738 Lower NO X Precalciner Kiln and SNCR Planned for late 2008 SO X 29 400 11.5 164 Absorption occurs in the preheater / rawmill 10 30 4.0 12.3 34721 107748 750 1300 297 533 2.6 x10 6 4.7 x10 6 29 400 11.5 164 100740 1.4 x10 6 1. Concentrations should be based on Normal conditions of temperature and pressure, (i.e. 0 o C,101.3kPa). Wet/dry should be the same as given in Table E.1(ii) unless clearly stated otherwise. E - 30 of 50
TABLE E.1(iii): MAIN EMISSIONS TO ATMOSPHERE - Chemical characteristics of the emission (1 table per emission point) Emission Point Reference Number: A2-09 - Kiln 3 Grate Cooler Parameter Prior to treatment (1) Brief As discharged (1) mg/nm 3 kg/h description mg/nm 3 kg/h. kg/year Avg Max Avg Max of treatment Avg Max Avg Max Avg Max Particulates 60000 60000 9541 13140 Exhaust gases are cleaned by a bag filter. 10 30 1.6 6.6 13929 57553 1. Concentrations should be based on Normal conditions of temperature and pressure, (i.e. 0 o C,101.3kPa). Wet/dry should be the same as given in Table E.1(ii) unless clearly stated otherwise E - 31 of 50
TABLE E.1(iii): MAIN EMISSIONS TO ATMOSPHERE - Chemical characteristics of the emission (1 table per emission point) Emission Point Reference Number: A2-10 - Cement Mill 4 Parameter Prior to treatment (1) Brief As discharged (1) mg/nm 3 kg/h description mg/nm 3 kg/h. kg/year Avg Max Avg Max of treatment Avg Max Avg Max Avg Max Particulates 60000 60000 6600 6600 Exhaust gases are cleaned by a bag filter. 10 30 1.1 3.3 9636 28908 1. Concentrations should be based on Normal conditions of temperature and pressure, (i.e. 0 o C,101.3kPa). Wet/dry should be the same as given in Table E.1(ii) unless clearly stated otherwise. E - 32 of 50
TABLE E.1(iv): EMISSIONS TO ATMOSPHERE - Minor atmospheric emissions Emission point Description Emission details 1 Abatement system employed Reference Numbers material mg/nm 3 Wet (2) kg/h. kg/year A3-1 Limestone Crusher Limestone 50 2.1 8188 Bag Filter A3-2 Mansfield Crusher Limestone/ 50 0.5 3460 Bag Filter Shale A3-3 Old Shale crusher Shale 50 1.0 4470 Bag Filter A3-4 Homogenising Raw Meal 50 1.8 13920 Bag Filter A3-5 Homogenising Silo DCE filter Raw Meal 50 0 0 Bag Filter (opposite 13568) Stand-by A3-6 Raw Mill 1 Fluxo Raw Meal 50 0.4 2830 Bag Filter A3-7 Kiln 2 Homogenising silo Raw Meal 50 Bag Filter Intensive filter 1.1 8831 A3-8 Kiln 1 feed (Redundant) Raw Meal - - - - A3-9 Kiln No 1 Cooling tower Raw Meal 50 0.4 3165 Bag Filter A3-10 Clinker drag chain (5thfloor) Clinker 50 0.2 1076 Bag Filter A3-11 Road Clinker Hopper Clinker 50 0.5 3571 Bag Filter A3-12 Clinker from silo's 1.2&3. Clinker 50 Bag Filter (Building 48 5th floor) 0.3 2108 A3-13 Silo 2 3rd 48. 5th Floor Clinker Clinker 50 Bag Filter to mills Drag Chain 0.3 2108 A3-14 CM1 Fluxo Cement 50 0.5 3898 Bag Filter A3-15 CM 1 Sepax Seperator Cement 50 0.3 2031 Bag Filter A3-16 Cement Mill 1 Additive Raw Meal 50 0.1 1029 Bag Filter A3-17 New Clinker bin feed silo Clinker 50 0.1 1004 Bag Filter A3-18 Fine Coal Hopper Kiln 1 Coal 50 0.2 1503 Bag Filter A3-19 Cement Transport Screws Cement 50 Bag Filter Tunnel 0.4 2796 A3-20 Rail Bulk Loading Cement 50 0.2 134 Bag Filter A3-21 Rail Bulk Loading Cement 50 0.2 134 Bag Filter A3-22 Rail Bulk Silo (Top) Cement 50 0.2 126 Bag Filter A3-23 Rail Bulk Loading Cement 50 0.2 149 Bag Filter A3-24 Shale Crusher (Replaced 12521 Shale 50 0.6 2765 Bag Filter Old) A3-25 Raw mill 2 Elevator Raw Meal 50 0.1 863 Bag Filter E - 33 of 50
Emission point Description Emission details 1 Abatement system employed Reference Numbers material mg/nm 3 Wet (2) kg/h. kg/year A3-26 Kiln 2 feed 5th floor Raw Meal 50 0.4 3062 Bag Filter A3-27 k2 Preheating Tower 2nd floor Raw Meal 50 0.3 1963 Bag Filter back end A3-28 Kiln 2 Preheating tower 3rd floor Raw Meal 50 0.3 1963 Bag Filter A3-29 Kiln 2 Preheating tower 6th floor Raw Meal 50 0.3 2343 Bag Filter A3-30 Kiln 2 Feed ground floor Raw Meal 50 0.4 2826 Bag Filter A3-31 Kiln 2 Grate Cooler (North) Clinker 50 0.5 4004 Bag Filter A3-32 kiln 2 Grate Cooler (South) Clinker 50 0.5 4004 Bag Filter A3-33 Unassigned - - - - - A3-34 Clinker to Silo 1 (DCE Building Clinker 50 0.2 1255 Bag Filter 48 5th Floor) A3-35 Clinker Silo 4 (top of silo) Clinker 50 0.6 4589 Bag Filter A3-36 Clinker Silo 5 (top of silo) Clinker 50 0.2 1255 Bag Filter A3-37 Clinker Silo 6 (top of silo) Clinker 50 0.2 1255 Bag Filter A3-38 Clinker 7 (top of Silo) Clinker 50 0.2 1255 Bag Filter A3-39 Clinker to silo's (top) Clinker 50 0.2 1255 Bag Filter A3-40 Clinker Transport to silo 1 (DCE Clinker 50 0.2 1255 Bag Filter Building 48 5th Floor) A3-41 Clinker to mills Elevator Clinker 50 0.8 6053 Bag Filter A3-42 Clinker feed Hopper CM1 Clinker/ 50 0.5 3650 Bag Filter Gypsum A3-43 Clinker feed Hopper CM2 (Top Clinker/ 50 0.5 3177 Bag Filter Build) Gypsum A3-44 Clinker feed Hopper CM3 Clinker/ 50 0.5 3213 Bag Filter Gypsum A3-45 Clinker silo's 1.2&3. Btm Clinker 50 3.0 21510 Bag Filter A3-46 CM2 Pneumex Pump Cement 50 0.3 2151 Bag Filter A3-47 Kiln 2 back end coal feed (Coal Coal 50 0.1 544 Bag Filter Silo) A3-48 Raw Meal 1 Filler additive Raw Meal 50 0.0 196 Bag Filter A3-49 Coal Mill 2 Feed Cement 50 0.1 623 Bag Filter A3-50 Fine Coal Hopper Kiln 2 Coal 50 0.2 1766 Bag Filter A3-51 Cement silo 3 Cement 50 0.4 2632 Bag Filter E - 34 of 50
Emission point Description Emission details 1 Abatement system employed Reference Numbers material mg/nm 3 Wet (2) kg/h. kg/year A3-52 Cement Silo 2 Cement 50 0.5 3490 Bag Filter A3-53 Sulphate Additive Packaging Sulphate 50 0.1 188 Bag Filter and Despatch Plant A3-54 Slag Loading bay (Packing plant Slag Cement 50 0.1 627 Bag Filter walkway) Truck despatch A3-55 Slag screw conveyor Truck Slag 50 0.3 2000 Bag Filter despatch A3-56 Rail SR Cement Packing Plant Cement 50 0.4 2904 Bag Filter A3-57 Packing Plant No 1 Cement 50 1.4 2878 Bag Filter A3-58 Top of Slag Silo D2 GGBS/Slag 50 0.4 2868 Bag Filter A3-59 Packing Plant No 2 Cement 50 1.3 2742 Bag Filter A3-60 Road Dispatch 3rd Floor Cement 50 0.4 1504 Bag Filter A3-61 Road Bulk No. 1 Loading Cement 50 0.2 781 Bag Filter A3-62 Road Bulk No. 2 Loading Cement 50 0.2 1488 Bag Filter A3-63 Road Bulk No. 3 Loading Cement 50 0.2 1488 Bag Filter A3-64 Road Bulk No. 4 Loading Cement 50 0.2 1488 Bag Filter Road Dispatch 1st Floor (Road Cement 50 0.4 1764 Bag Filter A3-65 bulk elv.) A3-66 CM3 (Roof) Cement 50 0.2 1714 Bag Filter A3-67 Silo 7 Top floor filter Cement 50 2.0 14102 Bag Filter A3-68 Silo 8 Top floor filter Cement 50 2.0 14102 Bag Filter A3-69 Packing Plant Ground floor Cement 50 0.3 1050 Bag Filter A3-70 Silo 7 Btm Cement 50 0.2 1699 Bag Filter A3-71 Silo 8 Btm Bulk Rapid 50 0.2 1699 Bag Filter Cement A3-72 K1 feed building 35 Raw meal 50 0.2 1911 Bag filter A3-73 Steel bucket Augmond Elevator Clinker 50 0.5 3519 Bag Filter (bottom) A3-74 Steel bucket Augmond Elevator Clinker 50 0.5 3519 Bag Filter (top) A3-75 Top of clinker silo 1 Clinker 50 0.04 372 Bag Filter E - 35 of 50
Emission point Description Emission details 1 Abatement system employed Reference Numbers material mg/nm 3 Wet (2) kg/h. kg/year A3-76 Not Assigned - - - - - A3-77 RAW MEAL SILO 4 Raw meal 30 0.0972 769.82 Bag Filter A3-78 RAW MILL 3 Raw meal 30 0.4482 3549.74 Bag Filter A3-79 RAW MILL 3 Raw meal 30 0.4752 3763.58 Bag Filter A3-80 RAW MEAL SILO 4 Raw meal 30 0.2052 1625.18 Bag Filter A3-81 BESIDE PREHEATER TOWER Raw meal 30 0.0918 727.06 Bag Filter K3 A3-82 RAW MEAL SILO 4 Raw meal 30 0.5544 4390.85 Bag Filter A3-83 DEPT 35 KILN FEED Raw meal 30 0.0576 456.19 Bag Filter BUILDING A3-84 PREKEATER TOWER K3 Raw meal 30 0.234 1853.28 Bag Filter A3-85 PREKEATER TOWER K3 Raw meal 30 0.1458 1154.74 Bag Filter Kiln 3 A3-86 GRATE COOLER Raw meal 30 0.2124 1682.21 Bag Filter A3-87 COAL MILL 3 DEPT Coal dust 30 0.0612 484.70 Bag Filter A3-88 COAL MILL 3 DEPT Coal dust 30 0.0882 698.54 Bag Filter A3-89 COAL MILL 3 DEPT Coal dust 30 0.0882 698.54 Bag Filter A3-90 CEMENT MILL 4 DEPT Cement 30 0.4014 3179.09 Bag Filter A3-91 CEMENT MILL 4 DEPT Cement 30 0.3456 2737.15 Bag Filter E - 36 of 50
Emission point Description Emission details 1 Abatement system employed Reference Numbers material mg/nm 3 Wet (2) kg/h. kg/year A3-92 CEMENT MILL 4 DEPT Cement 30 0.3384 2680.13 Bag Filter A3-93 CEMENT MILL 4 DEPT Cement 30 0.1152 912.38 Bag Filter There will be a further 20 filters associated with the Kiln 3 line which is expected to be operational in late 2008. They will meet an emission level of 30mg/Nm 3. They will be used to dedust the material transport system. The specification of the filters is yet to be received. 1 The maximum emission should be stated for each material emitted, the concentration should be based on the maximum 30 minute mean. 2 Concentrations should be based on Normal conditions of temperature and pressure, (i.e. 0 o C101.3kPa). Wet/dry should be clearly stated. Include reference oxygen conditions for combustion sources. E - 37 of 50
TABLE E.1(v): EMISSIONS TO ATMOSPHERE Fugitive and Potential atmospheric emissions Emission point ref. no. (as per flow diagram) Description Malfunction which could cause an emission Emission details (Potential max. emissions) 1 Material mg/nm 3 kg/hour A4-1 (ICL Ref 16570) 21 Overpressure panels A4-2 (ICL Ref 16529) 1 Overpressure Diaphragm A4-3 (ICL Ref 26629) 1 Overpressure Diaphragm A4-4 (ICL Ref 16532) 2 Overpressure Diaphragm A4-5 (ICL Ref 26632) 4 Overpressure Diaphragm A4-6 (ICL Ref 26636) 4 Overpressure Diaphragm A4-7 (ICL Ref 16546) 1 Overpressure flap A4-8 (ICL Ref 16543) 1 Overpressure Diaphragm A4-9 (ICL Ref 26643) 1 Overpressure Diaphragm A4-10 (ICL Ref 26670) 21 Overpressure panels A4-11 (ICL Ref 16590) 1 Overpressure Diaphragm A4-12 (ICL Ref 24370) 4 Overpressure flap Overpressure in system only Coal dust 30,000 10kg in total as plant will stop automatically Overpressure in system only Coal dust 30,000 10kg in total as plant will stop automatically Overpressure in system only Coal dust 30,000 10kg in total as plant will stop automatically Overpressure in system only Coal dust 30,000 10kg in total as plant will stop automatically Overpressure in system only Coal dust 30,000 10kg in total as plant will stop automatically Overpressure in system only Coal dust 30,000 10kg in total as plant will stop automatically Overpressure in system or failure of spring fasteners Coal dust 30,000 10kg in total as plant will stop automatically Overpressure in system only Coal dust 30,000 10kg in total as plant will stop automatically Overpressure in system only Coal dust 30,000 10kg in total as plant will stop automatically Overpressure in system only Coal dust 30,000 10kg in total as plant will stop automatically Overpressure in system or failure of spring fasteners Overpressure in system or failure of spring fasteners Coal dust 30,000 10kg in total as plant will stop automatically Coal dust 30,000 10kg in total as plant will stop automatically E - 38 of 50
Emission point ref. no. (as per flow diagram) Description Malfunction which could cause an emission Emission details (Potential max. emissions) 1 Material mg/nm 3 kg/hour A4-13 (ICL Ref 26660) 1 Overpressure flap A4-14 (ICL Ref 14310) 1 Overpressure flap A4-15 (ICL Ref 16560) 1 Overpressure flap A4-16 (ICL Ref 26646) 3 Overpressure flap A4-22 (ICL Ref ) Spilled liquid surface in bund Overpressure in system or failure of spring fasteners Overpressure in system or failure of spring fasteners Overpressure in system or failure of spring fasteners Overpressure in system or failure of spring fasteners Ammonia water spill into bund A4-23 (ICL Ref 14433) Kiln 1 stack Safety trip of ESP abatement system A4-24 (ICL Ref 24450 ) Kiln 2 stack Safety trip of ESP abatement system Coal dust 30,000 10kg in total as plant will stop automatically Coal dust 30,000 10kg in total as plant will stop automatically Coal dust 30,000 10kg in total as plant will stop automatically Coal dust 30,000 Overpressure in system or failure of spring fasteners Ammonia vapour The Kiln 3 line is expected to be operational in late 2008. The associated potential emission points are as follows: A4-20 (ICL Ref 463.BF550) A4-21 (ICL Ref 463.BI600) A4-17 (ICL Ref 463.EX460) A4-18 (ICL Ref 463.BF300) 3 Overpressure flap 3 Overpressure flap 1 Overpressure flap 6 Overpressure flap Overpressure in system or failure of spring fasteners Overpressure in system or failure of spring fasteners Overpressure in system or failure of spring fasteners Overpressure in system or failure of spring fasteners N/A N/A Dust N/A If ESP filter is not rectified within several minutes the kiln is shut down. Dust N/A If ESP filter is not rectified within several minutes the kiln is shut down. Coal dust 30,000 Overpressure in system or failure of spring fasteners Coal dust 30,000 Overpressure in system or failure of spring fasteners Coal dust 30,000 Overpressure in system or failure of spring fasteners Coal dust 30,000 Overpressure in system or failure of spring fasteners A4-19 (ICL Ref 1 Overpressure Overpressure in system or Coal dust 30,000 Overpressure in system or failure E - 39 of 50
Emission point ref. no. (as per flow diagram) Description Malfunction which could cause an emission Emission details (Potential max. emissions) 1 Material mg/nm 3 kg/hour 463.BF530) flap failure of spring fasteners of spring fasteners 1 Estimate the potential maximum emission for each malfunction identified. E - 40 of 50
TABLE E.2(i): EMISSIONS TO SURFACE WATERS (One page for each emission) Emission Point: Emission Point Ref. N o : SW1 (ICL Ref. W4) Source of Emission: Storm water, Process Cooling water, Domestic sewage water and Quarry ground water Location : Adjacent to Quarry Gate Entrance Grid Ref. (12 digit, 6E,6N): Name of receiving waters: Flow rate in receiving waters: Available waste assimilative capacity: Emission Details: (i) Volume to be emitted 306673E, 271226N River Nanny Information not available m 3.sec -1 Dry Weather Flow m 3.sec -1 95%ile flow Normal/day 10,000 m 3 Maximum/day 28,000m 3 Maximum rate/hour 1,167m 3 kg/day (ii) Period or periods during which emissions are made, or are to be made, including daily or seasonal variations (start-up /shutdown to be included): Periods of Emission (avg) 60 min/hr 24 hr/day 365 day/yr E - 41 of 50
The current IPC Licence Reg. No. P0030-02 flow limit from emissions point W4 is 15000m 3 /day. An increased flow limit at SW1 of 28,000m 3 /day is required to allow continued Licence compliance as ICL Platin continues to develop the Limestone Quarry and in turn increases the volumes of Quarry deep well water pumping. E - 42 of 50
TABLE E.2(ii): EMISSIONS TO SURFACE WATERS - Characteristics of the emission (1 table per emission point) Emission point reference number : SW1 (ICL Ref. W4) Parameter Prior to treatment As discharged % Efficiency Max. hourly average (mg/l) Max. daily average (mg/l) kg/day kg/year Max. hourly average (mg/l) Max. daily average (mg/l) Max. kg/day Max. kg/year Suspended solids 400 400 6000 2.2 x10 6 35 35 525 191,625 100 Oils, fats and greases 10 10 150 54,750 2.0 2.0 30 10,950 100 BOD 6.0 6.0 90 32,850 6.0 6.0 90 32,850 100 Lead 0.1 0.1 1.5 548 0.1 0.1 1.5 548 N/a Copper 0.1 0.1 1.5 548 0.1 0.1 1.5 548 N/a Zinc 0.5 0.5 7.5 2738 0.5 0.5 7.5 2738 N/a E - 43 of 50
TABLE E.3(i): EMISSIONS TO SEWER (One page for each emission) Emission Point: Not Applicable Emission Point Ref. N o : Location of connection to sewer: Grid Ref. (12 digit, 6E,6N): Name of sewage undertaker: Emission Details: (i) Volume to be emitted Normal/day m 3 Maximum/day m 3 Maximum rate/hour m 3 (ii) Period or periods during which emissions are made, or are to be made, including daily or seasonal variations (start-up /shutdown to be included): Periods of Emission (avg) min/hr hr/day day/yr E - 44 of 50
TABLE E.3(ii): EMISSIONS TO SEWER - Characteristics of the emission (1 table per emission point) Emission point reference number : Not Applicable Parameter Prior to treatment As discharged % Efficiency Max. hourly average (mg/l) Max. daily average (mg/l) kg/day kg/year Max. hourly average (mg/l) Max. daily average (mg/l) kg/day kg/year E - 45 of 50
TABLE E.4(i): EMISSIONS TO GROUND (1 Page for each emission point) Emission Point or Area: Emission Point/Area Ref. N o : Not Applicable Emission Pathway: (borehole, well, percolation area, soakaway, landspreading, etc.) Location : Grid Ref. (12 digit, 6E,6N): Elevation of discharge: (relative to Ordnance Datum) Aquifer classification for receiving groundwater body: Groundwater vulnerability assessment (including vulnerability rating): Identity and proximity of groundwater sources at risk (wells, springs, etc): Identity and proximity of surface water bodies at risk: Emission Details: (i) Volume to be emitted Normal/day m 3 Maximum/day m 3 Maximum rate/hour m 3 (ii) Period or periods during which emissions are made, or are to be made, including daily or seasonal variations (start-up /shutdown to be included): E - 46 of 50
Periods of Emission (avg) min/hr hr/day day/yr TABLE E.4(ii): EMISSIONS TO GROUND - Characteristics of the emission (1 table per emission point) Emission point/area reference number: Not Applicable Parameter Prior to treatment As discharged % Efficiency Max. hourly average (mg/l) Max. daily average (mg/l) kg/day kg/year Max. hourly average (mg/l) Max. daily average (mg/l) kg/day kg/year E - 47 of 50
Table E.5(i): NOISE EMISSIONS - Noise sources summary sheet Kiln 1 Source Emission point Ref. No Equipment Ref. No Sound Pressure 1 dba at reference distance Octave bands (Hz) Sound Pressure 1 Levels db(unweighted) per band Impulsive or tonal qualities Periods of Emission 31.5 63 125 250 500 1K 2K 4K 8K Limestone N1-88@5m 88 87 85 86 84 81 82 78 71 Minor 24h/day Crusher Kiln1 Exhaust N2-96@1m 99 100 96 93 92 93 87 84 80 None 24h/day Fan and Drive Kiln 1 Coolers N3-87@3m 89 86 87 88 83 80 79 77 72 None 24h/day Kiln 1 Gantry N4-97@2m 88 89 96 98 95 92 87 80 73 None 24h/day Cooling Fans Kiln 1 Primary Air Fan N5-88@1m 93 92 91 90 87 80 77 72 70 None 24h/day 1. For items of plant sound power levels may be used. E - 48 of 50
Table E.5(i): NOISE EMISSIONS - Noise sources summary sheet Kiln 2 Source Emission point Ref. No Equipment Ref. No Sound Pressure 1 dba at reference distance Octave bands (Hz) Sound Pressure 1 Levels db(unweighted) per band Impulsive or tonal qualities Periods of Emission 31.5 63 125 250 500 1K 2K 4K 8K Kiln 2 Booster N6-94@1m 89 86 83 88 91 87 87 86 79 None 24h/day Fan and Drive Kiln 2 Exhaust N7-95@1m 101 102 97 92 88 92 86 83 81 None 24h/day Fan and Drive Kiln 2 Exhaust N8-95@1m 101 102 97 92 88 92 86 83 81 None 24h/day Fan and Drive Raw Mill 2 Fan N9-93@1m 100 98 92 91 88 89 86 79 72 None 24h/day and Drive Raw Mill 2 Fan N10-94@1m 100 99 97 91 91 90 90 86 80 None 24h/day and Drive Kiln 2 Gantry N11-97@2m 88 89 96 98 95 92 87 80 73 None 24h/day Cooling Fans Cement Mill 3 N12-94@1m 87 85 93 94 91 90 83 78 74 None 24h/day Bag Filter Fan and Drive Kiln 2 Grate Cooler ESP Fan and Drive N13-93@1m 88 86 82 86 90 87 86 85 77 None 24h/day 1. For items of plant sound power levels may be used. E - 49 of 50
Table E.5(i): NOISE EMISSIONS - Noise sources summary sheet Kiln 3 Source Kiln 3 Exhaust Fan and Drive Kiln 3 Raw Mill Fan and Drive Kiln 3 Booster Fan and Drive Kiln 3 Grate Cooler ESP Fan and Drive Kiln 3 Gantry Cooling Fans Cement Mill 4 Bag Filter Fan and Drive Emission point Ref. No Equipment Ref. No Sound Pressure 1 dba at reference distance Octave bands (Hz) Sound Pressure 1 Levels db(unweighted) per band Impulsive or tonal qualities Periods of Emission 31.5 63 125 250 500 1K 2K 4K 8K N14-95@1m 101 102 97 92 88 92 86 83 81 None 24h/day N15-94@1m 100 99 97 91 91 90 90 86 80 None 24h/day N16-94@1m 89 86 83 88 91 87 87 86 79 None 24h/day N17-93@1m 88 86 82 86 90 87 86 85 77 None 24h/day N18-97@2m 88 89 96 98 95 92 87 80 73 None 24h/day N19-92@1m 87 86 82 85 88 88 86 80 77 None 24h/day 1. For items of plant sound power levels may be used. E - 50 of 50