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Annual Environmental Report Chemifloc Ltd. (March 2009) 1 Chemifloc Ltd Annual Environmental Report January 2008 – December 2008

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Page 1: Chemifloc Ltd - Environmental Protection AgencyAccreditation. Chemifloc has successfully retained accreditation through external biannual audits. The products manufactured by Chemifloc

Annual Environmental Report Chemifloc Ltd. (March 2009)

1

Chemifloc Ltd Annual Environmental Report

January 2008 – December 2008

Page 2: Chemifloc Ltd - Environmental Protection AgencyAccreditation. Chemifloc has successfully retained accreditation through external biannual audits. The products manufactured by Chemifloc

Annual Environmental Report Chemifloc Ltd. (March 2009)

2

Contents Section Page 2.1 Introduction 3 Environmental Policy 4 Company Organisation Chart 5 2.2 Summary Information 6 Waste Management 7 Agency Monitoring and Enforcement 11 Energy Usage 12 Environmental Incidents and Complaints 12 2.3 EMP Report 13 EMP Proposal 14 Pollution Emission Register 16 2.4 Licence Specific Reports N/A PRTR/AERRReturnsRWorksheet

Page 3: Chemifloc Ltd - Environmental Protection AgencyAccreditation. Chemifloc has successfully retained accreditation through external biannual audits. The products manufactured by Chemifloc

Annual Environmental Report Chemifloc Ltd. (March 2009)

3

Introduction Licence Register Number P0076-01 Name and Location Chemifloc Ltd., Smithstown Industrial Estate, Shannon, Co. Clare. Site Description Chemifloc Ltd. is a chemical manufacturing company situated in Smithstown Industrial Estate in Shannon Co. Clare. This industrial estate is separated from residential and amenity areas and lies directly below the flight path to Shannon Airport which is approximately 1 mile away. Chemifloc Ltd is involved in the manufacture and distribution of chemicals, primarily for the water and wastewater treatment industry. In 2001, Chemifloc applied for ISO 9001:2000 Registration and was successful in gaining Accreditation. Chemifloc has successfully retained accreditation through external biannual audits. The products manufactured by Chemifloc Ltd. are Aluminium Sulphate, Dilute Sulphuric Acid, Ferric Nitrate, Ferrous sulphate solutions, Ferric Sulphate solutions, Sodium Hydroxide (30%), Ferric Chloride and various blends of these products. Chemifloc Ltd also supplies various other products for water and wastewater treatment. These products include Sodium Carbonate, Sodium Chlorite, Sodium Bicarbonate, Sodium Hypochlorite, Activated Carbon, Antifoam, Odour Control agents and Polyelectrolytes. Chemifloc Ltd. currently employ 25 employees, 2 Directors, 1 Project Manager, 1 Production Manager, 1 Plant Chemist (Quality Manager, Environmental), 2 chemical analysts (Quality, Environmental), 3 Senior Operators, 6 General Operators, 2 Truck Drivers, 1 Technical Representative, 1 Financial Controller and 5 Administration Staff. Chemifloc Ltd. use the services of local contractors for electrical and mechanical installations and maintenance. There would be 2 - 3 of these firms employees on site regularly. Chemifloc Ltd. also contract several haulage firms to deliver its product(s).

Page 4: Chemifloc Ltd - Environmental Protection AgencyAccreditation. Chemifloc has successfully retained accreditation through external biannual audits. The products manufactured by Chemifloc

Annual Environmental Report Chemifloc Ltd. (March 2009)

4

Chemifloc Ltd Environment Policy

Chemifloc is a manufacturer of water and wastewater treatment chemicals. Our aim is to “To continually

pursue product innovation, customer satisfaction, and operational excellence.” To fulfill our aim, one of our

Key Goals is to “Make Chemifloc the most desirable company to do business with.” Because Environmental

Management is good business sense, we integrate environmental considerations into all business decisions.

Chemifloc Ltd believes in managing all its processes for the continued improvement of our products,

services and the environment for now and for the future.

Chemifloc Ltd. is strongly committed to the following Guiding Principles which form our Environmental

Policy:

• Continual improvement of our processes by monitoring technology and management practices to prevent

pollution during the manufacture, storage, transportation and disposal of our products throughout their life

cycle

• Compliance to relevant environmental legislation and regulations, and with other regulations effecting the

design and production of our products as they arise

• Establishing and reviewing environmental objectives, targets, performance evaluation procedures and

associated environmental indicators

• Minimizing any adverse environmental impacts of new product development through the use of

integrated environmental management procedures and planning

• Encouraging the selection and use of environmentally qualified Suppliers and Vendors

• Documenting and maintaining this policy as changes to environmental regulations occur

• Training our employees to conduct their activities in an environmentally responsible manner

• Communicating this policy to all employees, business associates and interested parties in the public sector

These guiding principles set our goals for environmental responsibility and the performance required by our

organization, against which subsequent actions will be assessed. To ensure success, Mr Ed Storey, Managing

Director, has the executive responsibility and authority to oversee and implement this policy at all Chemifloc

owned facilities.

Ed Storey

Managing Director Date:1/09/08

Chemifloc Ltd Rev:0

Page 5: Chemifloc Ltd - Environmental Protection AgencyAccreditation. Chemifloc has successfully retained accreditation through external biannual audits. The products manufactured by Chemifloc

Annual Environmental Report Chemifloc Ltd. (March 2009)

5

Environmental Management Chart

The Managing Director has overall responsibility for all aspects of the Chemifloc Plant, Environmental, Quality and Health and Safety. The Managing Director has a 3rd Level qualification in the scientific field and 34 years experience in the Environmental and related fields. The Project Manager is responsible for the implementation of all aspects of the IPC Licence. The Project Manager's functions include the design, purchase, installation and operation of all environmental equipment. The Project Manager is also responsible for the production and implementation of all procedures. The Project Manager has a 3rd level qualification in the scientific field, with 17 yrs experience in the environmental field and 24 yrs experience in chemical production and plant design. The Production Manager is responsible for the operation of all environmental equipment and training of plant operators in the operation of this equipment. The Production Manager has a 3rd level qualification in the scientific field with 22 yrs experience in Production Management. The Plant Chemist is responsible for the monitoring of all environmental emissions and the production of reports as specified in the IPC Licence. The Chemist co-ordinates with the Production Manager to ensure that all environmental equipment is working effectively and all environmental emissions are within specified limits. The Plant Chemist has a 3rd level qualification in the scientific field with 18 yrs experience in environmental monitoring. The Chemical Analyst carries out environmental analysis as specified by the IPC Licence and submits these results to the Plant Chemist. The Chemical analyst has a 3rd level qualification in the scientific field, 2 yrs experience and has received in-house training in all procedures related to environmental monitoring. The Plant Operators are responsible for the operation of all production and environmental equipment under the supervision of the Production Manager. The Plant Operators receive in-house training in the operation of this equipment. There are written procedures for all operations (environmental and operational) with an environmental impact and these procedures are available at all times.

SupervisorHealth & Safety

Production Team

SupervisorsProduction

Production ManagerTraining and Operation of Equipment

Chemical AnalystsQuality/Environmental

Plant ChemistQuality/Environmental

Project ManagerImplementation of IPC Licence

Invoicing

Purchasing

Sales

Financial Controller

Managing DirectorsOverall Plant Responsibility

Page 6: Chemifloc Ltd - Environmental Protection AgencyAccreditation. Chemifloc has successfully retained accreditation through external biannual audits. The products manufactured by Chemifloc

Annual Environmental Report Chemifloc Ltd. (March 2009)

6

Summary Information Emissions to Waters/Sewer Parameter Mass Emissions (Kg)

(2007) Mass Emission (Kg)

(2008) Licensed (Kg)

Mass Emissions Flow 1,250,000 1,320,000 7,300,000 PH 6 - 9 6 - 9 6-9 Temperature <30oC <30oC <30oc C.O.D. 140.94 100.5840 3650 B.O.D. 1.3500 3.1450 N/A Suspended Solids 29.0800 36.6450 547 Oils & Fats 5.0000 5.3900 365.00 Sulphate 98.7800 427.0250 7,300.00 Sulphide 0.0356 0.0823 1.825 Chloride 28.0650 43.8550 7,300.00 Cyanide 0.1250 0.1320 3.65 Chromium Cr (111) 0.0063 0.0056 7.30 Chromium Cr (VI) 0.0375 0.0333 0.219 Cobolt 0.0064 0.0051 3.65 Copper 0.5196 0.2774 3.65 Lead 0.0087 0.0067 3.65 Nickel 0.0068 0.0082 3.65 Zinc 0.1112 0.0982 14.60 Iron 7.9024 343.50 73.00 Manganese 0.0369 0.0883 7.30 Emissions to Waters/Sewer Non-Compliances Date Non-Compliance Cause Corrective Action(s)

20/10/08 Ferric Chloride leakage from a reactor that resulted in an overflow from the containment tank to the foul sewer line. Ref P0076-01/NC05CN

A fracture of the glass wall allowed HCL to corrode through the mild steel shell thus causing the contents to fill the underground containment tank.

Heavy rainfall also contributed to the filling of the tank and when full

overflowed into the foul sewer line.

Fabrication and installation of new bund. Certificate of Integrity for Bund

passed to the Agency.

Ref P0076-01/NC05CN

Emissions to Atmosphere Parameter Mass Emissions

(Kg) (2007)

Mass Emission (Kg) (2008)

Licensed (Kg) Mass Emissions

Nitrogen Oxides as NO2 348.48 237.6 2190.00 Sulphur as SO2 57.024 57.024 2190.00 HCL 28.512 28.512 219.00 H2SO4 1.9 1.9 219.00

Page 7: Chemifloc Ltd - Environmental Protection AgencyAccreditation. Chemifloc has successfully retained accreditation through external biannual audits. The products manufactured by Chemifloc

Annual Environmental Report Chemifloc Ltd. (March 2009)

7

Waste Management Company Name Chemifloc Ltd IPPC Register No. P0076-01 NACE CODES DG 2013 Class 3 of EPA Act

Calendar Year 2008

ITEM (Tonnes/annum)

Total quantity of waste produced in calendar year 22.65 · total quantity of waste disposed of on-site 0.0 · total quantity of waste disposed of off-site 14.31 · total quantity of waste recovered on-site 0.0 · total quantity of waste recovered off-site 4.66

Quantity of non-hazardous waste produced in calendar year 18.97 · quantity of non-hazardous waste disposed of on-site 0.0 · quantity of non-hazardous waste disposed of off-site 14.31 · quantity of non-hazardous waste recovered on-site 0.0 · quantity of non-hazardous waste recovered off-site 4.66

Quantity of hazardous waste produced in calendar year 3.68 · quantity of hazardous waste disposed of on-site 0.0 · quantity of hazardous waste disposed of off-site 3.68 · quantity of hazardous waste recovered on-site 0.0 · quantity of hazardous waste recovered off-site 0.0

Page 8: Chemifloc Ltd - Environmental Protection AgencyAccreditation. Chemifloc has successfully retained accreditation through external biannual audits. The products manufactured by Chemifloc

Annual Environmental Report Chemifloc Ltd. (March 2009)

8

Waste Management Register Date EWC

Code Hazardous (Y or N)

Description Quantity (tonnes)

Person Responsible for Ultimate

Disposal/Recovery

Ultimate Destination

Name of Disposal

Contractor 4/01/08 20 03 01 N General 0.29 J.O’Donoghue Ballyduffbeg

Landfill, Inagh, Clare Clean Ireland Ltd.

11/01/08 20 03 01 N General 0.29 J.O’Donoghue Ballyduffbeg Landfill, Inagh, Clare Clean Ireland

Ltd. 18/01/08 20 03 01 N General 0.29 J.O’Donoghue Ballyduffbeg

Landfill, Inagh, Clare Clean Ireland Ltd.

08/02/08 20 03 01 N General 0.68 J.O’Donoghue Ballyduffbeg Landfill, Inagh, Clare Clean Ireland

Ltd. 8/02/08 15 01 02 N Plastic 0.12 J.O’Donoghue Cree

Recycling Fac. Clean Ireland

Ltd. 12/02/08 20 03 01 N General 0.76 J.O’Donoghue Ballyduffbeg

Landfill, Inagh, Clare Clean Ireland Ltd.

15/02/08 20 03 01 N General 0.29 J.O’Donoghue Ballyduffbeg Landfill, Inagh, Clare Clean Ireland

Ltd. 22/02/08 20 03 01 N General 0.29 J.O’Donoghue Ballyduffbeg

Landfill, Inagh, Clare Clean Ireland Ltd.

29/02/08 20 03 01 N General 0.29 J.O’Donoghue Ballyduffbeg Landfill, Inagh, Clare Clean Ireland

Ltd. 07/03/08 20 03 01 N General 0.29 J.O’Donoghue Ballyduffbeg

Landfill, Inagh, Clare Clean Ireland Ltd.

14/03/08 20 03 01 N General 0.17 J.O’Donoghue Ballyduffbeg Landfill, Inagh, Clare Clean Ireland

Ltd. 21/03/08 20 03 01 N General 0.29 J.O’Donoghue Ballyduffbeg

Landfill, Inagh, Clare Clean Ireland Ltd.

31/03/08 15 01 02 N Plastic 2.82 J.O’Donoghue Cree Recycling Fac.

Clean Ireland Ltd.

04/04/08 20 01 01 N Cardboard 0.12 J.O’Donoghue Cree Recycling Fac.

Clean Ireland Ltd.

04/04/08 20 03 01 N General 0.17 J.O’Donoghue Ballyduffbeg Landfill, Inagh, Clare Clean Ireland

Ltd. 18/04/08 20 03 01 N General 0.29 J.O’Donoghue Ballyduffbeg

Landfill, Inagh, Clare Clean Ireland Ltd.

02/05/08 20 03 01 N General 0.17 J.O’Donoghue Ballyduffbeg Landfill, Inagh, Clare Clean Ireland

Ltd. 02/05/08 15 01 02 N Plastic 0.17 J.O’Donoghue Cree

Recycling Fac. Clean Ireland

Ltd. 02/05/08 20 03 01 N General 0.29 J.O’Donoghue Ballyduffbeg

Landfill, Inagh, Clare Clean Ireland Ltd.

09/05/08 20 03 01 N General 0.29 J.O’Donoghue Ballyduffbeg Landfill, Inagh, Clare Clean Ireland

Ltd. 16/05/08 20 03 01 N General 0.29 J.O’Donoghue Ballyduffbeg

Landfill, Inagh, Clare Clean Ireland Ltd.

23/05/08 20 03 01 N General 0.29 J.O’Donoghue Ballyduffbeg Landfill, Inagh, Clare Clean Ireland

Ltd.

Page 9: Chemifloc Ltd - Environmental Protection AgencyAccreditation. Chemifloc has successfully retained accreditation through external biannual audits. The products manufactured by Chemifloc

Annual Environmental Report Chemifloc Ltd. (March 2009)

9

Date EWC Code

Hazardous (Y or N)

Description Quantity (tonnes)

Person Responsible for Ultimate

Disposal/Recovery

Ultimate Destination

Name of Disposal

Contractor 30/05/08 20 03 01 N General 0.29 J.O’Donoghue Ballyduffbeg

Landfill, Inagh, Clare Clean Ireland Ltd.

31/05/08 20 03 01 N General 0.29 J.O’Donoghue Ballyduffbeg Landfill, Inagh, Clare Clean Ireland

Ltd. 06/06/08 20 03 01 N General 0.29 J.O’Donoghue Ballyduffbeg

Landfill, Inagh, Clare Clean Ireland Ltd.

13/06/08 20 03 01 N General 0.29 J.O’Donoghue Ballyduffbeg Landfill, Inagh, Clare Clean Ireland

Ltd. 20/06/08 20 03 01 N General 0.29 J.O’Donoghue Ballyduffbeg

Landfill, Inagh, Clare Clean Ireland Ltd.

27/06/08 20 03 01 N General 0.29 J.O’Donoghue Ballyduffbeg Landfill, Inagh, Clare Clean Ireland

Ltd. 22/06/07 20 03 01 N General 0.17 J.O’Donoghue Ballyduffbeg

Landfill, Inagh, Clare Clean Ireland Ltd.

1/02/08 20 03 01 N General 0.46 J.O’Donoghue Ballyduffbeg Landfill, Inagh, Clare Clean Ireland

Ltd. 28/03/08 20 03 01 N General 0.46 J.O’Donoghue Ballyduffbeg

Landfill, Inagh, Clare Clean Ireland Ltd.

4/07/08 20 03 01 N General 0.29 J.O’Donoghue Ballyduffbeg Landfill, Inagh, Clare Clean Ireland

Ltd. 4/07/08 20 01 01 N Cardboard 0.17 J.O’Donoghue Cree

Recycling Fac. Clean Ireland

Ltd. 11/07/08 20 03 01 N General 0.29 J.O’Donoghue Ballyduffbeg

Landfill, Inagh, Clare Clean Ireland Ltd.

11/07/08 15 01 02 N Plastic 0.17 J.O’Donoghue Cree Recycling Fac.

Clean Ireland Ltd.

15/08/08 20 03 01 N General 0.46 J.O’Donoghue Ballyduffbeg Landfill, Inagh, Clare Clean Ireland

Ltd. 22/08/08 20 03 01 N General 0.46 J.O’Donoghue Ballyduffbeg

Landfill, Inagh, Clare Clean Ireland Ltd.

5/09/08 20 03 01 N General 0.46 J.O’Donoghue Ballyduffbeg Landfill, Inagh, Clare Clean Ireland

Ltd. 19/09/08 20 03 01 N General 0.46 J.O’Donoghue Ballyduffbeg

Landfill, Inagh, Clare Clean Ireland Ltd.

26/09/08 20 01 01 N Cardboard 0.29 J.O’Donoghue Cree Recycling Fac.

Clean Ireland Ltd.

26/09/08 15 01 02 N Plastic 0.17 J.O’Donoghue Cree Recycling Fac.

Clean Ireland Ltd.

03/10/08 20 03 01 N General 0.46 J.O’Donoghue Ballyduffbeg Landfill, Inagh, Clare Clean Ireland

Ltd. 17/10/08 20 03 01 N General 0.46 J.O’Donoghue Ballyduffbeg

Landfill, Inagh, Clare Clean Ireland Ltd.

31/10/08 20 03 01 N General 0.46 J.O’Donoghue Ballyduffbeg Landfill, Inagh, Clare Clean Ireland

Ltd.

Page 10: Chemifloc Ltd - Environmental Protection AgencyAccreditation. Chemifloc has successfully retained accreditation through external biannual audits. The products manufactured by Chemifloc

Annual Environmental Report Chemifloc Ltd. (March 2009)

10

Date EWC Code

Hazardous (Y or N)

Description Quantity (tonnes)

Person Responsible for Ultimate

Disposal/Recovery

Ultimate Destination

Name of Disposal

Contractor 7/11/08 20 03 01 N General 0.46 J.O’Donoghue Ballyduffbeg

Landfill, Inagh, Clare Clean Ireland Ltd.

19/11/08 15 01 02 N Plastic 0.17 J.O’Donoghue Cree Recycling Fac.

Clean Ireland Ltd.

19/11/08 20 01 01 N Cardboard 0.29 J.O’Donoghue Cree Recycling Fac.

Clean Ireland Ltd.

21/11/08 15 01 02 N Plastic 0.17 J.O’Donoghue Cree Recycling Fac.

Clean Ireland Ltd.

21/11/08 20 03 01 N General 0.29 J.O’Donoghue Ballyduffbeg Landfill, Inagh, Clare Clean Ireland

Ltd. 28/11/08 20 03 01 N General 0.46 J.O’Donoghue Ballyduffbeg

Landfill, Inagh, Clare Clean Ireland Ltd.

12/12/08 20 03 01 N General 0.29 J.O’Donoghue Ballyduffbeg Landfill, Inagh, Clare Clean Ireland

Ltd. 19/12/08 20 03 01 N General 0.46 J.O’Donoghue Ballyduffbeg

Landfill, Inagh, Clare Clean Ireland Ltd.

22/12/08 19 12 11 Y Waste Fibreglass

3.68 A.Chmielouslu Corrin, Fermoy, Co.

Cork

AVR Safeway Ltd.

Waste Stream: General (domestic): 14.31 tonnes Cardboard: 0.87 tonnes Plastic: 3.79 tonnes Waste fibreglass: 3.68 tonnes

TOTAL WASTE: 22.65 tonnes

Page 11: Chemifloc Ltd - Environmental Protection AgencyAccreditation. Chemifloc has successfully retained accreditation through external biannual audits. The products manufactured by Chemifloc

Annual Environmental Report Chemifloc Ltd. (March 2009)

11

Agency Monitoring and Enforcement Emissions Sampling and Analysis

Air Monitoring dated 3/03/08 and carried out by Euro Environmental Services Ltd. Monitoring results compliant with Licence limits. Effluent Monitoring dated 15/04/08 by EPA. Grab sample and Composite samples taken. Both compliant with Licence limits.

Effluent Monitoring dated 16/12/08 by EPA. Sample unavailable as EPA arrived after pump-out and only a daily sample was available.

Site Visits and Inspections Unscheduled Visits dated 23/04/08 & 15/07/08.

Site Audit No audit during 2008.

Page 12: Chemifloc Ltd - Environmental Protection AgencyAccreditation. Chemifloc has successfully retained accreditation through external biannual audits. The products manufactured by Chemifloc

Annual Environmental Report Chemifloc Ltd. (March 2009)

12

Energy and Water Consumption

Environmental Incidents and Complaints

Environmental Incidents

Complaints

Date Category Actions 28/02/08 Odour See P0076-01/cc15noc.doc correspondence. Odour noted in

the area of Chemifloc rd. Source not located, however we have initiated a Register logging any nuisance odours in the vicinity. Also contacted Environmental Engineer in Clare County Council to ask her to alert us if any similar odour

occurs so as to ensure swift investigation/sourcing.

Energy 2006 2007 2008 Diesel 223,679 litres 242,378 litres 206,558 litres Kerosene 5,299 litres 6,004 litres 15,243 litres Electricity 762,200 MW 888,000 MW 940,450 MW

Water Usage M3 2006 2007 2008 On-site ground water 26,868 20,589 28,797 On-site surface water 2,265 2,400 2,650 Municipal supply 17,071 26,241 19,697 Production Units 66,006 70,328 72,603

Date Description Nature Cause Corrective Action 20/10/08 Ferric Chloride

leakage from a reactor that resulted in an overflow from the containment tank to the foul sewer line.

Ref P0076-01/NC05CN

Emission to Sewer Non-Compliance

A fracture of the glass wall allowed HCL to corrode

through the mild steel shell thus causing the contents to

fill the underground containment tank. Heavy

rainfall also contributed to the filling of the tank and when full overflowed into the foul

sewer line.

Fabrication and installation of new bund. Certificate of Integrity for Bund

passed to the Agency.

Ref P0076-01/NC05CN

Page 13: Chemifloc Ltd - Environmental Protection AgencyAccreditation. Chemifloc has successfully retained accreditation through external biannual audits. The products manufactured by Chemifloc

Annual Environmental Report Chemifloc Ltd. (March 2009)

13

Environmental Management Programme Report There was one incomplete Environmental Objective in place at Chemifloc Ltd. This was broken down into 4 stages.

Environmental Objective Achievement V Target Reduction in Fugitive Air Emissions (Stage 1). Reduction in Fugitive Air Emissions (Stage 2). Reduction in Fugitive Air Emissions (Stage 3).

Reduction in Fugitive Sewer Emissions (Stage 1). Reduction in Fugitive Sewer Emissions (Stage 2). Reduction in Fugitive Sewer Emissions (Stage 3).

Reduction in Fugitive Sewer Emissions (Stage 4).

Reduction in Fugitive Sewer Emissions (Stage 5).

Waste Management Programme (Stage 1). Waste Management Programme (Stage 2). Waste Management Programme (Stage 3).

Savings in Energy and Materials Usage (Stage 1).

Savings in Energy and Materials Usage (Stage 2).

Savings in Energy and Materials Usage (Stage 3).

Savings in Energy and Materials Usage (Stage 4).

Savings in Energy and Materials Usage (Stage 5).

Air-Dispersion Modelling (Stage 1) Air-Dispersion Modelling (Stage 2) Air-Dispersion Modelling (Stage 3) Reduction in NOx production from the Ferric Sulphate Process (Stage 1) Reduction in NOx production from the Ferric Sulphate Process (Stage 2) Reduction in NOx production from the Ferric Sulphate Process (Stage 3) Reduction in NOx production from the Ferric Sulphate Process (Stage 4)

Completed. No difficulties. Completed. No difficulties. Completed. No difficulties.

Completed. No difficulties. Completed. No difficulties. Completed. No difficulties. Completed. No difficulties. Completed. No difficulties. Completed. No difficulties. Completed. No difficulties. Completed. No difficulties. Completed. No difficulties. Completed. No difficulties. Completed. No difficulties. Completed. No difficulties. Completed. No difficulties. Completed. No difficulties. Completed. No difficulties. Completed. No difficulties. Revised & Completed. Revised & Completed. Revised. See EMP below. Revised. See EMP below.

Page 14: Chemifloc Ltd - Environmental Protection AgencyAccreditation. Chemifloc has successfully retained accreditation through external biannual audits. The products manufactured by Chemifloc

Annual Environmental Report Chemifloc Ltd. (March 2009)

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Environmental Management Programme Proposal Environmental Objective 4 Savings in Energy and Materials Usage Reason To reduce energy and materials usage. Programme Stage 6 Complete the changeover to the new process Ferric Sulphate Production. This

enables Chemifloc to decrease the total kerosene usage by approx 6,500 L per annum. See Environmental Objective 6.

Timeframe Before end Q4, 2009. Stage 7 Complete the changeover to the new process Ferric Sulphate Production. This

enables Chemifloc to decrease the total electricity usage by approx 40% by means of fewer electrical plant needed. Namely, continuous scrubbing, reactor agititation, sparging etc.

Timeframe Before end Q4, 2009. Stage 8 Decrease municipal water mains usage by up to 1000M3. This decrease is expected

when roofing on the smallpack bunded area is complete and water gullies erected to capture more rainwater.

Timeframe Before end Q3, 2009. Environmental Objective 6, Reduction in NOx production from the Ferric Sulphate Process has been modified at the end of Q3 2008. This modification has been made in an effort to totally eliminate the production of NOx from the Ferric Sulphate process altogether. These changes to Environmental Objective 6, Reduction in NOx production from the Ferric Sulphate Process are outlined below. Environmental Objective 6 Reduction in NOx production from the Ferric Sulphate Process Reason To minimise the amount NOx production in the Ferric Sulphate Production Process Stage 1 Carry out Research & Development program in the laboratory using alternative iron

sources, Sulphuric acid to manufacture Ferric Sulphate. Timeframe Complete.

Page 15: Chemifloc Ltd - Environmental Protection AgencyAccreditation. Chemifloc has successfully retained accreditation through external biannual audits. The products manufactured by Chemifloc

Annual Environmental Report Chemifloc Ltd. (March 2009)

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Stage 2 Source alternative iron supplier capable of supplying in excess of required quantities

per annum. Timeframe Complete. Stage 3 Design, modify/fabricate new plant (including bulk storage of raw material and

finished product) to produce non NOx producing ferric sulphate. Timeframe By end of Q4 2008. Now Complete Cost 300,000 euro Stage 4 Commence trial batch production of Ferric Sulphate using alternative oxidants eg:

Air, Oxygen, Ozone. Timeframe By end of Q4 2008. Now Complete Stage 5 Commence normal batch production of the new Ferric Sulphate process. Timeframe By end of Q1 2009. Responsibility The Production Manager and Quality Manager are responsible for this objective. Revised GANT chart detailing Chemifloc progress of New Ferric Sulphate Process.

Task Jan 08

Feb 08

Mar 08

Apr 08

May 08

Jun 08

Jul 08

Aug 08

Sep 08

Oct 08

Nov 08

Dec 08

Jan 09

Feb 09 Mar

09 R & D

Raw Material Handling

Plant Modification

Pilot Test Runs Equipment

Modification Full Scale

Trials Final

Shakedown & Commissioning

Page 16: Chemifloc Ltd - Environmental Protection AgencyAccreditation. Chemifloc has successfully retained accreditation through external biannual audits. The products manufactured by Chemifloc

Annual Environmental Report Chemifloc Ltd. (March 2009)

16

Pollution Emission Register Facility Identification

Facility Name Chemifloc Ltd Licence No. P0076-01 National Grid Reference R14111633 Reporting Period 01/2008 to 12/2008 Production Units 72,603 Employee Nos. 25 Pollutants Summary

Outputs Pollutant Name

CAS No.

Input Gross Usage Air mom Liquid

effluent mom Waste mom Product mo

m Re- covery

Treated Un- accounted

IGEE INEE

HNO3 7697-32-2 276.710 276.472 0.348 M None None 377.71 M None None None 0.08587 0.08587

H2SO4 7664-93-9 15155.790 15155.731 0.059 M None None 15072.03 M None None None 0.00039 0.00039

Page 17: Chemifloc Ltd - Environmental Protection AgencyAccreditation. Chemifloc has successfully retained accreditation through external biannual audits. The products manufactured by Chemifloc

| PRTR# : P0076 | Facility Name : Chemifloc Ltd. | Filename : P0076_2008 AER PRTR.xls | Return Year : 2008 |

Version 1.1.03REFERENCE YEAR 2008

1. FACILITY IDENTIFICATIONParent Company Name Chemifloc Ltd.

Facility Name Chemifloc Ltd.PRTR Identification Number P0076

Licence Number P0076-01

Waste or IPPC Classes of ActivityNo. class_name

5.4.0 The manufacture of inorganic chemicals.

5.2.0The manufacture of olefins and their derivatives or of monomers and polymers including

Address 1 Smithstown Industrial EstateAddress 2 ShannonAddress 3 Co. ClareAddress 4

Country IrelandCoordinates of Location

River Basin DistrictNACE Code 2013

Main Economic Activity Manufacture of other inorganic basic chemicalsAER Returns Contact Name Eamon Nunan

AER Returns Contact Email Address [email protected] Returns Contact Position Project Manager

AER Returns Contact Telephone Number 061-708699AER Returns Contact Mobile Phone Number

AER Returns Contact Fax Number 061-708653Production Volume 72603.0

Production Volume Units 72,603Number of Installations 5

Number of Operating Hours in Year 3300Number of Employees 25

User Feedback/CommentsWeb Address www.chemifloc.ie

2. PRTR CLASS ACTIVITIESActivity Number Activity Name

3. SOLVENTS REGULATIONS (S.I. No. 543 of 2002)Is it applicable? No

Have you been granted an exemption ? NoIf applicable which activity class applies (as per

Schedule 2 of the regulations) ?Is the reduction scheme compliance route being

used ?

AER Returns Worksheet

Page 18: Chemifloc Ltd - Environmental Protection AgencyAccreditation. Chemifloc has successfully retained accreditation through external biannual audits. The products manufactured by Chemifloc

4.1 RELEASES TO AIR | PRTR# : P0076 | Facility Name : Chemifloc Ltd. | Filename : P0076_2008 AER PRTR.xls | Return Year : 2008 | 23/03/2009 10:108 8 16 18 26 26 6 6 6

SECTION A : SECTOR SPECIFIC PRTR POLLUTANTS

QUANTITY

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/Year0.0 0.0 0.0 0.0

* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button

SECTION B : REMAINING PRTR POLLUTANTS

QUANTITY

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

08 Nitrogen oxides (NOx/NO2) C OTH

KG per year = max concentration (mg/M3) x flowrate (M3)/1,000,000 x number of working hours per year 237.6 237.6 0.0 0.0

11 Sulphur oxides (SOx/SO2) C OTH

KG per year = max concentration (mg/M3) x flowrate (M3)/1,000,000 x number of working hours per year 57.02 57.02 0.0 0.0

80 Chlorine and inorganic compounds (as HCl) C OTH

KG per year = max concentration (mg/M3) x flowrate (M3)/1,000,000 x number of working hours per year 28.51 28.51 0.0 0.0

* 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)

QUANTITY

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

239 Sulphuric Acid C OTH

KG per year = max concentration (mg/M3) x flowrate (M3)/1,000,000 x number of working hours per year 1.9 1.9 0.0 0.0

* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button

Additional Data Requested from Landfill operators

Landfill: Chemifloc Ltd.Please enter summary data on the quantities of methane flared and / or utilised

additional_pollutant_no T (Total) kg/Year M/C/E Method CodeDesignation or

DescriptionFacility Total Capacity m3

per hourTotal estimated methane generation (as per

site model) 0.0 N/AMethane flared 0.0 0.0 (Total Flaring Capacity)

Methane utilised in engine/s 0.0 0.0 (Total Utilising Capacity)Net methane emission (as reported in Section

A above) 0.0 N/A

METHOD

POLLUTANT METHODMethod Used

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:

Method Used

RELEASES TO AIRPOLLUTANT METHOD

Method Used

POLLUTANT

RELEASES TO AIR

RELEASES TO AIR

Method Used

Page 19: Chemifloc Ltd - Environmental Protection AgencyAccreditation. Chemifloc has successfully retained accreditation through external biannual audits. The products manufactured by Chemifloc

4.2 RELEASES TO WATERS | PRTR# : P0076 | Facility Name : Chemifloc Ltd. | Filename : P0076_2008 AER PRTR.xls | Return Year : 2008 | 23/03/2009 10:148 8 16 16 24 24 6 6 6 6 6 6

SECTION A : SECTOR SPECIFIC PRTR POLLUTANTS Data on ambient monitoring of storm/surface water or groundwater, conducted as part of your licence requirements, should NOT be submitted under AER / PRTR Reporting as this only concerns Releases from your facility

QUANTITY

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/Year0.0 0.0 0.0 0.0

* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button

SECTION B : REMAINING PRTR POLLUTANTS

QUANTITY

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/Year0.0 0.0 0.0 0.0

* 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)

QUANTITY

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/Year0.0 0.0 0.0 0.0

* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button

RELEASES TO WATERS

Method Used

RELEASES TO WATERS

RELEASES TO WATERS

Method Used

POLLUTANTMethod Used

POLLUTANT

POLLUTANT

Page 20: Chemifloc Ltd - Environmental Protection AgencyAccreditation. Chemifloc has successfully retained accreditation through external biannual audits. The products manufactured by Chemifloc

4.3 RELEASES TO WASTEWATER OR SEWER | PRTR# : P0076 | Facility Name : Chemifloc Ltd. | Filename : P0076_2008 AER PRTR.xls | Return Ye 23/03/2009 11:418 14 22 30 6 6 6 6

SECTION A : PRTR POLLUTANTS

QUANTITY

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

79 Chlorides (as Cl) C OTH

KG per year = SUM mg/L (composites) x flow (L) / 1,000,000 43.855 685.575 641.72 0.0

19 Chromium and compounds (as Cr) C OTH

KG per year = SUM mg/L (composites) x flow (L) / 1,000,000 0.0389 0.0389 0.0 0.0

20 Copper and compounds (as Cu) C OTH

KG per year = SUM mg/L (composites) x flow (L) / 1,000,000 0.278 0.278 0.0 0.0

23 Lead and compounds (as Pb) C OTH

KG per year = SUM mg/L (composites) x flow (L) / 1,000,000 0.007 0.007 0.0 0.0

22 Nickel and compounds (as Ni) C OTH

KG per year = SUM mg/L (composites) x flow (L) / 1,000,000 0.008 0.008 0.0 0.0

24 Zinc and compounds (as Zn) C OTH

KG per year = SUM mg/L (composites) x flow (L) / 1,000,000 0.098 0.098 0.0 0.0

82 Cyanides (as total CN) C OTH

KG per year = SUM mg/L (composites) x flow (L) / 1,000,000 0.132 0.132 0.0 0.0

* 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)

QUANTITY

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

303 BOD C OTH

KG per year = SUM mg/L (composites) x flow (L) / 1,000,000 3.145 3.145 0.0 0.0

306 COD C OTH

KG per year = SUM mg/L (composites) x flow (L) / 1,000,000 100.584 100.584 0.0 0.0

240 Suspended Solids C OTH

KG per year = SUM mg/L (composites) x flow (L) / 1,000,000 36.645 36.645 0.0 0.0

314 Fats, Oils and Greases C OTH

KG per year = SUM mg/L (composites) x flow (L) / 1,000,000 5.39 5.39 0.0 0.0

343 Sulphate C OTH

KG per year = SUM mg/L (composites) x flow (L) / 1,000,000 427.025 427.025 0.0 0.0

353 Sulphides C OTH

KG per year = SUM mg/L (composites) x flow (L) / 1,000,000 0.082 0.082 0.0 0.0

356 Cobalt C OTH

KG per year = SUM mg/L (composites) x flow (L) / 1,000,000 0.0051 0.0051 0.0 0.0

357 Iron C OTH

KG per year = SUM mg/L (composites) x flow (L) / 1,000,000 6.506 343.506 337.0 0.0

321 Manganese (as Mn) C OTH

KG per year = SUM mg/L (composites) x flow (L) / 1,000,000 0.088 0.088 0.0 0.0

* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button

OFFSITE TRANSFER OF POLLUTANTS DESTINED FOR WASTE-WATER TREATMENT OR SEWER

OFFSITE TRANSFER OF POLLUTANTS DESTINED FOR WASTE-WATER TREATMENT OR SEWER

Method Used

Method Used

POLLUTANT METHOD

POLLUTANT METHOD

Page 21: Chemifloc Ltd - Environmental Protection AgencyAccreditation. Chemifloc has successfully retained accreditation through external biannual audits. The products manufactured by Chemifloc

4.4 RELEASES TO LAND | PRTR# : P0076 | Facility Name : Chemifloc Ltd. | Filename : P0076_2008 AER PRTR.xls | Return Year : 2008 | 23/03/2009 11:438 8 16 16 6 6 6 6

SECTION A : PRTR POLLUTANTS

QUANTITY

No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year0.0 0.0 0.0

* 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)

QUANTITY

Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year0.0 0.0 0.0

* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button

POLLUTANT METHODMethod Used

RELEASES TO LAND

RELEASES TO LAND

POLLUTANT METHODMethod Used

Page 22: Chemifloc Ltd - Environmental Protection AgencyAccreditation. Chemifloc has successfully retained accreditation through external biannual audits. The products manufactured by Chemifloc

5. ONSITE TREATMENT & OFFSITE TRANSFERS OF WASTE | PRTR# : P0076 | Facility Name : Chemifloc Ltd. | Filename : P0076_2008 AER PRTR.xls | Return Year : 2008 | 23/03/2009 12:125 8

Transfer DestinationEuropean Waste

Code HazardousQuantity T/Year Description of Waste

Waste Treatment Operation M/C/E Method Used

Location of Treatment

Name and Licence / Permit No. of Recoverer / Disposer /

BrokerAddress of Recoverer /

Disposer / Broker

Name and Address of Final Destination i.e. Final

Recovery / Disposal Site (HAZARDOUS WASTE

ONLY)

Licence / Permit No. of Final Destination i.e. Final

Recovery / Disposal Site (HAZARDOUS WASTE

ONLY)

Within the Country 20 03 01 No 19.31 General Domestic Waste D1 C Volume Calculation Offsite in Ireland

Clean (Irl) Refuse & Recycling Co. Ltd. WCP Number WCP/LK073/04c Cree, Kilrush, Co. Clare

Within the Country 15 01 02 No 3.79 Plastic Packaging R3 C Volume Calculation Offsite in Ireland

Clean (Irl) Refuse & Recycling Co. Ltd. WCP Number WCP/LK073/04c Cree, Kilrush, Co. Clare

Within the Country 15 01 01 No 0.87 Cardboard Packaging R5 C Volume Calculation Offsite in Ireland

Clean (Irl) Refuse & Recycling Co. Ltd. WCP Number WCP/LK073/04c Cree, Kilrush, Co. Clare

Within the Country 19 12 11 Yes 3.68 Waste fibreglass D15 M Weighed Offsite in Ireland

Veolia Environmental Services WCP Number 0050-02 Fermoy, Co Cork KWA, Germany NR.498/1713/ESB

* Select a row by double-clicking the Description of Waste then click the delete button

Method Used