For inspection purposes only. Consent of copyright owner … · · 2011-10-21... (spent(wash,(along(with(separator ... (Plant(The("alcohol"(plant(comprises(one(aeration(circuit(with

CPPU - UCC,16 South Bank,Crosses Green, Cork City

T 021 4836823F 021 [email protected]

www.ucc.ie/cI2Pu

14 October 2011Office of Climate, Licensing & Resource Use,Environmental Protection Agency,PO. Box 3000,Johnstown Castle Estate,Co. Wexford.

cc. Mr. Pat McCathy, Environmental Manager, Carbery

To whom it may concern:

On behalf of Carbery Milk Products Ltd., (IPPC Licence Register No. P0390-03) please

find enclosed a completed application and supporting documentation for the review of

the facilities discharges to water under the EC Environmental Objectives (Surface Wa-

ters) Regulations 2009.

Please do not hesitate to contact me if you have any queries.

Sincerely yours,

Niall Dunphy

Encl:

1 original and 1 hardcopy (unbound) of the completed review application form

2 copies on CD-ROM

Cleaner Production Promotion Unit, Department of Civil & Environmental Engineering, University College Cork

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Integrated Pollution Prevention and Control (IPPC)/Waste Licensing

Review Form and Guidance

Note

for the purposes of

EC Environmental Objectives (Surface Waters) Regulations 2009

Environmental Protection Agency P.O. Box 3000, Johnstown Castle Estate, Co. Wexford

Lo Call: 1890 335599 Telephone: 053-9160600 Fax: 053-9160699 Web: www.epa.ie Email: [email protected]

EPA Reg. No: (Office use only)

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Introduction

INTRODUCTION

This Form is for the purposes of a review of an IPPC/Waste Licence in order to ensure that all authorisations under the EPA Act 1992 to 2007 and the Waste Management Acts 1996 to 2010 having discharges liable to cause water pollution are in compliance with the EC Environmental Objectives (Surface Waters) Regulations 2009. While every effort has been made to ensure the accuracy of the material contained in the Review Form, the EPA assumes no responsibility and gives no guarantees, undertakings and warranties concerning the accuracy, completeness or up-to-date nature of the information provided herein and does not accept any liability whatsoever arising from any errors or omissions. The Review Form and all supporting information shall be submitted to the Headquarters of the Agency in a format of a signed original, one hardcopy and two copies on CD-Rom. In cases where an Environmental Impact Statement (EIS) is required in support of the Review Form, a signed original, one hardcopy plus 16 copies (or 18 copies if the activity is within Energy sector) on CD-Rom shall be submitted. All pages, including maps/drawings/plans, shall be no larger than A3 size. All files on CD-Rom shall be submitted in searchable PDF format and be no larger than 10MB each in size. All CD-Roms shall be labelled with the Licensees name, Licence Register Number, address of the activity and name of the file (i.e. Review Form).

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Contents

CONTENTS SECTION A: GENERAL ........................................................... 1

SECTION B: EMISSIONS ....................................................... 2

SECTION C: CONTROL & MONITORING ................................ 3

SECTION D: EXISTING ENVIRONMENT & IMPACT OF THE

ACTIVITY .........................................................7

SECTION E: STATUTORY REQUIREMENTS .......................... 12

SECTION F: APPROVED ADJUSTMENTS & CONDITIONS ..... 13

SECTION G: DECLARATION ................................................ 14

ANNEX 1: TABLES/ATTACHMENTS ...................................... 15

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SECTION A: GENERAL

A.1 Licensee Name*: Carbery Milk Products Ltd. Address: Ballineen Co. Cork

Tel: 023 8822200 Fax: 023 8847541 e-mail: [email protected]

Name and Address for Correspondence

Name: Niall Dunphy Address: Cleaner Production Promotion Unit University College Cork 16 South Bank, Crosses Green, Cork City, Ireland. Tel: 021 4836823 Fax: 021 4316323 e-mail: [email protected]

Address of registered or principal office of Body Corporate (if applicable)

Address: Ballineen Co. Cork Ireland Company Register No.

22819

Tel: 023 8822200 Fax: 023 8847541 e-mail: [email protected]

A.2 Location of Activity

Name: Carbery Milk Products Ltd. Address*: Ballineen, Co. Cork

Tel: 023 8822261 Fax: 023 8847541 Contact Name: Pat McCarthy Position: Environmental Manager e-mail: [email protected]

National Grid Reference (12 digit 6E,6N)

E 132367 N 053659

Attachment No A.2 contains location maps with the site boundary outlined on the map in red colour. Geo-referenced digital drawing files are included in in the accompanying CD-s.

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SECTION B: EMISSIONS B.1 Emissions to Surface Waters Wastewater(on(the(Carbery(facility(derives(from(influent(to(the(WWTPs(arise(from(process(wastewater,(boiler(blow;down,(condensates,(aqueous(wastes(and(contaminated(runoff(from(bunded(areas,(contaminated(wastes(from(truck(unloading(and(storage(areas,(contaminated(storm(waters,(floor(washing,(domestic(effluent(and(laboratory(wastewater.(This(wastewater(is( treated( at( the( companys( anaerobic( and( aerobic( wastewater( treatment( plants( and(discharged(to(the(River(Bandon(at(SW1.(

Cooling(water( (which( has( been( originally( abstracted( from( the( River( Bandon)( is( sent( along(with(storm(water(from(clean(hard(surface(areas(collected(during(periods(of(rain(back(to(the(River(Bandon(at(SW2.((Storm(water(collected(from(than(car(park(opposite(the(main(entrance(is(discharged(to(the(River(Bandon(at(SW3.(

A( summary( list( of( the( emission( points,( together( with( maps/drawings( is( included( as(Attachment)No)B.1.((

(

B.2 Tabular Data on Emission Points to surface water

Point Code Easting Northing Verified Emission SW1 E 133576 N053925 Y pH, COD, BOD,

Suspended Solids, Ortho-P, Total P, Total No, Ammonia as N, Oils, fats & greases

SW2 E 132473 N 053546 Y pH

SW3 E 132220 N 053541 Y N/A

The( tabular( data( is( included( on( an( Excel( file( entitled( tabular_data.xls,( worksheet( B.2( on(accompanying(CD(with(a(row(for(each(emission(point(as(requested.(

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SECTION C: CONTROL & MONITORING Describe the proposed technology and other techniques for preventing or, where this is not possible, reducing emissions from the installation/facility. C.1 Treatment, Abatement and Control Systems

Wastewater(Treatment(Summary((

Between( 1968( and( 1975( the( effluent( from( Carbery( was( treated( by( means( of( a( spray(irrigation(system(on(the(company's(farm(at(Ballineen,(Co.(Cork.(Subsequently,(a(wastewater(treatment(plant( (WWTP)(of( the("Carrousel"(system(was(constructed(to(cater( for( increased(production(and(diversification.(The(WWTP(has(been(expanded(and(developed(in(conjunction(with( the( manufacturing( facility( over( the( years.( Figure( 1( illustrates( the( treatment( of(wastewater(at(Carbery.(Refer(also(to(drawings(No.(211134;05(and(211134;04,(which(show(the(layout(of(Aerobic(and(the(Anaerobic(plants(respectively.(

Figure 1: Carbery Wastewater treatment Schematic

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Anaerobic(Treatment(

The(spent(wash,(along(with(separator(desludge(from(the(UF(plant(and(milk( intake,(goes(to(the( effluent( farm( where( it( is( pH( adjusted( with( caustic,( lime( as( well( as( chlorus( dosing( to(control( bacterial( activity.( The( effluent( then( enters( a( Dissolved( Air( Floatation( (DAF)( unit(where(a(flocculating(agent((anionic(polyelectrolyte)(is(added(to(precipitate(phosphorus.(The(sludge(produced(from(this(process,(accounting(for(circa.(50%(of(the(influent,( is( later(mixed(with( sludge( from( the( aerobic( plant( for( application( to( land.( ( The( supernatant( from( this(process( feeds( into( an( anaerobic( digestion( systems,( where( at( least( 90%( of( the( COD( is(converted(to(methane,(which(is(used(for(a(fuel(for(onsite(boilers.(

There(are(two(internal(circulation((IC)(reactors,(which(work( independent(of(each(other.(pH(levels( for( the( IC(reactors(are(maintained( in( the(range(pH(6.8;7.5(to(optimise(performance.((The(gases(produced(through(anaerobic(digestion(are(collected(and(used(as(a(biogas(fuel( in(an(onsite( boiler.(H2S( gases(produced(as( a( by;product( are( scrubbed( through( calcium( shells(which(removes(all(the(H2S.(The(effluent(from(the(IC(reactors(after(the(anaerobic(digestion(is(completed( is(pumped( in(conjunction(with( the(dairy(effluent( to( the(aerobic(plant(via(a(10"(line.(((

(

Aerobic(Treatment(

Carbery( has( 3( separate( aerobic( treatment( plants( namely( the( Alcohol( carousel,( Dairy(carousel( 1( and( Dairy( carousel( 2.( Aerobic( dairy( effluent( consists( of( 7( internal( effluent(streams(from(different(production(departments(on(the(site(as(well(as(the(effluent(from(the(IC( reactors(described(above.(At( the(start(of( the(aerobic( treatment(process(a( large(balance(tank((c.(5000m)(facilitates(the(optimisation(of(volumetric(and(mass(loadings(to(the(aerobic(WWTP( increasing( its( operational( performance.( During( the( aerobic( treatment( process( the(effluent(is(aerated(and(mixed(in(large(tanks,(called(aeration(carousels,(by(forcing(air/oxygen(through( the(effluent.( ( This( increases( the(amount(of(dissolved(oxygen(and(hence( increases(the( rate( of( biodegradation.( An( independent(metered( pump( feeds( the( effluent( into( the( 2("dairy"(treatment(plants(and(the("alcohol"(plant(aeration(circuits.(

Dairy(Plant(

The("dairy"(plant(comprises(two(effluent(aeration(circuits(with(vertical(surface(aerators(with(automatic(speed(control(based(on(dissolved(oxygen(set(points,(with(the(aerators(adjusting(their( speed( according( to( the( D.O.( levels.( ( As( required,( aluminium( sulphate( is( added( for(phosphate(precipitation.((The(effluent(overflows(a(3.5(metre(fixed;weir(and(is(discharged(to(a(settlement(tank,(where(the(sludge(settles(and(the(treated(effluent(overflows(a(peripheral(weir,( through( a(measurement( chamber( and( on( to( the( outfall( pipe.( ( The( settled( sludge( is(pumped(back(to(the(aeration(circuit(as(returned(activated(sludge((RAS),(or(is(withdrawn(to(a(picket(fence(thickener(to(maintain(Mixed(Liquor(Suspended(Solids((MLSS)(of(approximately(4000ppm(in(aeration(circuit.(An(anoxic(zone(at(the(start/end(of(the(aeration(process(is(used(to(reduce(the(N(content(of(the(feed.(Both(aeration(circuits(are(operational(all(year(round.(

Alcohol(Plant(

The("alcohol"(plant(comprises(one(aeration(circuit(with(4(jet(aerators,(4(flow(boosting(pumps(and(3(blowers.((Aluminium(sulphate(is(also(added(to(the(alcohol(effluent(plant(for(phosphate(precipitation.( ( The( effluent( overflows( an( adjustable( weir( to( two( alcohol( plant( settlement(

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tanks.((The(sludge(settles(and(the(treated(effluent(overflows(a(peripheral(weir(to(the(outfall(pipe.((The(settled(sludge(is(pumped(back(to(the(aeration(circuit(as(returned(activated(sludge((RAS),( or( is( withdrawn( to( a( picket( fence( thickener( to( maintain( Mixed( Liquor( Suspended(Solids((MLSS)(of(approximately(4000ppm(in(aeration(circuit.(An(anoxic(zone(at(the(start/end(of(the(aeration(process(is(used(to(reduce(the(N(content(of(the(feed.(The(outfall(pipe(with(the(combined(effluent( from(both(the("dairy"(and("alcohol"(plants(aeration(circuits(discharges(into(the(River(Bandon.(

Variations(for(Start6Up(and(Shutdown(of(WWTP(

As(the(WWTP(operates(for(365(days(a(year(and(there(are(no(routine(start;up(and(shutdown(situations.(In(the(event(of(non;routine(shutdown,(the(balancing(tank(can(be(used(to(store(up(to(4,948(m(of(wastewater(equivalent(to(circa.(1(day(of(influent,(to(allow(for(the(plant(to(be(brought( back( into( action.( Scenarios( where( there( are( substantial( reductions( in( influent(loadings,( the(plant(will(be(reseeded(to(ensure(that( it(continues(to(operate(at( full(capacity.(There(are(start(up(and(shutdown(detailed(procedures(in(the(Service(Manual.(

Sludge(Management(

The(excess( sludge( from( the( aeration( circuits( is( pumped( to( the(picket( fence( thicker,(which(thickens(the(sludge(from(approximately(0.8%(dry(solids(to(approximately(2.0%(dry(solids.(A(decanter( system( dewaters( the( sludge( further( to( approximately( 15%( dry( solids.( Cationic(polyelectrolyte( is(dosed( in( line(prior( to(decanter( to(aid(coagulation.(The(decanter(centrate(passes(to(the(alcohol(aeration(circuit(for(further(treatment.((

The( "chemical"( sludge( from( the(DAF( is(pumped(directly( to(a(holding( tank,(at( ca.(3;4%(dry(solids.( It( is( fed( into( a( separate( decanter,( Anionic( polyelectrolyte( is( dosed( in( line( prior( to(decanter(to(aid(coagulation,(and(the(final(solids(are(up(to(20%(dry(solids.(The(return(centrate(from(the(decanter(goes(back(to(the(DAF.(

The( final( sludges( are(mixed( at( a( ratio( of( ca.( 70%( Biological( (brown)( and( 30%( Chemical((white)(sludges.(The(sludge(is(then(stored(in(a(concrete(yard(and(is(taken(for(spreading(on(EPA(approved(landbank(under(a(nutrient(management(plan(from(15(January(to(15(October(weather(permitting.(During(the(closed(season,(the(sludge(is(stored(onsite(in(a(storage(yard.(

Carberys(sludge(from(has(been(awarded(the(Organic(Trust(Symbol((No.(56).(((

Anticipated(Malfunctions(

In( the( event( of( overload( to( one( of( the( three( aerobic( plants,( the( effluent( can( be( either(diverted( to( the( other( aerobic( plant( or( as( required,( or( to( the( feed( balance( tank.( WWTP(controls(monitor(and(alert(operators(of(potential(malfunctions.(

Influent(Monitoring(

The( influent( flows(and(COD( loadings(of( the( dairy( and( alcohol(wastewater( streams(are(monitored( on( a( daily( basis.( In( addition( the( flow( rates( and( COD( loadings( of( wastewaters(arising( from( the( cheese( process,( powder( plant,( ultrafiltration( plant,( milk( intake( plant,(fermentation(process(and(CIP(systems(are(monitored,(results(are(discussed(at(daily(effluent(meeting(and(issues(investigated.((

In6treatment(Monitoring(

Information(on(the(In;treatment(is(detailed(in(table(C.1(i).(

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C.2 Monitoring and Sampling Points

The(effluent(from(the(aerobic(wastewater(treatment(plant,(is(sampled(as(it(leaves(the("dairy"(and( "alcohol"( plants( aeration( circuits( at( SW1(i)( and( SW1(ii)( respectively.( ( This( effluent( is(continuously( monitoring( for( flow( and( temperature( and( a( 24;hour( composite( sampled( is(taken(and(tested(for(pH,(COD,(SS,(Ortho;P(and(Ammonia(on(a(daily(basis;(BOD(is(performed(weekly;(and(Total(N(&(Oils,(fats(&(greases(monthly(

A(24;hour(composite(sample(of(the(cooling(water(and(storm(water(discharge(is(tested(daily(for(pH(at(SW2(i).(

Ambient(monitoring(on(the(River(Bandon(is(performed(biannually(at(five(locations(where(it(is(testing( for( ortho;phosphate( and( biological( quality( (Q( value)( using(macro( invertebrates( as(biological(indicators.(

ASW1(is(located(upstream(of(Manch(Bridge(and(upstream(of(the(discharges(from(the(factory.(

ASW2(is(situated(just(below(a(sharp(bend(in(the(river(shortly(downstream(of(the(discharge(from(the(factorys(cooling(water(discharge.(

ASW2a( is( located( just( downstream( of( the( main( effluent( treatment( plant(discharge.(

ASW3( is( situated( further( downstream( at( a( point( immediately( upstream( of(Ballineen(Bridge.(

ASW4(is(situated(at(Murragh(Bridge,(the(second(next(bridge(on(the(Bandon(River(downstream(of(Ballineen.(

A(summary(of(sampling(and(testing(methods(are(included(as(table(C.2(i).( C.3 Tabular Data on Monitoring and Sampling Points

Point Code Easting Northing Verified Emission SW1(i) E 133640 E 053640 Y pH, COD, BOD,

Suspended Solids, Ortho-P, Total P, Total N, Ammonia as N, Oils, fats & greases

SW1(ii) E 133643 (E 133770)

N 053664 (N 053674)

Y

SW2(i) E 132384 N 053595 Y pH ASW1 E 129204 N 052129 Y N/A Ambient Monitoring ASW2 E 132790 N 053523 Y N/A Ambient Monitoring ASW2a E 133623 N 053964 Y N/A Ambient Monitoring ASW3 E 134337 N 053869 Y N/A Ambient Monitoring ASW4 E 138085 N 054115 Y N/A Ambient Monitoring

The( tabular( data( is( included( on( an( Excel( file( entitled( tabular_data.xls,( worksheet( C.3( on(accompanying(CD(with(a(row(for(each(emission(point(as(requested.(

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SECTION D: EXISTING ENVIRONMENT & IMPACT OF THE ACTIVITY

D.1 Assessment of Impact on Receiving Surface Water The( discharges( from( Carbery( are( into( the( River( Bandon,( there( are( no(downstream water dependent protected areas. The Discharge is a( short( distance( downstream( of( a( defunct(hydrometric(station((#20013).(Data(from(this(station(was(collected(during(1981(to(1999(and(shows( a( 95%ile( flow( of( 0.379m3.( There( is( no( more( recent( data( available( and( so( it( is(considered(that(this(is(the(most(appropriate(source(to(use.(((It(was(decided(to(use(the(annual(mean( flow( (Q( mean)( as( the( basis( of( the( calculations( and( this( was( derived( by( pro;rata(extrapolation( of( published( data( from( monitoring( station( #20002( at( Curranure( which( is(downstream(of(the(Carbery(outfalls.(

The(River(Bandon(is(classified(as(moderate(quality(and(the(assimilative(capacity(is(believed(to(be( negligible.( It( is( Carberys( considered( opinion( that( the(most( appropriate( and( equitable(methodology(to(calculate(emissions(limit(is(to(use(a(notional(clean(river(approach(along(with(mean(flows(and(EQSs,(as(has(been(the(case(for(Wastewater(Discharge(License(application(to(the(Agency(from(Local(Authorities.(We(present(the(results(of(such(calculations(below:((

Notes:(

(i) An(adjusted(background(of(1/5(of(the(relevant(mean(EQS((high(quality(status)(is(used(in(each(case(

(ii) The(mean(flow(for(station(20013(at(Carbery( is(extrapolated(pro;rata(from(the(Curranure(Station(using(the(ratio(of(the(95%ile(data.(

(iii) The(Maximum(values(presented(are(the(current(license(limits(

(

Biological(Oxygen(Demand(

Flow(of(river((Q(mean)( F( ( ( 4.286(m3/s(

Mean(BOD((upstream)( C( ( ( 0.26(mg/l((

Max(BOD(in(Discharge( c( ( ( 20(mg/l(

Max(volume(Discharge( f( ( ( 0.0462963(m3/s( (

@4000m3( Therefore(( T( =( ( 0.24)mg/l(

( ( ( Mean(EQS((Good(Status)( ( 1.5(mg/l(

(


Mean(BOD((upstream)( C( ( ( 0.26(mg/l((

Max(BOD(in(Discharge( c( ( ( 10(mg/l(


@6000m3( Therefore(( T( =( ( 0.19)mg/l(


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Ortho;Phosphate(


Mean(ortho;P((upstream)( C( ( ( 0.005(mg/l(

Max(ortho;P(in(Discharge( c( ( ( 1(mg/l(


@4000m3( Therefore(( T( =( ( 0.016)mg/l(


(


Mean(ortho;P((upstream)( C( ( ( 0.005(mg/l(

Max(ortho;P(in(Discharge( c( ( ( 0.6(mg/l(

Max(volume(Discharge( f( ( ( 0.0694444(m3/s( ( (

@6000m3( Therefore(( T( =( ( 0.014)mg/l(

( ( ( Mean(EQS( ( ( ( 0.035(mg/l(

(

Total(Ammonia(


Mean(Ammonia((upstream)(C( ( ( 0.008(mg/l(

Max(Ammonia(in(Discharge(c( ( ( 1.0(mg/l(


@4000m3( Therefore(( T( =( ( 0.019)mg/l(


(


Mean(Ammonia((upstream)(C( ( ( 0.008(mg/l(

Max(Ammonia(in(Discharge(c( ( ( 0.6(mg/l(


@6000m3( Therefore(( T( =( ( 0.017)mg/l(

( ( ( Mean(EQS((Good(Status)( ( 0.065mg/l(

(

For(upstream(concentrations(of(BOD,(ammonia(and(ortho;phosphate(the(notional(clean(river(approach(is(used(which(takes(an(adjusted(background(of(1/5(of(the(relevant(mean(EQS((high(quality(status)(in(each(case.(This(methodology(has(been(used(for(local(authority(calculations(as(well(as(recent(licenses.(

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For( flow(calculations,( the( SI(No.(272/2009( regulations(permit(either( the(mean( flow(or( the(95%ile(flow(to(be(used.(The(Environmental(Quality(Standards((EQS)( in(the(SI(No.(272/2009(regulations(are(designed( to(protect( the( river(water(quality(using(either( the(95%ile( flow(or(the( mean( flow.( The( differing( EQS( concentration( values( reflect( this( in( the( standard( and(therefore(either(flow(can(be(used(

The( above( calculations( show( that( on( the( basis( of( Notional( Clean( Water( approach( that(Carberys( current( discharges( do( not( result( in( a( breach( of( the( mean( EQS( for( good( status(waterways(and(so(are(compliant(with(SI(No.(272/2009.(

Carbery( conduct(biannual(monitoring(of( the(biological(quality(and(ortho;phosphate(at( five(locations( on( the( River( Bandon.( The( monitoring( locations( include( upstream,( adjacent( and(downstream(of(the(companys(discharges.(Historic(results,(refer(to(table(D.1(i),(have(shown(that( the( activities( of( the( plant( have( not( had( a( detrimental( effect( on( the( quality( of( the(waterway.(During(the(period(covered(by(the(data((2004((2010),(the(quality(of(the(water(in(terms( of( both( Q;valves( and( Ortho;phosphate( levels( across( the( five( sampling( points( were(shown(not(to(have(degraded(but(somewhat(improved(in(quality(in(the(waterway.((

In( light( of( this( demonstrated( improvement( stability/improvement( in( water( quality,( we(suggest(that(the(discharges(from(the(Carbery(facility(at(current(volumetric(and(concentration(levels(do(not(present(a(risk(to(the(quality(of(the(water.(

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D.2 Environmental Considerations and Best Available Techniques (BAT) Note:(As( this( is(a( licence( review( for(an(existing(activity( consideration(of(alternatives( if(not(applicable.(

Carbery(operates(under(an(IPPC(licence((register(No.(P0390;03),(which(governs(the(minimum(environmental( performance( onsite.( As(mandated( by( this( licence,( Carbery( have( developed(and( implemented( an( Environmental( Management( System,( built( upon( an( Environmental(policy,( which( commits( the( company( to( continued( improvement( in( environmental(performance(in(areas(of(activities(which(are(appropriate,(relevant(and(economically(viable.((

In( relation( to( the( environmental( performance( of( its( facility( the( policy( formally( commits(Carbery( to( the( continuous( improvement( of( following( aspects( of( its( environmental(performance:(

Waste(reduction(and(avoidance,(recycling(and(reuse;( Conservation(of(Energy(and(resources;( Examination( of( environmental( impacts( of( all( new( processes,( products( and( plant(

extensions.(

The( company( sets( itself( environmental( objectives( and( targets,( reviewed( annually( and(develops( a( rolling( Environmental(Management( Programme( to( achieve( these( objectives( &(targets;(within(this(EMP(Carbery(undertakes(project(to(improve(its(performance(in(all(of(its(identified(environmental(aspects,( including(the(adoption(of(cleaner(production(approaches(such( as( cleaner( technologies,( waste( minimisation( and( raw( material) substitution.( This(frontend( approach( of( cleaner( production( minimises( and( where( possible( eliminates((potential)(emissions.(

Best( Available( Techniques( (BAT)( are( adopted( throughout( the( plant( and( Carbery( regularly(examines( the( economic( and( technical( feasibility( of( improving( the( specific( techniques( and(technologies( it(adopts(so(as( to( improvement( its(environmental(performance.(For(example,(the( wastewater( treatment( described( elsewhere( in( this( document,( involves( a( variety( of(technologies( including(activated( sludge,( anaerobic(digestion,(phosphorus(precipitation( etc.(which(have(been(developed(over( the(years( to(ensure( the(minimum(environmental( impact(and(that(no(significant(pollution(is(caused.(

As( indicated( above( waste( onsite( is( in( line( with( the( waste( hierarchy,( furthermore( in(accordance(with(the(conditions(of(its(IPPC(licence,(handling,(transfer(and(recovery/disposal(of(waste(are(strictly(controlled(and(recorded.(

Carbery( is( a(member(of( the( Large( Industry( Energy(Network( (LIEN)( is( a( voluntary(network,(facilitated( by( Sustainable( Energy( Authority( of( Ireland,( of( companies( working( to( maintain(strong(energy(management.(Carbery(as(a(member(of(LIEN(have(committed(to(developing(a(management(programme(for(energy(use;(setting(and(reviewing(energy(targets;(undertaking(an(annual(energy(audit(and(producing(an(annual(statement;of;(energy(account.(

In(2006,(Carbery(won(the(LIEN(national(award(for(its(energy(saving(initiatives,(comprising(a(thorough( thermodynamic( examination( of( all( production( processes( integrating( all( heating(and(cooling(processes(into(a(single(heat(exchanger(network.((Energy(is(an(ongoing(priority(at(Carbery( and( there( are( energy( conservation( and( optimisation( projects( each( year( in( the(Environmental(Management( Programme.(Carbery( is( also( in( the( Emissions( Trading( Scheme((ETS)(and(are(committed(to(reducing(its(carbon(emissions(required(for(Phase(III(of(the(ETS.(

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There( are( no( direct( emissions( to( groundwater( and( inadvertent( indirect( emissions( will( be(prevented(by(bunding(and(correct(material(handling(protocols.( Integrity(testing(of(bunding(structures(is(carried(out(on(a(3;year(cycle,(in(accordance(with(the(facilitys(IPPC(license.((

Carbery( have( developed( an( Emergency( Response( Plan( (ERP)( and( an( accident( prevention(strategy( to(provide( for(a( system(of(preparedness( for(dealing(with(all( emergency( scenarios(with( an( environmental( or( health( and( safety( impact( on( its( site.( These( emergency(preparedness(plan(include:(

Developing( plans( and( procedures( to( manage( potential( emergencies( that( are(foreseeable.(

Selecting(and(training(key(individuals(to(respond(in(the(event(of(an(emergency.(

Providing(the(necessary(resources(to(facilitate(an(appropriate(emergency(response.(

Testing(emergency(plans(by(regular(drills,(announced(and(unannounced.(

Reviewing(emergency(plans(on(an(on(going(basis.(

In( 2009,( Carbery(went( through( a( process( to( prepare( a( Closure,( Restoration( and(Aftercare(Management(Plan((CRAMP).(As(a(clean(closure(was(envisaged(only(the(Closure(plan(aspect(of( the( CRAMP(was( found( to( be( required.( A( site( evaluation(was( carried( out( and( the(main(closure(considerations(were(found(to(relate(to(the(decommissioning(and(decontamination(of(buildings,(plant(and(equipment.( In( the(event(of(closure,(much(of( the(plant(and(equipment(will(be(sold(on(the(open(market(and(it(is(planned(that(the(decommissioned(buildings(remain(in( place( for( alternative( use.( It( is( not( envisaged( that( aftercare( maintenance( or( long;term(monitoring(will( be( required.( Due( to( the( nature( of(much( of( the( plant( and( equipment( it( is(considered(that(the(sale(of(same(would(be(sufficient(to(meet(the(costs(of(the(closure(plan.

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SECTION E: STATUTORY REQUIREMENTS

E.1 Best Environmental Practices Compliance with Legislation

Demonstrate if the best environmental practices are in place for control of diffuse emissions from the installation/facility as set out in the following legislation:

(a) a specification prepared by the Agency in accordance with Section 5 of the

Environmental Protection Agency Act 1992 as amended by Section 7 of the Protection of the Environment Act 2003;

Cabery have applied BAT and have implemented an Environmental Management System at its facility at Ballineen, please refer to section D.2 above for further details. (b) the Urban Waste Water Treatment Regulations 2001 (S.I. No. 254 of 2001)

as amended by the Urban Waste Water Treatment (Amendment) Regulations 2004 (S.I. No. 440 of 2004) or any future amendment thereof;

Wastewater from Carbery is not sent to urban wastewater treatment plants and therefore the requirement for pretreatment is not applicable.

Nevertheless, Carbery ensures that its own wastewater treatment process are managed in such a manner so that: the health of WWTP staff working is protected; WWTP and associated equipped is maintained and provides for the effective operation of the plant and treatment of sludge; discharges comply with its IPPC licence and WWTP sludge is recovered to land in an environmental beneficial manner.

Note: The River Bandon is not designated Sensitive Areas under the Urban Wastewater Treatment Regulations 2001 (S.I. 254 of 2001). (c) the European Communities (Good Agricultural Practice for Protection of

Waters) Regulations 2009 (S.I. No. 101 of 2009) or any future amendment thereof;

Carbery comply with the S.I. No. 610 of 2010 (which superseded SI 101/2009) through the operation of a Nutrient Management Plan (NMP) for the land spreading of sludge arising from its WWTP. The plan is updated annually and submitted to the EPA for approval under its IPPC licence. This plan specifies the land on which the sludge is to be spread; the rates of application (based on an assessment of soil nutrient requirement (based on soil testing & information on planned crop) and analysis of the sludge; buffer zones and exclusion periods to be observed during the land application of the sludge. (d) the Local Government (Water Pollution) Act, 1977 (Control of Cadmium

Discharges) Regulations 1985 (S.I. No. 294 of 1985); Cadmium not produced, handled or used onsite and consequently will not arise in wastewater SI 294/1985 is therefore considered not relevant to the activities. (e) the Local Government (Water Pollution) Act, 1977 (Control of

Hexachlorocyclohexane and Mercury Discharges) Regulations 1986 (S.I. No. 55 of 1986);

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Hexachlorocyclohexane and Mercury are not produced, handled or used onsite and consequently will not arise in wastewater SI 55/1986 is therefore considered not relevant to the activities. (f) the Local Government (Water Pollution) Acts, 1977 and 1990 (Control of

Carbon Tetrachloride, DDT and Pentachlorophenol Discharges) Regulations 1994 (S.I. No. 43 of 1994); and,

Carbon Tetrachloride, DDT and Pentachlorophenol are not produced, handled or used onsite and consequently will not arise in wastewater SI 43/1994 is therefore considered not relevant to the activities. (g) measures or controls identified in a pollution reduction plan for the river

basin district prepared in accordance with Part V of the EC Environmental Objectives (Surface Waters) Regulations 2009 S.I. No. 272 of 2009 for the reduction of pollution by priority substances or the ceasing or phasing out of emissions, discharges and losses of priority hazardous substances.

Efficient and effective management of WWTP to ensure that current emission limit values are not exceeded.

SECTION F: APPROVED ADJUSTMENTS & CONDITIONS

Where the Office of Environmental Enforcement (OEE) of the Agency has agreed any variations or adjustments to the conditions of the existing licence, the licensee must supply a schedule detailing these agreed variations and adjustments to the existing licence conditions. An updated, scaled drawing of the site layout (no larger than A3) providing visual information on such adjustments or variations where appropriate should be included. In the case of once-off assessments/ reports required under conditions of the existing licence the licensee must supply a schedule detailing those assessments/ reports that have been completed and agreed with the Office of Environmental Enforcement (OEE) or as otherwise agreed. Attachment No F1 shall include the schedule of variations and/or adjustments together with the updated drawing.

Condition

No. Existing

Condition Proposed Wording

(where appropriate)

OEE Agreement Reference

Description

Not Applicable

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SECTION G: DECLARATION

Declaration

I certify that the information given in this Review Form is truthful, accurate andcomplete.

I give consent to the EPA to copy this Review Form for its own use and to make itavailable for inspection and copying by the public, both in the form of paper filesavailable for inspection at EPA and via the EPA's website. This consent relates to thisReview Form itself and to any further information, submission, objection, or submissionto an objection whether provided by me as Licensee, any person acting on the Licensee'sbehalf, or any other person.

Signed by: to\.~U ~~(on behalf of the organisation) \

Date: _

Print signature name : .'..:N'!:ia~I~I..':'D~u:!!.n_'1p:!!.h~yl_ _

Position in organisation : .."E~n~v~ir_'"'o~n~mC':e~nC':t....a'.'_l~A~d~v~is"'-'o"'-'r_(\."C"'_'P'__'P'__'U'"'J_, ~U_'=C'-'=C'J) _

Company stamp or seal:

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ANNEX 1: TABLES/ATTACHMENTS

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TABLE B.1(i): EMISSIONS TO SURFACE WATERS (One page for each emission) Emission Point:

Emission Point Ref. No.: SW1

Source of Emission: Effluent from the anaerobic and aerobic wastewater treatment plants (WWTP); [influent to the WWTPs arise from process wastewater, boiler blow-down, condensates, aqueous wastes and contaminated runoff from bunded areas, contaminated wastes from truck unloading and storage areas, contaminated storm waters, floor washing, domestic effluent and laboratory wastewater]

Location : Knockanedy, Ballineen, Co. Cork

Grid Ref. (12 digit, 6E,6N): E 133576 N 053925

Name of receiving waters: River Bandon

Flow rate in receiving waters: 0.379 m3.sec-1 95%ile flow

4.286 m3.sec-1 Mean flow

Emission Details:

(i) Volume to be emitted

Normal/day 4,000 m3 Maximum/day 6,000 m3 note1

Maximum rate/hour 250m3 Note 1: refer to conditions 6.15 & 11.12 of IPPC licence ref. no. PO390-03 for circumstances in which lower maximum of 4,000m would apply

(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

Note 1: 95%ile flow data from Cork Co. Co. Carbery 20013 Hydrometric Monitoring Station 1981-99; refer also to Agency correspondence MMACC/AJ 28/01/98

Note 2: No median flow data for Carbery Station; data calculated from the OPW Hydrometric Station at Curranure, Bandon, Co. Cork using ratio of the stations 95%ile values

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Source of Emission: Storm water and cooling water

Location : Adjacent to Anaerobic treatment plant Carrigmore, Ballineen, Co. Cork





Emission Details:


Normal/day Not measured m3 Maximum/day Not measured m3

Maximum rate/hour Not measured m3


to be included):

Periods of Emission (avg) 60 min/hr 24 hr/day 365 day/yr

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Source of Emission: Storm water

Location : Car Park Carrigmore, Ballineen, Co. Cork





Emission Details:


Normal/day Not measured m3 Maximum/day Not measured m3

Maximum rate/hour Not measured m3


to be included):

Periods of Emission (avg) Weather dependant min/hr Weather dependant hr/day Weather dependant day/yr

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TABLE B.1(ii): EMISSIONS TO SURFACE WATERS - Characteristics of the emission (One table per emission point) Emission Point Reference Number: SW1

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)


kg/day kg/year

pH Not Measured

Not Measured

Not Measured

Not Measured

8.64 @SW1(i) N/A Not measured

COD Not Measured

Not Measured

Not Measured

Not Measured

473.61 77,744 Not Measured

BOD Not Measured

Not Measured

Not Measured

Not Measured

46.33 4,494 Not measured

Suspended Solids Not Measured

Not Measured

Not Measured

Not Measured


Ortho-P Not Measured

Not Measured

Not Measured

Not Measured

3.97 608 Not measured

Total P

Not Measured

Not Measured

Not Measured

Not Measured


Total N

Not Measured

Not Measured

Not Measured

Not Measured


Ammonia as N

Not Measured

Not Measured

Not Measured

Not Measured


Oils, fats & greases Not Measured

Not Measured

Not Measured

Not Measured


Note: Maximum daily averages, and mass loadings presented are based on the 2010 monitoring data

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kg/day kg/year

pH N/A N/A N/A N/A N/A N/A N/A N/A N/A

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kg/day kg/year

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A



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TABLE C.1(i): ABATEMENT/TREATMENT CONTROL Emission Point Reference Number: SW1

Control 1 parameter

Equipment 2 Equipment maintenance

Equipment calibration

Equipment back-up

Monitoring to be carried out 3

Monitoring equipment

Monitoring equipment calibration

Influent to WWTP (for individual streams)

Flow Pumps As required N/A Standby pumps & spares onsite

Continuous Flow meter/ recorder

Monthly

TOC WWTP As required N/A Balance Tank Daily TOC meter/ recorder

Monthly

COD WWTP As required N/A Balance Tank Daily Std Methods N/A

Anaerobic plant

Temperature Plate Heat Exchangers

As required N/A Spares onsite Continuous Temp probe/ recorder

Monthly

pH Lime, caustic, chlorus pumps

As required N/A Spares onsite Continuous 5 x pH probes Monthly

Flow to IC Reactors

Pumps As required N/A Standby pumps Continuous Flow meter/ recorder

Monthly

Phosphorous removal

Alum Dosing Pumps

As required N/A Spares on site Weekly Std Methods N/A

Effluent from anaerobic plant to aerobic plant

pH Anaerobic WWTP

As required N/A Aerobic WWTP / Balance tank

Weekly pH probe Monthly

COD Anaerobic WWTP


Daily Sampler / Std Methods

Volatile Fatty Acids VFA (total)

Anaerobic WWTP


Daily Sampler / Std Methods

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Control 1 parameter



Equipment back-up




VFA (individual) Anaerobic WWTP


When Total VFAs exceed design levels

Sampler / GC

Calcium Anaerobic WWTP


Weekly Sampler / Std Methods

Phosphate Anaerobic WWTP



Nitrogen Anaerobic WWTP



Aerobic Plant

Influent Flow Aerobic Flow As required N/A Balance Tank/ Other circuit

Continuous Flow meter Monthly

DO (3 basins) Aeration circuits

As required N/A Balance Tank/ Other circuit

Continuous DO meters/ recorder

Monthly

pH Aeration circuits


Daily 3x pH probes/ recorders

Monthly

MLSS / SVI Aeration circuits


Daily Std Methods

F/M Ratio Aeration circuits


Weekly N/A

Floating matter Clarifiers As required N/A Balance Tank/ Other circuit

Daily Visual

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Control 1 parameter



Equipment back-up




Sludge dewatering

% Dry Solids Decanter As required N/A Spares onsite biannually Std Methods

Suspended Solids

Picker Fence Thickener

As required N/A Spares onsite Daily Visual

1 List the operating parameters of the treatment/abatement system, which control its function. 2 List the equipment necessary for the proper function of the abatement/treatment system. 3 List the monitoring of the control parameter to be carried out.

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TABLE C.2(i): EMISSIONS MONITORING AND SAMPLING POINTS (One table per monitoring point) Emission Point Reference Number: SW1(i)

Parameter Monitoring frequency Accessibility of Sampling Points

Sampling method Analysis method/ technique

Flow Continuous Secure safe access Inline meter/ recorder Flow meter

Temperature Continuous Secure safe access Inline probe/ recorder Temperature probe

pH Daily Secure safe access 24-hour composite sample

pH Probe

BOD Weekly Secure safe access 24-hour composite sample

Std Methods

COD Daily Secure safe access 24-hour composite sample

Std Methods

Suspended Solids Daily Secure safe access 24-hour composite sample

Gravimetric

Ortho-P Daily Secure safe access 24-hour composite sample

Std Methods

Total P Weekly Secure safe access 24-hour composite sample

Std Methods

Ammonia as N Daily Secure safe access 24-hour composite sample

Ion Selective Electrode

Total No Monthly Secure safe access 24-hour composite sample

Std Methods

Oils, fats & greases Monthly Secure safe access 24-hour composite sample

Std Methods

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TABLE C.2(i): EMISSIONS MONITORING AND SAMPLING POINTS (One table per monitoring point) Emission Point Reference Number: SW1(ii)



Flow Continuous Secure safe access Inline meter/ recorder Flow meter

Temperature Continuous Secure safe access Inline probe/ recorder Temperature probe


pH Probe

BOD Weekly Secure safe access 24-hour composite sample

Std Methods

COD Daily Secure safe access 24-hour composite sample

Std Methods

Suspended Solids Daily Secure safe access 24-hour composite sample

Gravimetric

Ortho-P Daily Secure safe access 24-hour composite sample

Std Methods

Total P Weekly Secure safe access 24-hour composite sample

Std Methods

Ammonia as N Daily Secure safe access 24-hour composite sample

Ion Selective Electrode

Total No Monthly Secure safe access 24-hour composite sample

Std Methods

Oils, fats & greases Monthly Secure safe access 24-hour composite sample

Std Methods

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TABLE C.2(i): EMISSIONS MONITORING AND SAMPLING POINTS (One table per monitoring point) Emission Point Reference Number: SW2(i)




pH Probe

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TABLE C.2(ii): AMBIENT ENVIRONMENT MONITORING AND SAMPLING POINTS (One table per monitoring point) Monitoring Point Reference Number: ASW1 (Manch Bridge)

Parameter Monitoring frequency Accessibility of Sampling point


Biological Quality (Q) Rating / Q Index

Biannually

Safe Access Kick Sample Q System

Ortho-Phosphate

Biannually

Safe Access Grab Sample Standard Methods

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TABLE C.2(ii): AMBIENT ENVIRONMENT MONITORING AND SAMPLING POINTS (One table per monitoring point) Monitoring Point Reference Number: ASW2 (@ sharp bend shortly downstream of the cooling water discharge)




Biannually


Ortho-Phosphate

Biannually


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TABLE C.2(ii): AMBIENT ENVIRONMENT MONITORING AND SAMPLING POINTS (One table per monitoring point) Monitoring Point Reference Number: ASW2a (just downstream of the main effluent treatment plant discharge)




Biannually


Ortho-Phosphate

Biannually


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TABLE C.2(ii): AMBIENT ENVIRONMENT MONITORING AND SAMPLING POINTS (One table per monitoring point) Monitoring Point Reference Number: ASW3 (Ballineen Bridge)




Biannually


Ortho-Phosphate

Biannually


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TABLE C.2(ii): AMBIENT ENVIRONMENT MONITORING AND SAMPLING POINTS (One table per monitoring point) Monitoring Point Reference Number: ASW4 (Bridge South of Enniskean)




Biannually


Ortho-Phosphate

Biannually


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Table D.1(i) RECEIVING WATER SURFACE WATER QUALITY Monitoring Point/Grid Reference: _____ASW1____________________________ Parameter Results 1 (mg/l) Sampling

method (grab, drift

etc.)

Normal Analytical

Range

Analysis method/ techniqu

e Jun 04

Sep 04

Jun 05

Sep 05

Jun 06

Sep 06

Jun 07

Sep 07

May 08

Sep 08

Jun 09

Sep 09

Jun 10

Aug 10

pH Temp Conductivity NH (as N) COD BOB DO Total N Nitrite (as N) Nitrate (as N) Total P (as P) Ortho -P 0.0

09 0.003

0.003

0.01

0.01

Table D.1(i) RECEIVING WATER SURFACE WATER QUALITY Monitoring Point/Grid Reference: _______ASW2__________________________ Parameter Results 1 (mg/l) Sampling

method (grab, drift

etc.)

Normal Analytical

Range

Analysis method/ technique

Jun 04

Sep 04

Jun 05

Sep 05

Jun 06

Sep 06

Jun 07

Sep 07

May 08

Sep 08

Jun 09

Sep 09

Jun 10

Aug 10


11 0.004

0.01

0.01

0.01

0.01

0.01

0.01

Table D.1(i) RECEIVING WATER SURFACE WATER QUALITY Monitoring Point/Grid Reference: _______ASW2a__________________________ Parameter Results 1 (mg/l) Sampling

method (grab, drift

etc.)

Normal Analytical

Range


Sep 04

Jun 05

Sep 05

Jun 06

Sep 06

Jun 07

Sep 07

May 08

Sep 08

Jun 09

Sep 09

Jun 10

Aug 10


48 0.027

0.03

0.03

0.04

0.01

0.03

0.02

0.01

0.02


method (grab, drift

etc.)

Normal Analytical

Range


Jun 04

Sep 04

Jun 05

Sep 05

Jun 06

Sep 06

Jun 07

Sep 07

May 08

Sep 08

Jun 09

Sep 09

Jun 10

Aug 10


34 0.022

0.03

0.02

0.03

0.03

0.02

0.01

0.01

0.01


method (grab, drift

etc.)

Normal Analytical

Range


Jun 04

Sep 04

Jun 05

Sep 05

Jun 06

Sep 06

Jun 07

Sep 07

May 08

Sep 08

Jun 09

Aug 09

Jun 10

Aug 10


23 0.026

0.045

0.02

0.03

0.02

0.02

0.02

0.01

0.02

Attachment)No.)A.2)

A"location"map"(Drawing"211134501)"with"the"site"boundary"outlined"in"red"colour"and"a"layout" plan" (Drawing" 211134506)" of" the" main" production" facility" are" included" in" this"attachment." " In" addition," geo5referenced" digital" drawing" files" are" included" on" the"accompanying"CDs."

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Attachment)No.)B.1)

A"summary"list"of"the"emission"points,"is"shown"in"tabular"form"on"pg"2;"this"data"is"also"included"on"an"Excel"file"entitled"tabular_data.xls,"worksheet"C.3"on"accompanying"CDs."

The" emission" points" are" shown"on" the" layout" drawings" for" the"Anaerobic"WWTP" and"Aerobic" WTTP," please" refer" to" Drawings" 21334504" (SW2" &" SW3)" &" 21334505" (SW1),"which"are"included"as"attachment"C.1"

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Attachment)No.)C.1)

Drawings" 21334504" &" 21334505," included" in" this" attachment," show" the" layout" of" the"Anaerobic" WWTP" and" Aerobic" WTTP" respectively." In" addition," geo5referenced" digital"drawing"files"are"included"on"the"accompanying"CDs."

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Attachment)No.)C.2)

The"summary" list"of"monitoring"and"sampling"points" is"presented"on"page"6."SW1(i)"&"SW1(ii)"are"included"on"drawing"21334505"(refer"to"attachment"C.1.);"SW2(i)"is"included"on"drawing"21334504"(refer"to"attachment"C.1.)."

The" ambient" surface" water" monitoring" points" are" presented" on" drawing" 21334502"(ASW1,"ASW2,"ASW2a"&"ASW3)"and"drawing"21334503"(ASW3"&"ASW4)"included"in"this"attachment." In" addition," geo5referenced" digital" drawing" files" are" included" on" the"accompanying"CDs."

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EPA Export 21-10-2011:03:33:10

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