January – December 2009

QuinnCement

Annual Environmental ReportIPPC Licence No. P0378-01

1.0 INTRODUCTION...........................................................................................................3

1.1 RAW MATERIAL PROCESSING.................................................................................................31.2 CLINKER PRODUCTION...........................................................................................................4 1.3 CEMENT MANUFACTURE.......................................................................................................51.4 ORGANISATIONAL CHART.....................................................................................................6

2.0 SUMMARY INFORMATION – SELF MONITORING DATA.............................7

2.1 RESOURCE CONSUMPTION SUMMARY....................................................................................7 2.1.2 RAW MATERIALS.............................................................................................................7 2.1.3 FUEL USAGE..................................................................................................................72.1.4 ELECTRICITY USAGE (KWH) ...............................................................................................7

2.2 EMISSIONS TO AIR.....................................................................................................8

2.2.1 JANUARY 2009 - DECEMBER 2009....................................................................................8 2.2.2 DUST GAUGES..................................................................................................................92.3 EMISSIONS TO WATER.......................................................................................................13 2.3.1 SURFACE WATER EMISSIONS JANUARY 2009 – DECEMBER 2009......................................132.3.2 GROUNDWATER MONITORING SUMMARY............................................................................132.4 NOISE MONITORING............................................................................................................14 2.4.1 NOISE MONITORING ASSESSMENT.....................................................................................152.5 WASTE MANAGEMENT.......................................................................................................162.6 BUND TESTING REPORT.....................................................................................................182.7 ENVIRONMENTAL INCIDENTS .............................................................................................192.8 COMPLAINTS SUMMARY.....................................................................................................202.9 REPORT ON PROGRESS OF ENVIRONMENTAL MANAGEMENT PROGRAMME...........................212.10 SCHEDULE OF ENVIRONMENTAL OBJECTIVES AND TARGETS .............................................232.11 ENVIRONMENTAL MANAGEMENT PLAN ............................................................................242.12AER RETURNS WORKSHEET............................................................................................25

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1.0 Introduction

This Annual Environmental Report relates to Quinn Cement Works (IPPC No. P0378-01) located at Scotchtown, Ballyconnell, Co. Cavan. Scotchtown Cement Works produces Portland Cement, which is a composite of synthetic minerals exhibiting hydraulic properties on mixing with water. The main raw materials are limestone (rich in calcium) and shale (rich in silica). These are extracted from quarries both close to and remote from the cement works.

The raw materials used in the manufacture of cement are processed by crushing, blending and milling to produce a homogenous “raw meal”, which passes through a high temperature kiln, where a thermal process produces a synthetic mineral “clinker”. The clinker and additives are milled into a fine powder - “cement”.

There are three main stages in the cement manufacturing process as follows:• Raw Material Processing• Clinker Production • Cement Manufacture

1.1 Raw Material ProcessingThe main raw materials used in the production of cement are limestone and shale (85%). The chemical composition of these materials may vary, even within a deposit, therefore small quantities of other materials such as sand and silt (10%), bauxite and ironore (1%) are added to enable the required blend to be obtained. Limestone is blasted from the 155-acre quarry site, the high investment in new technology ensures that the rock fragmentation is constant in size. It is then loaded onto dumpers and taken to the crushing and screening plant. Any combination of five separate crushing installations are used depending on the raw material type and source, to provide properly sized materials for feeding into the Pre-Blending Store and ultimately the Raw Mill.

The limestone transported to site is almost crushed down to the required size. The shale/clay however, needs to be processed through the crushers on site. Carefully proportioned quantities of each material are fed by conveyor belt to the Pre-Blending Store, at a rate of 900 tonne per/hr. With a 40,000 tonne storage capacity, this store provides a valuable six day buffer stock of materials as well as efficiently blending the Raw Mix by its stacking and reclaiming mechanism. This blend of raw material is “fine-tuned” with the addition of small amounts of other components to ensure the consistent chemical composition of the raw mix, which is then fed to the Raw Mill via weigh-feeders and conveyors.

The Atox type vertical Raw Mill crushes and grinds 340 tonnes per/hr of raw materials to a very fine powder, known as raw meal. During the grinding process, the raw mix is dried by introduction of hot waste flue gases re-circulated from the kiln. The air from the Raw Mill is passed through an Electrostatic Precipitator to remove the particulate before being released to the atmosphere. The Precipitator is used to purify exhaust gases; the dust particles become electrically charged and attach themselves to plates inside the precipitator. The plates are cyclically rapped and the discharged dust is collected. The raw meal is thus separated out of the air stream by a system of cyclones before it is brought to the C.F. Homogenisation Silo. This C.F. Silo with its 16,000 tonne capacity stores and homogenises the raw meal, while also providing a controlled and programmable extraction system in conjunction with a loss-of-weight Kiln feeding system in order to feed the raw meal on to the next stage of the process.

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1.2 Clinker ProductionThe raw meal is extracted from the homogenisation silo and conveyed by bucket elevator to the top cyclones of a five stage Pre-Heating Tower via the kiln feed system which controls the rate of feed by the “Loss-of-Weight” principle. The raw meal enters the cyclone preheater in the top and travels through the five cyclones by the force of gravity. The cyclone preheater is equipped with an In-Line-Calciner; where up to 60% of the total amount of fuel is combusted. This creates the conditions for the beginning of the chemical pyro-process and reduces NOx in the flue gases. At 600oC the calcium carbonate (CaCO3) in the limestone decomposes to produce quicklime (CaO) and carbon dioxide (CO2).

The material reaches the Kiln Inlet one minute later having reached a temperature of 860 degrees Celsius approx., the material is also 95% calcined at this point. The heated material gradually moves down the rotating kiln, which has energy supplied by a coal heated fuelled burner. Coal is milled on site in a vertical air-swept mill capable of pulverising 25 tonnes per/hr. The fine coal is then fed to the Calciner in the Pre-Heater Tower and to the Kiln Burner at a 60/40 ratio respectively. The Kiln is really the heart of the whole process, because here the raw meal temperature is raised from 860 to 1500 degrees Celsius, thereby enabling the chemical reactions, which allow the formation of Clinker to take place.

This relatively short 54 M Kiln offers many design improvements on previous conventional kilns, such as its two-pier support system, tyre attachments by tangential suspension and self-aligning kiln supports. At 1200OC, the fusion reaction starts and calcium silicates, calcium aluminates and other compounds, such as calcium aluminoferrite are formed. During the fusion, oxides of iron, aluminium and magnesium from the shale assist the process by acting as a flux, enabling the reactions to take place at temperatures much lower than would occur normally. At the lower end (outlet end) of the kiln, temperatures of over 1500OC are reached in the “Burning Zone” and the clinker is formed. Some 36% of the raw meal is burnt out (Loss On Ignition), such that for each 100 tonnes of raw meal, approximately 60 tonnes of clinker are produced.

Clinker is a hard mineral, similar to stone, and is generally between 20mm and 40mm in size. The clinker leaves the kiln and enters the clinker grate cooler, where they are cooled down to 100OC above ambient temperature by passing over grates with a forced airflow passing through the hot clinker. The purpose of the Grate Cooler is to cool the Clinker after it exits the Kiln. While cooling the Clinker the Cooler recuperates as much heat as possible and returns it to the Pre-Heater/Calciner, thereby reducing overall heating costs and fuel consumption. The excess air from the cooler is passed through another electrostatic precipitator for removal of particulate before being released to the atmosphere. The clinker is then conveyed to the clinker storage silo. This concrete storage shed has the capacity to hold 70,000 tonnes of clinker. Any combination of nine extraction points can be used to extract Clinker to feed the Cement Mill.

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1.3 Cement ManufactureThe clinker is finally conveyed to the Cement Mill from the Clinker Storage Shed. Within the Mill the Clinker is mixed together with approximately 5% of gypsum and is ground into a fine powder “Cement”. The gypsum controls the setting time of the finished product “Cement”. The Cement Mill itself is a two-chamber cylindrical ball mill; this closed circuit grinding mill can yield up to 170 tonnes of cement per/hr. The cement is then conveyed to three cement storage silos for storage. Two of these Silos are used for the despatch of Bulk Cement via Bulk Loader Tankers. The third Silo is used to supply the Bagging and Packaging Plant; the cement is fed from Silo 3 to the highly automated Bagging Plant via a system of Blowers. The cement is packed at a rate of 2,000 bags per hour in 25Kg sacks; the sacks are stacked on pallets and shrink wrapped ready for despatch.

The entire operation is carefully monitored in the Central Control Room, where several thousand parameters affecting the plant are monitored. From here operators can monitor the performance of the process control systems and intervene where necessary to ensure process stability and product quality. Quality of product is of utmost importance to Quinn Cement therefore its not surprising that they a completely automated quality control laboratory, known as the Robolab. This Robolab system instructs, supervises and conducts the testing of all routine samples from the various departments within the entire process.

Furthermore, all three major areas of the process; the raw meal preparation, clinker burning and cement milling, are controlled by advanced fuzzy-logic software systems, designed with the sole purpose of continuously reacting and behaving in the same pre-programmed harmonised way during plant operation. The considerable investment in all these systems has been done in order to provide even greater consistency, uniformity and therefore quality of process and product.

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1.4 Organisational Chart

Tony Lunney Operations Director

TPFeehan Divisional Manager

Dermot SmithMaintenance Manager

Engineering ManagerPaul Carron

AdministrationCaroline MooreSheila O’Keefe

Donal KellyH&S Officer

Declan CathcartSales Manager

Anna McNally Environmental

Advisor

Catriona McGormanSales Office Manager

Edel McCuskerSales Administrator

Sinead BurkeReceptionist

Tina MaguireDamien McKenna

Weighbridge Supervisor

Kenneth Coyle Pat McGovern

Despatch Administrator

Control InstrumentationMartin McDermott

Kevin Feehan

Electrical SupervisorMichael McDonnell

Mechanical SupervisorAidan CassidyMichael Rowan

Pearse WestTechnician

Patrick FitzpatrickSite Maintenance

Mechanical FittersBrian McDonaghKenneth Lambe

Paul PriorGerard GumleyGregory Cassidy

Gerry GavinMarius CurryEamon ReillyMartin Brady

Gabriel McManusRobert Smith (CN)

Plant LubricationLiam Prunty

Leo MartinPreventative Maintenance

Damien ReillyProduction Manager

Shift Co-ordinatorPat Lunney

Raw Materials Co-ordinator

Brian JohnsonTechnical Manager

Don McDonald

Site MaintenancePauric McGovern

Dermot LytleCharlie McNamee

Padraig TobinJohn Carthy

Bagging PlantBrian Early

Vacuum OperatorDamien McNamee

Bagging PlantPatrick Moran

Patrick McCarronKyle Barkley

Paddy McCusker

Lab TechnicianPhillip Kelly

Shift SupervisorEamon Leonard

Shift SupervisorCiaran Traynor

Shift Supervisor Michael McLoughlin

Shift SupervisorBrendan Meehan

Physical LabPius Martin

Ignatius McManusMichael Murphy (LTS)

CCR/LabSean CookePaul Moss

Shift OperatorJimmy BrownPaul Treacy

Irmantas Kavaljauskas

Shift ElectricianGerard Green

CCR / LabKyle WarnockMicheal Curran

Shift OperatorTomasz ZynantasGarry McGrade

Hubert McCaffrey

Shift ElectricianCiaran Maguire

CCR / LabAdrian McAloonMartin McKillion

Shift OperatorVaidas Martsius

Donald McGovernSzymon Puczkarski

Shift Electrician Ciaran Maguire

CCR / LabPaul Lunney

Eamon McGovern

Shift OperatorTom O’Brien

Brendan McKiernanPaulius Sinskas

Shift Electrician Barry Cadden

John Paul McGarry Noel Maguire

Mechanical Apprentice

Mark KirwanGraduate

Mechanical Engineer

Kevin McCuskerElectrical Apprentice

Adrian McPhillips Electrician

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2.0 Summary Information – Self Monitoring Data

2.1 Resource consumption Summary

2.1.2 Raw Materials

Raw material Usage (Tonnes/year)Raw Material January 2009 – December 2009

Limestone 992,000Clay/silt 148,230Shale 182,000Gypsum 45,977Iron-ore 4,278

2.1.3 Fuel usage

Fuel usage (per year)Fuel January 2009 – December 2009

Coal 114,301 tonneDiesel 402,403 litresKerosene 2,940 litres

2.1.4 Electricity usage (kWh)

Electricity usage (kWh)January 2009 – December 2009

96,523,947

2.2 Emissions to Air

2.2.1 January 2009 - December 2009

Emission referencepoint

Parameter Average emission(mg/Nm3)

Total No. of operationalhours

Average Flow Rate (Nm3/hr)1

Calculated Mass Emission (Tonnes)

Emissionlimit(mg/Nm3)

A2-01 - kiln Sulphur dioxide 274.0 5,791 335,488 532.4 600A2-01 - kiln Nitrogen Oxide 498.0 5,791 335,488 967.6 1300A2-01 - Kiln Particulates 5.4 5,791 335,488 10.5 50A2-02 - Grate cooler Particulates 13.5 5,791 179,993 6.9 50A2-03 - Coal mill Particulates 6.7 5,772 35,361 2.7 50A2-04 – Cement mill Particulates 11.8 6,885 26,817 2.2 50A2-05 – Sepax Filter Particulate 12.5 6,885 136,123 11.7 501 An average figure taken from Air Assessment Reports Carried out by QED 2009.

2.2.2 Dust GaugesIn accordance with section 5.8 of our IPC licence we operate a set of five dust gauges around the cement manufacturing plant at locations agreed with the Agency. The dust gauges are operated in accordance with BS1747-5:1972. The results of monthly measurements from these gauges are retained on site for inspection by the Agency. The gauges contain 4 deposit chambers directed in opposite directions. Sampling jar 1 is North, 2 is East, 3 is South and 4 is West for all of the sample Sites except at the Crushers. At the Crushers 3 is North, 4 is East, 1 is South and 2 is West. The following results table provides averages for the five gauges on site from January to December 2009.

Sample Site

No

Total Retained Water measured (ml)

pH Total Undissolved Matter (mg/L)

Total Dissolved Matter (mg/L)

Total Solids (mg)

Mg/m2/day

Site 1Work shop

1234

77.83426.67602.92188.33

7.68 23.3320.4212.1722.00

91.2582.9287.75105.67

11.9434.5655.9526.09

67.77100.87131.9596.90

Site 2Hilltop

1234

245.42431.67595.0088.08

7.62 24.8318.4214.9226.50

97.7567.0051.6777.83

21.3826.7033.8410.40

80.8875.8785.4353.21

Site 3 ESB

1234

155.00281.25430.83247.92

7.51 25.0817.5013.0821.50

103.4262.5050.4294.75

15.7720.4025.6724.38

68.7167.5870.7671.77

Site 4Treacy’s Field

1234

572.50709.58495.00253.75

7.42 7.337.5010.2519.25

49.2545.4257.3375.42

31.1930.7831.5122.50

75.1674.8377.9164.18

Site 5Crusher

1234

620.83363.33769.17860.83

7.30 11.5017.508.507.50

36.1752.1737.2533.42

26.2520.1531.4433.25

64.5964.6779.1480.82

* Note collection area = 154.26cm2

2.2.2.1 Assessment of Directional Dust Deposition

Site 1

0

50

100

150

mg/

m2/

day

Workshop - Directional Deposition Data

Series1 67.77 100.87 131.95 96.90

North East South West

Dust is predominantly originating from a southerly direction at the workshop dust gauge. The Plant is located to the Southwest of this gauge. This would suggest the majority of the dust is coming from the direction of the Plant.

Site 2

0

20

40

60

80

100

mg/

m2/

day

Hill-top - Directional Deposition Data

Series1 80.88 75.87 85.43 53.21

North East South West

There appears to be an even dispersion of dust at the Hill-top dust gauge from the north, south and east which would represent the general direction of the Plant, the west facing gauge would be directed away from the Plant.

Site 3

64

66

68

70

72

mg/

m2/

day

ESB - Directional Deposition Data

Series1 68.71 67.58 70.76 71.77

North East South West

At site 3 - the ESB dust gauge, there appears to be quite an even distribution of dust from all direction s ranging from 67.58 – 71.77 mg/m2/day. The plant is located to the north east of this gauge. It would appear there is marginally less dust emanating from the direction of the plant.

Site 4

0

20

40

60

80

mg/

m2/

day

Treacy's Field - Directional Deposition Data

Series1 75.16 74.83 77.91 64.18

North East South West

At Treacy’s field dust gauge, there is an relatively even distribution of dust in all directions, with slightly less coming from a westerly direction at 64.18 mg/m2/day.

Site 5

0.00

20.00

40.00

60.00

80.00

100.00

mg/

m2/

day

Crusher - Directional Deposition Data

Series1 79.14 80.82 64.59 64.67

North East South West

The dust gauge at the Crusher is located at the northern fringe of the site. The majority of dust is emanating from the north and the east which shows the majority of dust is coming from an off site location, the plant would location to the south of this dust gauge.

2.3 Emissions to water

2.3.1 Surface Water Emissions January 2009 – December 2009

Year Flow rate(m3/hr)

PH CODmg/l

SSmg/l

BODMg/l

NH4

mg/lCr mg/l

Almg/l

Mineral Oil

2009 12.5 7.78 11.9 9.65 1.08 0.039 0.031 0.24 0.022Limits 3000 6-9 - 35 10 - 0.05 0.2 -

2.3.1.1 Summary of Mass Emissions to Surface Water 2009

Year Flow (m3)

PH COD(Kg)

SS(kg)

BOD(kg)

NH4

(kg)Cr (kg)

Al(kg)

Mineral Oil (kg)

2009 109208 7.78 1300 1054 117 4 4 31 3

Note: Figures contained within Tables 2.3.1 and 2.3.1.1 are based on yearly average taken from weekly and monthly Surface water results.Where results were represented by a < figure e.g. <0.05 the highest possible figure i.e. 0.05 was used to calculate the average.

2.3.2 Groundwater Monitoring Summary

QED Engineering carried out ground water monitoring on the 4th June 2009 and the 9th December

2009. The sample was analysed by Environmental Laboratory Services, Blackrock, Co. Cork. An

average of the groundwater analysis performed is tabled below.

The results are as follows:

Parameter ResultpH 7.55TOC mg/l 0.46Conductivity µS/cm 370.50Total Ammonia mg/l 0.021Total Nitrogen mg/l 1.9Chromium (Cr VI) mg/l <0.03Aluminium mg/l <0.05Volatile Organic Compounds mg/l ND

2.4 Noise monitoring

Section 8.1 of the IPC license states that, “the licensee shall carry out a noise survey of the site

operations annually following commencement of cement production.” A noise survey was carried

out on the 17th of July during daytime and night time hours respectively by N and V Consultants.

The noise surveys were carried out at six noise sensitive locations previously agreed upon with the

Agency. The table immediately below indicates the location of the NSL measurement points

NSL No. LocationNSL 1 McHughs ResidenceNSL 2 Doon HeightsNSL 3 Slieve Russell HouseNSL 4 McKiernans ResidenceNSL 5+ Site CentreNSL 6 Kearns Residence

The following results were achieved:Recorded day time noise levels dB(A) –17th July 2009

Location Date Time Leq L10 L90 CommentsNSL1 17th July’09 12.30 43.5 42.5 35.1 Barely audible at 30dBA

NSL2 17th July’09 14.05 48.6 51.4 43.2 Audible at 43dBA

NSL3+ 17th July’09 14.40 53.2 55.8 45.6 Mainly road traffic

NSL4 17th July’09 15.10 56.3 58.7 52.7 Plant audible at 49dBA, also road traffic

NSL5+ 17th July’09 16.05 60.1 61.3 58.4 Mid –site beside mill

NSL6 17th July’09 16.50 47.6 49.9 44.2 Mainly cement plantNote + Not a noise sensitive location

Recorded night time noise levels dB(A) –17th July 2009

Location Date Time Leq L10 L90 CommentsNSL1 17th July’09 22.00 35.9 36.7 30.3 Plant inaudible, slight road traffic

NSL2 18th July’09 00.35 45.8 47.3 39.6 Road traffic from town

NSL3 17th July’09 23.20 47.9 48.2 44.4 Road traffic and plant noise at 44.4dBA

NSL4 17th July’09 22.55 52.1 55.2 47.5 Plant noise at 46.5 dBA

NSL5+ 17th July’09 23.30 58.1 58.9 57.1 Mid site beside mill

NSL6 17th July’09 22.45 45.5 47.4 43.2 Plant noise at 44.0 dBA

2.4.1 Noise monitoring Assessment

From the results of the above survey, noise levels were above the recommended daytime level of

55dB(A) at NSL 4, however the consultants comments indicate that plant noise was audible at 49

dBA, there is also significant noise from road traffic at this location.

The night-time noise limit of Leq(15min) of 45 dBA was exceeded in all locations except NSL 1,

however the exceedence was only attributed to plant noise in NSL 4, in all other noise sensitive

locations road traffic accounts for the additional noise.

There were no tonal or impulsive noise emissions from the works audible at any residence.

Following the results of the 2009 Noise Survey, Quinn Cement have implemented a Noise

Improvement Programme to reduce noise emissions from the plant and to ensure noise emissions are

below the specified limits. Details of the completed elements of the Improvement programme are

listed below.

(1) A noise curtain has been installed at the kiln drive, this resulted in a 10 dB reduction in noise

at source.

(2) Raw Mill dump bin has been enclosed.

(3) Replacement attenuators for the cement mill have been purchased and are due to be installed.

(4) The power Screen loader has been removed from the coal mill, sheet is due to be replaced.

(5) An assessment of suppression on all fans was completed, findings are to be assessed.

In addition to these measures, roller door maintenance is ongoing. Some roller doors have been

replaced by hinge doors. All staff have received Environmental training including the importance of

noise reduction on site.

The next noise survey is due to take place in 2010.

2.5 Waste Management

EWC Code

HW (Yes/ No)

Description of Waste

Quantity/year Disposal/ Recovery

Name of Agent and Transporter

Name and Location of Ultimate Destination

Licence/ Permit Reference for Treatment Facility

Consignment Note Ref. No.

TFS No. if applicable

150104 No 205 litre steel drums

4.58 tonne (229*205l)

Recovery R4

RILTA Environmental

Limited, Block 402, Greenogue Business Park, Rathcoole, Co.

Dublin WCP MH/2006/32B

A1 Metal Recycling,

Mountmellick, Co. Laois,

WMP007d N/A N/A

170201 No Pallets and wood waste

23 tonne Recovery R3

Pallet Supplies Ltd., Mountain Lodge,

Cootehill, Co. Cavan

WCP/MH/2001/53D

Pallet Supplies Ltd., Mountain

Lodge, Cootehill, Co.

Cavan

WP 06/29 N/A N/A

160214 No Mixed electrical

equipment

0.225 tonne Recovery R13

Rehab Recycle Rehab Building Kylemore Road

Ballyfermot Dublin 10 -

WCP/MH/2003/19D

Rehab Recycle, Unit 77

Broomhill Road, Tallaght,

Dublin 24.

WPR 033/2 N/A N/A

150102 No 25l plastic drums

0.393 tonne Disposal – D1

Guardian Silver Lining, Unit 61,

Cookstown Industrial Estate,

Tallaght, Dublin 24 - WCP

MH/2001/36C

KTK Landfill Co. Kildare

WL168-01 N/A N/A

150106 No Mixed Packaging

waste

4.5 tonne Recovery – R11

Greyhound Recycling &

Recovery Ltd., Crag Avenue, Clondalkin

Industrial Estate,

Greyhound Recycling &

Recovery Ltd., Crag Avenue,

Clondalkin

W0205-01 N/A N/A

EWC Code

HW (Yes/ No)

Description of Waste

Quantity/year Disposal/ Recovery

Name of Agent and Transporter

Name and Location of Ultimate Destination

Licence/ Permit Reference for Treatment Facility

Consignment Note Ref. No.

TFS No. if applicable

Dublin 22 – WCP MH2005/66C

Industrial Estate, Dublin

22150106 No Mixed

Packaging waste and Recyclable

waste

31.380 tonne Recovery – R11

Wilton Waste Recycling Ltd.,

Ballyjamesduff, Co. Cavan - WCP

MH/2006/17/B

Leinster Environmental, Claremont Bus

Pk Haggardstown Dundalk Co.

Louth

W0060-02 N/A N/A

200301 No Mixed waste 74.304 tonne Disposal – D1

Wilton Waste Recycling Ltd.,

Ballyjamesduff, Co. Cavan - WCP

MH/2006/17/B

White Water Landfill

WP 2004/30 N/A N/A

150203 No Tyvek suits 0.78 tonne Recovery – R13

Rehab Recycle Rehab Building Kylemore Road

Ballyfermot Dublin 10 -

WCP/MH/2003/19D

Gandon Enterprises Ltd., Navan, Co. Meath

WMP 2007/06 N/A N/A

See PRTR submission attached in Section 2.12 for hazardous waste which was above the PRTR reporting threshold.

2.6 Bund Testing ReportSection 9.2.1 of the IPC license requires that “….All bunds shall be tested at least once every three years. A report on such tests shall be included in the AER”.

An assessment of the integrity of Gas Oil and Grinding Aid bunded tanks used at Quinn Cement was carried out in September 2007. This assessment was carried out in accordance with the guidelines of BS 8007:1997 and the IPC Guidance Note on Storage and Transfer of Materials for Scheduled Activities.

The inspection and testing of the bunded tanks involved both visual and hydraulic testing over a period of 7 days between the September 5th and September 11th inclusive. Mr. Sean Feehan CEng ADCON Consultants performed the survey.

Both bunds were found adequate for their intended purpose.

The next bund integrity test is scheduled for 2010.

2.7 Environmental Incidents

The following is a list of environmental incidents experienced at Quinn Cement during the period January 2009 to December 2009.

Date Nature of Incident Action TakenAuthorities Contacted

13/02/2009

Precip trip - screw carrying dust from precips tripped Precip restarted EPA

28/02/2009

Precip trip - Analyser unit fault on W1A50 gas abalyser Electrician changed filter and reset probe EPA

07/05/2009

Cooler precip trip - blockage in W1J02 Drag Chain which tripped the chain off

Blockage was cleared asap and precip restarted EPA

01/05/2009

Surface water Aluminium and Suspended Solids Investigation and report EPA

08/06/2009Precip trip - gas analyser fault

Electrician reset fault and control room restarted precip EPA

25/08/2009

Release of rust from Main Stack on plat restart Investigation and road sweeper to clean area EPA

01/09/2009

EPA SW analysis (taken 14/07/09) showed high Aluminium Investigation into causes is ongoing EPA

August

High Aluminium in August Surface water sample Investigation into causes is ongoing EPA

28/08/2009

Release of dust emissions from Kiln outlet and Grate Cooler building due to blockage in the Preheater. Investigation into causes and report EPA

November

High Suspended Solids in weekly samples 18th and 25th November. Investigation into causes and report EPA

NovemberNovember SW high in Chromium Investigation into causes is ongoing EPA

DecemberDecember SW high in Aluminium Investigation into causes is ongoing EPA

2.8 Complaints Summary

The following is a list of environmental complaints received by Quinn Cement during the period January 2009 to December 2009.

Date of Complaint Dates Complaint was Observed Complainant Type

Dust Noise15/10/09 10-11/10/09 Ms Barbara McHugh X

This complaint was fully investigated and an investigation report was submitted to the EPA in

response the complaint as recorded above.

2.9 Report on Progress of Environmental Management ProgrammeLicence objectives Licensee Targets Progress

1 Noise Abatement Develop an improvement programme aimed at reducing noise emission levels to below the licence limits for day and night. Implement improvement programme on a phased basis.

Noise Improvement Programme has been developed, copy submitted to

the Agency 2nd November 2009. Implementation is ongoing, the

following items have been completed to date:

(1) A noise curtain has been installed at the kiln drive, this

resulted in a 10 dB reduction in noise at source.

(2) Raw Mill dump bin has been enclosed.

(3) Replacement attenuators for the cement mill have been

purchased and are due to be installed.

(4) The power Screen loader has been removed from the coal

mill, sheet is due to be replaced.

(5) An assessment of suppression on all fans was completed,

findings are to be assessed.

In additional Environmental Training which includes items on noise has

been delivered to staff.2 Waste Management Further develop waste segregation and recycling on site. Aim to

minimise land filling of waste. Further segregation in the waste area has been introduced, signed segregation areas for recyclable materials, plastic and cardboard for baling, WEEE, Tyvek suits, timber and pallets and scrap metal.

Environmental Training which highlights all waste segregation opportunities on site has been delivered to staff.

Licence objectives Licensee Targets Progress

3 Environmental Management System

Further develop Environmental Management System in 2009 with the intention of seeking formal accreditation for the system in late 2009 or early 2010.

EMS was updated and developed under the various clauses of ISO 14001. System is operational. Further work on documentation is required prior to certification.

4 Awareness and Training. Continue training personnel to ensure that employees are aware of; • the importance of compliance with the licence.,• the potential environmental effects of their work activities,• their specific environmental roles and responsibilities• good housekeeping practices and procedures,

• the waste management procedures in place

Environmental Training which included aspects of EMS: Policy, Objectives and Targets, Procedures and General Environmental Awareness detailing requirements for: Air, Waste, Noise, Water, Bunding and Energy Efficiency was delivered.

5 Energy Management Assess findings of 2008 energy audit and compressed Air Survey. Consider recommendations where feasible.

Carry out further special investigations.

Prepare and strive to implement Energy Management System based on IS393.

Findings of the 2008 energy audit and compressed air survey have been incorporated into the Register of Opportunities, part of the Energy Management System.

Development of the Energy Management System was commenced in 2009 and it is anticipated formal accreditation will be sought in 2010.

2.10 Schedule of Environmental Objectives and Targets

Licence Objectives Licensee Targets

1. Noise Abatement Quinn Cement aim to complete the majority of elements of the noise improvement programme prior to completion of the 2010 Noise Survey. It is hoped this will result in all emissions levels being below the licence limits for day and night.

2. Alternative Fuels Project Quinn Cement hope to commence construction of a new calciner, fuel storage bunker and feed system, SNCR system and silo and modify existing abatement systems and bypass set up to allow substitution of coal for Solid recovered fuel.This project will reduce use of non-renewable fuel, reduce transport CO2 of fuel as SRF will be sourced in Ireland and reduce CO2 emission from combustion.

3. New IPC Licence For the operation of the proposed Alternative Fuels project discussed under Objective 2 a new IPPC licence is required. Application for a new licence was submitted in 2010.

4. Environmental and Energy Management System Formal accreditation of Environmental and Energy Management System

2.11 Environmental Management Plan

No. Objectives & Targets Means of Achievement/Action Necessary Person Responsible Time frame for Achievement

1 Noise Abatement

Quinn Cement aim to complete the majority of elements of the noise improvement programme prior to completion of the 2010 Noise Survey. It is hoped this will result in all emissions levels being below the licence limits for day and night.

Plant Engineer, Maintenance Manager, Environmental Advisor

Before end 2010

2 Alternative Fuels Project

Quinn Cement hope to commence construction of a new calciner, fuel storage bunker and feed system, SNCR system and silo and modify existing abatement systems and bypass set up to allow substitution of coal for Solid recovered fuel.This project will reduce use of non-renewable fuel, reduce transport CO2 of fuel as SRF will be sourced in Ireland and reduce CO2 emission from combustion.

Project ManagerTo be commenced in 2010, may not be completed/ operational until 2011.

3 New IPC Licence

For the operation of the proposed Alternative Fuels project discussed under Objective 2 a new IPPC licence is required. Application for a new licence was submitted in 2010.

Environmental Advisor, Project Management

Application for New licence submitted January 2010. new licence to be issued during 2010.

4 Environmental and Energy Management System

Formal accreditation of Environmental and Energy Management System

Environmental Advisor and Cement Management Team 2010

2.12 AER Returns Worksheet

Version 1.1.10REFERENCE YEAR 2009

1. FACILITY IDENTIFICATIONParent Company Name Quinn Cement Limited

Facility Name Quinn Cement LimitedPRTR Identification Number P0378

Licence Number P0378-01

Waste or IPPC Classes of ActivityNo. class_name

10.1 The production of cement.

Address 1 Cement WorksAddress 2 ScotchtownAddress 3 BallyconnellAddress 4 Co Cavan

Country IrelandCoordinates of Location -7.57921 54.1313

River Basin District GBNIIENWNACE Code 2351

Main Economic Activity Manufacture of cementAER Returns Contact Name Anna McNally

AER Returns Contact Email Address Anna.McNally@quinn-group.comAER Returns Contact Position Environmental Advisor

AER Returns Contact Telephone Number 049-9525295AER Returns Contact Mobile Phone Number

AER Returns Contact Fax Number 049-9525201Production Volume 0.0

Production Volume UnitsNumber of Installations 0

Number of Operating Hours in Year 0Number of Employees 0

User Feedback/CommentsWeb Address

2. PRTR CLASS ACTIVITIESActivity Number Activity Name3(c)(i) Cement clinker in rotary kilns

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

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

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

used ?

AER Returns Worksheet