Quinn Cement Ltd. - Environmental Protection Agency · Quinn Cement Ltd. January – December ... consistent chemical composition of the raw mix, which is then fed to the Raw Mill

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Quinn Cement Ltd.

January – December 2010

Annual Environmental Report IPPC Licence No. P0378-01

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Contents

Contents .................................................................................................................................................2

1.0 Introduction.....................................................................................................................................4

1.1 Raw Material Processing ......................................................................................................4

1.2 Clinker Production ................................................................................................................5

1.3 Cement Manufacture.............................................................................................................6

1.4 Organisational Chart.............................................................................................................8

2.0 Summary Information – Self Monitoring Data .................................................................9

2.1 Resource consumption Summary.......................................................................................9

2.1.1 Raw Materials................................................................................................................9

2.1.2 Fuel usage .......................................................................................................................9

2.1.3 Electricity usage (kWh) .................................................................................................9

2.1.4 Water Consumption (m3) .............................................................................................9

2.2 Emissions to Air ...................................................................................................................10

2.2.1 January 2010 - December 2010 ...................................................................................10

2.2.2 Dust Gauges .................................................................................................................11

2.2.2.1 Assessment of Directional Dust Deposition.............................................................12

2.3 Emissions to water...............................................................................................................15

2.3.1 Surface Water Emissions January 2010 – December 2010 ......................................15

2.3.1.1 Summary of Mass Emissions to Surface Water 2010 ......................................15

2.3.2 Groundwater Monitoring Summary.........................................................................15

2.3.3 Toxicity Testing:...........................................................................................................16

2.4 Noise monitoring.................................................................................................................17

2.4.1 Noise monitoring Assessment ...................................................................................18

2.5 Waste Management .............................................................................................................19

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2.6 Bund Testing Report ...........................................................................................................25

2.7 Environmental Incidents ..........................................................................................................26

2.8 Complaints Summary ...............................................................................................................28

2.9 Environmental Management System......................................................................................29

2.9.1 Environmental Policy..................................................................................................29

2.9.2 Report on Progress of Environmental Management Programme................................30

2.9.3 Schedule of Environmental Objectives and Targets 2011 ......................................31

2.9.4 Environmental Management Plan.............................................................................32

2.10 RMP and ELRA................................................................................................................34

2.10.1 Residual Management Plan........................................................................................34

2.10.2 ELRA .............................................................................................................................34

2.11 AER Returns Worksheet .....................................................................................................35

Annex 1: Monitoring Locations:................................................................................................41

Dust Deposit Gauges.......................................................................................................................42

Noise:.................................................................................................................................................42

Surface water and Groundwater: ..................................................................................................42

Annex 2: Atmospheric Emission Points ..................................................................................43

Air Emission Points .........................................................................................................................44

Annex 3: Quinn Cement 14001 Accreditation.........................................................................45

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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 Processing

The 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 a number of nearby quarry sites, 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

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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.

1.2 Clinker Production

The 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

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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.

1.3 Cement Manufacture

The 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 there is a completely automated quality control

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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

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2.0 Summary Information – Self Monitoring Data 2.1 Resource consumption Summary

2.1.1 Raw Materials

Raw material Usage (Tonnes/year) Raw Material January 2010 – December 2010

Limestone 945,070 Clay/silt 50,000 Shale 178,621 Gypsum 36,931 Iron-ore 3,767

2.1.2 Fuel usage

Fuel usage (per year) Fuel January 2010 – December 2010

Coal 99,455 tonne Diesel 411,521 litres Kerosene 4,918 litres

2.1.3 Electricity usage (kWh)

Electricity usage (kWh) January 2010 – December 2010

82,161,175

2.1.4 Water Consumption (m3)

Source Consumption (m3) Use Mains 5,600 Welfare

Groundwater 154,030 Process

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2.2 Emissions to Air

2.2.1 January 2010 - December 2010

Emission reference Point

Parameter Average emission (mg/Nm3)

Total No. of operational hours

Average Flow Rate (Nm3/hr)1

Calculated Mass Emission (Tonnes)

Emission limit (mg/Nm3)

A2-01 - kiln Sulphur dioxide 219.3 4,759 345,909 360.9 600 A2-01 – kiln Nitrogen Oxide 390.8 4,759 345,909 643.3 1300 A2-01 – Kiln Particulates 13.8 4,759 345,909 22.7 50 A2-02 - Grate cooler Particulates 5.5 4,759 171,889 4.5 50 A2-03 - Coal mill Particulates 12.8 3,978 35,981 1.8 50 A2-04 – Cement mill Particulates 13.4 5,348 30,835 2.2 50 A2-05 – Sepax Filter Particulate 8.6 5,348 132,298 6.1 50 1 An average figure taken from Air Assessment Reports Carried out by QED 2010.

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2.2.2 Dust Gauges

In accordance with section 5.8 of the IPPC licence, five set of dust gauges are located 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 2010.

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 1 Work shop

1 2 3 4

206 245.5

483.18 175.33

7.64 163 15.4

10.91 18.75

126 107.8

111.27 129.75

28.67 30.82 51.15 20.44

59.89 67.08 113.18 44.06

Site 2 Hilltop

1 2 3 4

159 188.36 349.06 185.73

7.22 30.43 23.44 27.09 17.1

130 111.44 97.27 113.1

23.71 21.72 33.23 18.66

54.01 46.74 72.39 41.09

Site 3 ESB

1 2 3 4

220.73 284.09 276.36

353

7.22 21.8 12

14.91 15.27

131.2 99.73

107.36 143.18

20.64 25.05 28.2

28.01

44.7 55.03 61.92 52.97

Site 4 Treacy’s Field

1 2 3 4

208.27 816.82

515 312.3

7.14 26.1 8

13.09 13.67

226.2 52.64

86 92.33

25.07 47.23 33.07 24.62

55.9 104.75 74.64 54.78

Site 5 Crusher

1 2 3 4

415.45 277.73 587.5

600.91

6.96 10.73 15.27

8.4 9

55.18 30.82 42.5 44.09

19.03 15.46 25.44

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42.11 34.75 53.79 58.64

* Note collection area = 154.26cm2. (Samples collected and analysed by Biolabs, Scotstown, Co. Monaghan).

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2.2.2.1 Assessment of Directional Dust Deposition Site 1

0

50

100

150

mg/

m2/

day

Workshop - Directional Deposition Data

Series1 59.89 67.08 113.18 44.06

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 or the transport network to the Plant.

Site 2

0

20

40

60

80

mg/

m2/

day

Hill-top - Directional Deposition Data

Series1 54.01 46.74 72.39 41.09


The Plant is located to the east and south east of the monitor. The majority of the dust is emanating from the north and the south which is equivalent to the haul road which connects the cement plant to the raw material reserves. The majority is likely to be transport related at this spot.

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Site 3

0

20

40

60

80

mg/

m2/

day

ESB - Directional Deposition Data

Series1 44.70 55.03 61.92 52.79


The Plant is located to the north and northeast of this monitoring location. The dust seems to be predominantly southerly in composition which would suggest influence from the road network to the weighbridge area, transport related localised dust Site 4

0

50

100

150

mg/

m2/

day

Treacy's Field - Directional Deposition Data

Series1 55.90 104.75 74.64 54.78


The Plant is to the south east of this location. There is an even distribution of dust in all directions with slightly higher from the east. This would not be related to the Plant, but more likely to have influence from the main Ballyconnell to Derrylin Road.

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Site 5

0.00

20.00

40.00

60.00

mg/

m2/

day

Crusher - Directional Deposition Data

Series1 53.79 58.64 42.11 34.75


The Plant is located at the south of this location. The dust gauge at the Crusher is located at the northern fringe of the site. The influence on the north pot of the directional gauge is likely to be localised from the crusher. The results from the south and east are likely to have been influenced by the cement plant but also localised dust from the Crushers.

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2.3 Emissions to water

2.3.1 Surface Water Emissions January 2010 – December 2010

Year Flow rate (m3/hr)

PH COD mg/l

SS mg/l

BOD Mg/l

NH4

mg/l Cr

mg/l Al

mg/l Mineral

Oil 2010 12.47 7.72 7.4 8.42 <1 0.033 0.039 0.124 <0.01

Limits 3000 6-9 - 35 10 - 0.05 0.2 -

2.3.1.1 Summary of Mass Emissions to Surface Water 2010

Year Flow (m3)

PH COD (Kg)

SS (kg)

BOD (kg)

NH4

(kg) Cr

(kg) Al

(kg) Mineral Oil

(kg) 2010 109208 7.72 806 920 109 4 4 14 1

Note: Figures contained within Tables 2.3.1 and 2.3.1.1 are based on yearly average taken from weekly (Biolabs, Scotstown, Co. Monaghan) and monthly Surface water results (QED, Monaghan / Environmental Laboratory Services, Blackrock, Cork).

Where results were represented by a < figure e.g. <0.01 the highest possible figure i.e. 0.01 was used to calculate the average.

2.3.2 Groundwater Monitoring Summary QED Engineering (Monaghan) took ground water samples on the 6th May 2010 and the 13th October 2010. The sample was analysed by Environmental Laboratory Services, Acorn Business Campus, Mahon Industrial Park, Blackrock, Co. Cork. An average of the groundwater analysis performed is tabled below.

The results are as follows:

Parameter Result EPA Interim Guide Value

pH 7.35 6.5 < x > 9.5 TOC mg/l 0.56 No abnormal change Conductivity μS/cm 376 1000 Total Ammonia mg/l <0.007 0.15 Total Nitrogen mg/l 1.5 Chromium (Cr VI) mg/l <0.03 0.03 Aluminium mg/l <0.005 0.2 Volatile Organic Compounds mg/l ND

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2.3.3 Toxicity Testing:

The sample was collected by QED Engineering (Monaghan) and analysed by Aquatic Services Unit, Environmental Research Institute, Lee Road, Cork. Report was submitted to the Agency on 1st November 2010.

Testing was carried out in accordance with Condition 6.7 of the License. There were four species from different trophic levels examined for toxicity against effluent discharge from SW 1.

Species were rainbow trout (Onchorhynchus mykiss); waterflea (Daphnia magna); duckweed (Lemna minor) and bacteria (Vibrio fischeri). All were tested against standard methods in US EPA Whole Effluent Testing Guidelines (US EPA, 2002).

The results from the 4 bioassays performed on the effluent from SW1 at Quinn Cement indicated that the sample was non toxic across all species tested.

In future toxicity testing will be carried out annually and reported in the AER for analysis across bioassays for Daphnia magna and Vibrio fischeri in accordance with Condition 6.8 of the License.

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2.4 Noise monitoring

Section 8.1 of the IPPC 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 13th December 2010 during daytime and night time hours respectively by N and V Consultants, Navan, Co. Meath.

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. Location NSL 1 McHughs Residence NSL 2 Doon Heights NSL 3+ Slieve Russell House NSL 4 McKiernans Residence NSL 5+ Site Centre NSL 6 Kearns Residence

The following results were achieved:

Recorded day time noise levels dB(A) –13th December 2010.

Location Date Time Leq L10 L90 Comments

NSL1 13/12/2010 11.30 44.6 43.2 35.7 Barely audible at 31dBA

NSL2 13/12/2010 13.05 48.9 51.8 43.6 Audible at 44dBA

NSL3+ 13/12/2010 13.40 54.4 56.7 46.7 Mainly road traffic

NSL4 13/12/2010 14.10 56.1 58.5 52.4 Plant audible at 48dBA, also road

traffic

NSL5+ 13/12/2010 15.05 59.9 61.0 58.2 Mid –site beside mill

NSL6 13/12/2010 15.50 47.3 49.5 43.9 Mainly cement plant

Note + Not a noise sensitive location

Recorded night time noise levels dB(A) –13th December 2010

Location Date Time Leq L10 L90 Comments

NSL1 13/12/2010 22.10 33.8 35.5 29.8 Plant inaudible, slight road traffic

NSL2 13/12/2010 00.45 44.1 46.0 38.4 Road traffic from town

NSL3+ 13/12/2010 23.40 45.4 46.1 42.7 Road traffic and plant noise at 44.0dBA

NSL4 13/12/2010 23.05 51.8 55.0 47.1 Plant noise at 46 dBA

NSL5+ 13/12/2010 23.40 57.8 58.6 56.8 Mid site beside mill

NSL6 13/12/2010 22.55 45.2 47.1 43.0 Plant noise at 44.0 dBA

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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 48 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 at locations NSL 4 and NSL 6, however the exceedence was only attributed to plant noise in NSL 4 at 46 dBA, slightly in excess of the limit at this location, but there has been improvement since the previous AER.

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

All staff has received Environmental training including the importance of noise reduction on site. Doors are inspected and repaired regularly.

The next noise survey is due to take place in 2011.

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2.5 Waste Management

Date/

Period Waste Type

EWC CODE Quantity

(tonnes) Haulage

Contractor Waste Collection

Permit No.

Waste Disposal / Recovery

Contractor

Waste License Disposal

/ Recovery

Location of Disposal / Recovery

Consignment Note (C1

form) Reference

14/1/2010 mixed

municipal waste

150101, 150103, 200301

4.18 Wilton Waste Recycling Ltd.

WCP/MH/08/0080-01

Wilton Waste Recycling Ltd.

W.F.P-CN-09-0005-01 Disposal

Whiteriver Landfill (W0060-

03) N/a

14/1/2010 Mixed C&D waste 170904 2 Wilton Waste

Recycling Ltd. WCP/MH/08/0080-

01 Wilton Waste Recycling Ltd.



03) N/a

14/1/2010 Recyclable waste

150102 200139, 150101 200101


WCP/MH/08/0080-01


W.F.P-CN-09-0005-01 Recovery

Leinster Environmental (WP 2004/30)

N/a

04/02/2010 Scrap metal 170407 10.78 Felix Gormley WCP/MH/2001/76D Felix Gormley W.F.P-CN-10-006-01 Recovery

Clearway Disposals,

Belfast N/a


Clearway Disposals,

Belfast N/a

11/02/2010 Mixed C&D waste 170904 2.92 Wilton Waste





03) N/a






03) N/a






03) N/a






03) N/a

20

18/2/2010 drums 150104 158

RILTA Environmental Limited, Block

402, Greenogue

Business Park, Rathcoole, Co.

Dublin

WCP-DC-09-1192-01

RILTA Environmental Limited, Block

402, Greenogue

Business Park, Rathcoole, Co.

Dublin

WL 192/03 Recovery

A1 Metal Recycling,

Mountmellick, Co. Laois, WMP007d

N/a

25/2/2010 recyclable waste

150102 200139, 150101 200101


WCP/MH/08/0080-01




N/a






03) N/a






03) N/a

12/04/2010 oily rags + filters

150202, 160107

3*205l rags

1*205 l filters

Enva Ireland Ltd. WCP-DC-08-1116-01 Enva Ireland

Ltd. WL184-1 Recovery

R.D. Recycling, Houthalen,

Belgium, Reg.no. 51727/1/KD

B559328

27/4/2010 waste oil 130208 1500 litres


Ltd. WL184-1 Recovery Enva Ireland Ltd. N/a






03) N/a






03) N/a






03) N/a




W.F.P-CN-09-0005-01 Recovery Whiteriver

Landfill (W0060- N/a

21

03)






03) N/a

15/06/2010 Pallets 170201 96

pallets (2.76 t)

Pallet Supplies WCP/MH/2001/53D

Pallet Supplies Ltd.,

Mountain Lodge,

Cootehill, Co. Cavan


Pallet Supplies Ltd., Mountain

Lodge, Cootehill, Co.

Cavan f

N/a






03) N/a






03) N/a

22/6/2010 Oily rags 150202 3*205 l Enva Ireland Ltd. WCP-DC-08-1116-01 Enva Ireland




B559341

22/6/2010 waste oil 130208 1200 liters








03) N/a

21/7/2010 waste oil 130208 1300 liters



21/7/2010 pallets 170201 126 pallets Pallet Supplies WCP/MH/2001/53D


Mountain Lodge,





Cavan f

N/a

22






03) N/a

12/08/2010 oily rags 150202 4*205 l Enva Ireland Ltd. WCP-DC-08-1116-01 Enva Ireland




B559350






03) N/a


Clearway Disposals,

Belfast N/a






03) N/a

23/09/2010

2 x 205 l UN approved

drums and 2 x 205 l UN

approved drums

160708, 160504

4 x 205 l drums



Lindenschmidth, Germany,

Reg.no. E97095037

B559347

18/10/2010 Pallets 200138 3.16 (86 pallets) Pallet Supplies WCP/MH/2001/53D


Mountain Lodge,





Cavan

N/a






03) N/a

20/10/2010 Plastic 150102 1.66 Recyco WCP MH/10/0013-01 Recyco WML 25/01 Recovery 62 Gortin Road

Omagh N/a

20/10/2010 Cardboard 150101 0.6 Recyco WCP MH/10/0013-01 Recyco WML 25/01 Recovery 62 Gortin Road

Omagh N/a

23

20/10/2010 1 t bags 150105 0.1 Recyco WCP MH/10/0013-01 Recyco WML 25/01 Recovery 62 Gortin Road

Omagh N/a

20/10/2010 Recyclable waste 200301 0.78 Wilton Waste





N/a






03) N/a






03) N/a


150102 200139, 150101 200101


WCP/MH/08/0080-01

Wilton Waste Recycling Ltd. WP No. 06/32 Recovery


N/a

02/11/2010 Aerosol Cans 160504 0.48 Enva Ireland

Ltd. WCP-DC-08-1116-01 Enva Ireland Ltd. WL184-1 Recovery

Lindenschmidth, Germany,

Reg.no. E97095037

B620426


150102 200139, 150101 200101


WCP/MH/08/0080-01



N/a


Clearway Disposals,

Belfast N/a


150102 200139, 150101 200101


WCP/MH/08/0080-01



N/a


150102 200139, 150101 200101


WCP/MH/08/0080-01



N/a

24

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

08/12/2010 Landfill Materials 200301 2.88 Wilton Waste





03) N/a






03) N/a


150102 200139, 150101 200101


WCP/MH/08/0080-01




N/a

15/12/2010 Partswasher waste 161001 0.125

Arven Chemicals

Ltd. NSO.543465

Arven Industrial Chemicals

Limited

CB/JNSO17CU Recovery

Lanstar, Cadishead Manchester (BS.1538.IQ)

NSO.543465


150102 200139, 150101 200101


WCP/MH/08/0080-01




N/a

25

2.6 Bund Testing Report

Section 9.2.1 of the IPPC 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.

All bunds were found adequate for their intended purpose.

The next bund integrity test was scheduled for Quarter 4 of 2010. Tests were not completed at that stage due to severe weather conditions hampering tests.

The Agency was informed on the 20/12/2010. Tests will be completed in Quarter 1 2011 and forwarded to the Agency upon completion. Mr. Sean Feehan CEng ADCON Consultants will again perform the survey.

Bunds to be integrity tested include:

a. Gas Oil Bund

b. Grinding Aid Bund

c. Waste Segregation Area

d. Raw Mill Hydraulic Pump Sump

e. Mobile Oil and Chemical Bunds.

26

2.7 Environmental Incidents

The following is a list of environmental incidents experienced at Quinn Cement during the period January 2010 to December 2010.

Date Nature of Incident Action Taken Authorities Contacted

18/01/2011 Aluminium exceedances in discharge

from SW1 (0.2481 mg/l, limit 0.2 mg/l).

Investigation including analysis and report. Action ongoing.

EPA

January 2010

Settlement Pond was desludged and the sludge was analysed. No

discharge during the week ending 27/01/2010

EPA approval for recycling of sludge as a raw material in cement

production. Informed of non discharge.

EPA

08/02/2010 Chromium exceedances in discharge

from SW1 (0.12 mg/l, limit 0.05 mg/l).

Investigation including analysis and report. Action ongoing.

EPA

18/03/2010

Euro Environmental (on behalf of the Agency) carried out stack

monitoring). SOx was 820.9 mg/Nm3, limit 600 mg/Nm3.

Investigation including review of CEMS results and QED quarterly

analysis for this period. EPA

24/05/2010

There was a small fire at the base of the Pan Conveyor. Early detection

and implementation of the ERP. Fire Services were called.

SW monitored at SW1 for impact of fire water – there was no impact

found as foaming agent used to quench the fire. Investigation and

report.

EPA, CCC, HSA.

11/06/2010 ESP trip for 4 minutes due to raw

mill panel trip causing a downstream trip effect on the ESP.

Investigation and report. EPA

04/07/2010 ESP trip for 20 minutes due to a

problem with the air breaker in the switch room.

Investigation and report. EPA.

07/09/2010

EPA test on SW1 sample found an exceedance in SS (55 mg/l, limit 35 mg/l) and a exceedance in Al (0.430

mg/l, limit o.2 mg/l)

Investigation including analysis and report. Action ongoing

EPA

14th and 15th Sept

2010

Quarterly stack monitoring on A2-01 and A2-03 found an exceedance on 1

of 2 runs on particulate emissions.

Investigation and report. Subsequent monitoring.

EPA

27

Date Nature of Incident Action Taken Authorities Contacted

18/11/2010

EPA test on SW1 sample found an exceedance in Al (1.2118 mg/l, limit o.2 mg/l). this sample was split and tested by QED (ELS, Blackrock, Cork) and found an exceedance in Al (0.277

mg/l, limit 0.2 mg/l)

Investigation including analysis and report. Action ongoing

EPA

27/11/2010 ESP trip for 5 minutes due to a power

dip. Investigation and report. EPA

November 2010

Jars on the Crushers and the ESB station locations of dust deposit

gauges broken.

Repaired. Application to move to Bergerhoff method.

EPA

December 2010

Bund tests not carried out due to adverse weather causing freezing of

water during test procedure.

Rescheduled to Q 1 2011, EPA informed.

EPA

28

2.8 Complaints Summary

The following is a list of environmental complaints received by Quinn Cement during the period January 2010 to December 2010.

This complaint was fully investigated and an investigation report was submitted to the EPA in response to the complaint as recorded above on 11/01/2010.

Date of Complaint Dates Complaint was Observed Complainant Type

Dust Noise 08/01/2010 07/01/2010 Ms Barbara McHugh X

29

2.9 Environmental Management System

Section 2.1 of the License states that “The licensee shall establish and maintain an Environmental Management System (EMS) which shall fulfil the requirements of this license”.

In September 2010, the Quinn Cement EMS became accredited to the ISO 14001 standard for the first time.

2.9.1 Environmental Policy

30

2.9.2 Report on Progress of Environmental Management Programme

Licence objectives Licensee Targets Progress

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.

See results of the noise survey. Some of the improvements are

ongoing and will be reviewed again in 2011.

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 has not commenced, objective carried over.

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.

P0378-02 application still being assessed for proposed

determination. Objective carried over

Environmental and Energy Management System

Formal accreditation of Environmental and Energy Management System

Accreditation achieved to 14001, energy management system not

accredited, though formal system in place.

31

2.9.3 Schedule of Environmental Objectives and Targets 2011

Licence Objectives Licensee Targets

1. Noise Review and update the noise improvement programme

with a view to achieving the night time noise level at NSL 4 and maintain compliance at other locations.

2. Fuel Substitution (55% of coal with SRF)

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 IPPC License (P0378-02)

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. ISO 14001 To maintain and develop the EMS to the standards

achieved in 2010 with accreditation to 14001. To maintain accreditation.

5. ISO 16001

To continue development of the energy management system. To develop achievable goals on energy

efficiency, roll out of staff training and integration with environmental management system.

6. BES 6001 To achieve accreditation to BES 6001 sustainability standard across the supply chain.

7. Waste Management To establish a baseline on waste to landfill and to set in place a target for reduction that is achievable through

the hierarchy of waste management options.

8. Aluminium and Chromium in SW1

To carry out further investigation in spot high level findings in Al and Cr in the surface water discharge

through SW1 with an ultimate goal of eliminating such occurrences.

32

2.9.4 Environmental Management Plan

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

1 Noise

Review and update the noise improvement programme with a view to achieving the night

time noise level at NSL 4 and maintain compliance at other locations.

Plant Engineer, Maintenance Manager, Environmental Advisor

December 2011

2 Fuel Substitution (55% of coal with SRF)

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 Manager 2012

3 New IPPC License (P0378-02)

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 June 2011

4 ISO 14001 To maintain and develop the EMS to the

standards achieved in 2010 with accreditation to 14001. To maintain accreditation.

Environmental Advisor and Cement Management Team December 2011

5 ISO 16001

To continue development of the energy management system. To develop achievable

goals on energy efficiency, roll out of staff training and integration with environmental

management system.

Environmental Advisor and Cement Management Team

December 2011, accreditation (2012)

6 BES 6001 To achieve accreditation to BES 6001 Environmental Advisor and September 2011

33

sustainability standard across the supply chain. Cement Management Team

7 Waste Management

To establish a baseline on waste to landfill and to set in place a target for reduction that is achievable through the hierarchy of waste

management options.

Environmental Advisor, Maintenance Manager, Production Manager.

September 2011

8 Aluminium and Chromium in SW1

To carry out further investigation in spot high level findings in Al and Cr in the surface water discharge through SW1 with an ultimate goal of

eliminating such occurrences.

Cement Management July 2011

34

2.10 RMP and ELRA

2.10.1 Residual Management Plan

The residual management plan is kept on file at Quinn Cement Ltd. No significant changes have been made to this document.

2.10.2 ELRA

The ELRA is kept on file at Quinn Cement Limited. No significant changes have been made to this document.

35

2.11 AER Returns Worksheet | PRTR# : P0378 | Facility Name : Quinn Cement Limited | Filename : P0378_2010.xls | Return Year : 2010 |

Guidance to completing the PRTR workbook

Version 1.1.11REFERENCE YEAR 2010

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_name10.1 The production of cement.

Address 1 Quinn CementAddress 2 ScotchtownAddress 3 BallyconnellAddress 4 Co Cavan

Country IrelandCoordinates of Location -7.57841 54.1311

River Basin District GBNIIENWNACE Code 2351

Main Economic Activity Manufacture of cementAER Returns Contact Name Fintan Coyle

AER Returns Contact Email Address [email protected] Returns Contact Position Environmental Advisor

AER Returns Contact Telephone Number 049-9525200AER 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?

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 Workbook

36

4.1 RELEASES TO AIR Link to previous years emissions data | PRTR# : P0378 | Facility Name : Quinn Cement Limited | Filename : P0378_2010(1).xls | Return Year : 2010 | 30/03/2011 15:398 11 19 19 27 27 6 6 6

SECTION A : SECTOR SPECIFIC PRTR POLLUTANTSPlease enter all quantities in this section in KGs

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/Year03 Carbon dioxide (CO2) C ETS 655857000.0 655857000.0 0.0 0.008 Nitrogen oxides (NOx/NO2) M PER EN14792:2005 643300.0 643300.0 0.0 0.011 Sulphur oxides (SOx/SO2) M PER EN14792:2005 360900.0 360900.0 0.0 0.086 Particulate matter (PM10) M PER ISO 9096 22700.0 22700.0 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 POLLUTANTSPlease enter all quantities in this section in KGs

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


SECTION C : REMAINING POLLUTANT EMISSIONS (As required in your Licence)Please enter all quantities in this section in KGs

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


Additional Data Requested from Landfill operators

Landfill: Quinn Cement LimitedPlease 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

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

Method Used

RELEASES TO AIRPOLLUTANT METHOD

Method Used

POLLUTANT

RELEASES TO AIR

RELEASES TO AIRMETHOD

37

4.2 RELEASES TO WATERS Link to previous years emissions data | PRTR# : P0378 | Facility Name : Quinn Cement Limited | Filename : P0378_2010(1).xls | Return Year : 2010 | 30/03/2011 15:398 8 16 16 24 31 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 onPlease enter all quantities in this section in KGs

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/Year19 Chromium and compounds (as Cr) M PER EN ISO 17025:2005 4.0 4.0 0.0 0.0


SECTION B : REMAINING PRTR POLLUTANTSPlease enter all quantities in this section in KGs

QUANTITY



SECTION C : REMAINING POLLUTANT EMISSIONS (as required in your Licence)Please enter all quantities in this section in KGs

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/Year355 Aluminium M PER EN ISO 17025:2005 14.0 14.0 0.0 0.0238 Ammonia (as N) M PER EN ISO 17025:2005 4.0 4.0 0.0 0.0303 BOD M PER EN ISO 17025:2005 109.0 109.0 0.0 0.0306 COD M PER EN ISO 17025:2005 806.0 806.0 0.0 0.0324 Mineral oils M PER EN ISO 17025:2005 1.0 1.0 0.0 0.0331 Organohalogens M PER EN ISO 17025:2005 0.0 0.0 0.0 0.0240 Suspended Solids M PER EN ISO 17025:2005 920.0 920.0 0.0 0.0363 Total Dissolved Solids M PER EN ISO 17025:2005 25648.0 25648.0 0.0 0.0

RELEASES TO WATERS

Method Used

RELEASES TO WATERS

RELEASES TO WATERS

Method Used

POLLUTANTMethod Used

POLLUTANT

POLLUTANT

38

4.3 RELEASES TO WASTEWATER OR SEWER Link to previous years emissions data | PRTR# : P0378 | Facility Name : Quinn Cement Limited | Filename : P0378_2010(1).xls | Return Ye 30/03/2011 12:508 8 16 16 6 6 6 6

SECTION A : PRTR POLLUTANTSPlease enter all quantities in this section in KGs

QUANTITY



SECTION B : REMAINING POLLUTANT EMISSIONS (as required in your Licence)Please enter all quantities in this section in KGs

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


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

39

4.4 RELEASES TO LAND Link to previous years emissions data | PRTR# : P0378 | Facility Name : Quinn Cement Limited | Filename : P0378_2010(1).xls | Return Year : 2010 | 30/03/2011 12:508 8 16 16 6 6 6 6

SECTION A : PRTR POLLUTANTSPlease enter all quantities in this section in KGs

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


SECTION B : REMAINING POLLUTANT EMISSIONS (as required in your Licence)Please enter all quantities in this section in KGs

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



RELEASES TO LAND

RELEASES TO LAND


40

5. ONSITE TREATMENT & OFFSITE TRANSFERS OF WASTE | PRTR# : P0378 | Facility Name : Quinn Cement Limited | Filename : P0378_2010(1).xls | Return Year : 2010 | 30/03/2011 15:14

5 9 Please enter all quantities on this sheet in Tonnes 5

Quantity (Tonnes per

Year)

Haz Waste : Name and Licence/Permit No of Next

Destination Facility Non Haz Waste: Name and

Licence/Permit No of Recover/Disposer

Haz Waste : Address of Next Destination Facility

Non Haz Waste: Address of Recover/Disposer

Name and License / Permit No. and Address of Final Recoverer /

Disposer (HAZARDOUS WASTE ONLY)

Actual Address of Final Destination i.e. Final Recovery / Disposal Site

(HAZARDOUS WASTE ONLY)

Transfer DestinationEuropean Waste

Code Hazardous Quantity T/Year Description of Waste

Waste Treatment Operation M/C/E Method Used

Location of Treatment Name and Licence / Permi t No. of Recoverer / Disposer / Broker Address 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 Si te (HAZARDOUS WASTE ONLY)

Within the Country 13 02 08 Yes 4.0 other engine, gear and lubricating oils R9 M Weighed Offsite in Ireland Enva,184-1

Clonminam Industrial Estate,Portlaoise,Co. Laois,Co. Laois,Ireland Enva,184-1

Clonminam Industrial Estate,Portlaoise,Co. Laois,Co. Laois,Ireland

To Other Countries 15 02 02 Yes 1.23

absorbents, filter materials (including oil filters not otherwise specified), wiping cloths, protective clothing contaminated by dangerous substances R13 E Volume Calculation Abroad Enva,184-1


RD Recycling,51727/1/KD,.,.,Houthalen,.,Belgium .,.,Houthalen,.,Belgium

To Other Countries 16 01 07 Yes 0.1 oil filters R13 E Volume Calculation Abroad Enva,184-1


RD Recycling,51727/1/KD,.,.,Houthalen,.,Belgium .,.,Houthalen,.,Belgium

To Other Countries 16 05 04 Yes 0.72gases in pressure containers (including halons) containing dangerous substances R13 E Volume Calculation Abroad Enva,184-1


Lindenschmidt,E97095037,.,.,Kreuztal,.,Germany .,.,Kreuztal,.,Germany

To Other Countries 16 10 01 Yes 0.125aqueous liquid wastes containing dangerous substances R13 M Weighed Abroad

Arven Industrial Chemicals,CB/JNSO17CU

12 Goddard Road,Astmoor Industrial estate,Runcorn,Cheshire WA7IQF,United Kingdom

Lanstar,BS.1538.IQ,Lanstar,Cadishead,Manchester,.,United Kingdom

Lanstar,Cadishead,Manchester,.,United Kingdom

Method Used

41

Annex 1: Monitoring Locations:

Dust Deposit Gauges

D1 Site 1 Work shop

D2 Site 2 Hilltop

D3 Site 3 ESB

D4 Site 4 Treacy’s Field

D5 Site 5 Crusher

Noise:

**N1 NSL1

McHugh’s Residence

**N2 NSL2

Doon Heights

N3 NSL3

Slieve Russell House

N4 NSL4

McKiernan’s Residence

N5 NSL5

Site Centre

N6 NSL6

Kearns Residence

**NSL 1 and 2 outside the scope of the above drawing.

Surface water and Groundwater:

SW1 Discharge Point

GW1 Onsite Borehole

Annex 2: Atmospheric Emission Points

Air Emission Points

A2-01 Kiln

A2-02 Grate Cooler

A2-03 Coal Mill

A2-04 Cement Mill

A2-05 Sepax Filter

Annex 3: Quinn Cement 14001 Accreditation

Documents

Quinn Cement Ltd. - Environmental Protection Agency · Quinn Cement Ltd. January – December ... consistent chemical composition of the raw mix, which is then fed to the Raw Mill