P052701-AER 2009 - EPA
Annual Environmental Report 2009 For
Flemings Fireclays Manufacturing Ltd. The Swan Athy Co. Kildare
IPPC Reg. No. P0527-01
By QED Engineering Ltd. M-TEK Building 2 Armagh Road Monaghan Tel: 047 72060 Fax: 047 72061
April 2010
Flemings Fireclays Mfr. Ltd. The Swan, Athy, Co. Laois Annual Environmental Report 2009
IPPC Reg. No. P0527-01 Issue Date: 22/04/2010
Table of Contents
1. INTRODUCTION
2
2. SUMMARY INFORMATION
2
2.1 Emissions to Atmosphere
2
2.2 Emissions to Surface Water
4
2.3 Waste Management
5
2.4 Resource Consumption
8
2.5 Environmental Complaints & Incidents
8
3. MANAGEMENT OF THE ACTIVITY
9
3.1 Production Figures
9
3.2 Summary of Environmental Objectives & Targets
9
3.3 Report on EMP for 2009
10
3.4 EMP proposal for 2010
11
4. LICENCE-SPECIFIC REPORTS
13
4.1 Energy Audit
13
4.2 Noise Monitoring Report
13
4.3 Tank and Pipeline Testing and Inspection Report
13
4.4 Bund Integrity Testing Report
13
Prepared by: Q.E.D. Engineering Ltd, M-TEK Building 2, Armagh Road, Monaghan Tel: 047 72060, Fax: 047 72061
1
Flemings Fireclays Mfr. Ltd. The Swan, Athy, Co. Laois Annual Environmental Report 2009
IPPC Reg. No. P0527-01 Issue Date: 22/04/2010
1. Introduction The following AER is submitted for Flemings Fireclays Manufacturing Ltd, The Swan, Athy, Co. Laois (IPC Licence No P0527-01). The company manufactures coarse ceramics (flue liners and bricks). This deems that they are an activity under Class 13.4 of the IPC Licensing Regulations. The company th was granted an IPC licence on 5 February 2002. Mr. Ciaran O’Reilly is responsible for environmental management, and IPC licence compliance. Maintenance staff are responsible for keeping waste records and for taking water samples. This is the company’s sixth AER since obtaining the licence. It was drawn up following the EPA Guidance Note for Annual Environmental Report, 2000. It reports on the period January to December 2009.
2. Summary Information 2.1 Emissions to Atmosphere There are 2 kilns on the site, which need to be monitored as follows: Parameter SO2 CO Particulates Chlorides (as HCL) Fluorides (as HF)
Frequency Annually Annually Annually Quarterly Quarterly
Limit mg/m3 500 200 50 30 10
In addition, the following volume emissions are set in the licence. Kiln Old Kiln, A2-1 New Kiln, Stack A
Max rate/hr 3 m /hr 20,000 15,000
Max rate/day 3 m /day 480,000 360,000
During 2009, emissions from the new kiln, Stack A were measured in November. This was the only air monitoring conducted in 2009 due to the temporary closure of the facility. The Old Kiln, A2-1 was decommissioned in 2007 and has not been in operation to date. Results are presented in the following tables.
Prepared by: Q.E.D. Engineering Ltd, M-TEK Building 2, Armagh Road, Monaghan Tel: 047 72060, Fax: 047 72061
2
Flemings Fireclays Mfr. Ltd. The Swan, Athy, Co. Laois Annual Environmental Report 2009
IPPC Reg. No. P0527-01 Issue Date: 22/04/2010
Emission from Old Kiln, A2-1 - 2009 Kiln A2-1 was not monitored in 2009 as it was decommissioned in December 2007 and will not be in operation in the immediate future.
Emission from New Kiln, Stack A - 2009 Parameter
03/11/2009
Emission Limit
mgNm3
Value mgNm3
Total Particulates
12
50
11
50
9
30
-
30
9
10
-
10
Sulphur Dioxide (SO2)
0
500
Carbon Monoxide
66
200
-
-
-
-
3
6,624
15,000
3
158,976
360,000
Hydrogen Chloride
Hydrogen Fluoride
Oxygen % o
Temperature C Max. Volume Nm /hr Max. Volume Nm /day
st
nd
rd
Monitoring was not carried out in the 1 , 2 or 3 quarter due to the temporary closure of the facility. All emissions from the 4th quarter monitoring were within the set limits.
Prepared by: Q.E.D. Engineering Ltd, M-TEK Building 2, Armagh Road, Monaghan Tel: 047 72060, Fax: 047 72061
3
Flemings Fireclays Mfr. Ltd. The Swan, Athy, Co. Laois Annual Environmental Report 2009
IPPC Reg. No. P0527-01 Issue Date: 22/04/2010
2.2 Emissions to Surface Waters The licence requires that SW1, SW2, SW3, SW4 and SW5 are monitored quarterly for Suspended Solids and COD. A request was made by the agency in 2009 to conduct quarterly analysis of metals.
PARAMETER
UNITS
SW1
SW2
SW3
SW4
SW5
Env. Quality Standards for Surface Waters
Aluminium Arsenic Cadmium Chromium Iron Mercury Manganese Nickel Lead Antimony Selenium Boron Copper Sodium COD Suspended Solids
ug/l ug/l ug/l ug/l ug/l ug/l ug/l ug/l ug/l ug/l ug/l mg/l mg/l mg/l mg/l mg/l
797 13.4
Flemings Fireclays Manufacturing Ltd. The Swan Athy Co. Kildare
IPPC Reg. No. P0527-01
By QED Engineering Ltd. M-TEK Building 2 Armagh Road Monaghan Tel: 047 72060 Fax: 047 72061
April 2010
Flemings Fireclays Mfr. Ltd. The Swan, Athy, Co. Laois Annual Environmental Report 2009
IPPC Reg. No. P0527-01 Issue Date: 22/04/2010
Table of Contents
1. INTRODUCTION
2
2. SUMMARY INFORMATION
2
2.1 Emissions to Atmosphere
2
2.2 Emissions to Surface Water
4
2.3 Waste Management
5
2.4 Resource Consumption
8
2.5 Environmental Complaints & Incidents
8
3. MANAGEMENT OF THE ACTIVITY
9
3.1 Production Figures
9
3.2 Summary of Environmental Objectives & Targets
9
3.3 Report on EMP for 2009
10
3.4 EMP proposal for 2010
11
4. LICENCE-SPECIFIC REPORTS
13
4.1 Energy Audit
13
4.2 Noise Monitoring Report
13
4.3 Tank and Pipeline Testing and Inspection Report
13
4.4 Bund Integrity Testing Report
13
Prepared by: Q.E.D. Engineering Ltd, M-TEK Building 2, Armagh Road, Monaghan Tel: 047 72060, Fax: 047 72061
1
Flemings Fireclays Mfr. Ltd. The Swan, Athy, Co. Laois Annual Environmental Report 2009
IPPC Reg. No. P0527-01 Issue Date: 22/04/2010
1. Introduction The following AER is submitted for Flemings Fireclays Manufacturing Ltd, The Swan, Athy, Co. Laois (IPC Licence No P0527-01). The company manufactures coarse ceramics (flue liners and bricks). This deems that they are an activity under Class 13.4 of the IPC Licensing Regulations. The company th was granted an IPC licence on 5 February 2002. Mr. Ciaran O’Reilly is responsible for environmental management, and IPC licence compliance. Maintenance staff are responsible for keeping waste records and for taking water samples. This is the company’s sixth AER since obtaining the licence. It was drawn up following the EPA Guidance Note for Annual Environmental Report, 2000. It reports on the period January to December 2009.
2. Summary Information 2.1 Emissions to Atmosphere There are 2 kilns on the site, which need to be monitored as follows: Parameter SO2 CO Particulates Chlorides (as HCL) Fluorides (as HF)
Frequency Annually Annually Annually Quarterly Quarterly
Limit mg/m3 500 200 50 30 10
In addition, the following volume emissions are set in the licence. Kiln Old Kiln, A2-1 New Kiln, Stack A
Max rate/hr 3 m /hr 20,000 15,000
Max rate/day 3 m /day 480,000 360,000
During 2009, emissions from the new kiln, Stack A were measured in November. This was the only air monitoring conducted in 2009 due to the temporary closure of the facility. The Old Kiln, A2-1 was decommissioned in 2007 and has not been in operation to date. Results are presented in the following tables.
Prepared by: Q.E.D. Engineering Ltd, M-TEK Building 2, Armagh Road, Monaghan Tel: 047 72060, Fax: 047 72061
2
Flemings Fireclays Mfr. Ltd. The Swan, Athy, Co. Laois Annual Environmental Report 2009
IPPC Reg. No. P0527-01 Issue Date: 22/04/2010
Emission from Old Kiln, A2-1 - 2009 Kiln A2-1 was not monitored in 2009 as it was decommissioned in December 2007 and will not be in operation in the immediate future.
Emission from New Kiln, Stack A - 2009 Parameter
03/11/2009
Emission Limit
mgNm3
Value mgNm3
Total Particulates
12
50
11
50
9
30
-
30
9
10
-
10
Sulphur Dioxide (SO2)
0
500
Carbon Monoxide
66
200
-
-
-
-
3
6,624
15,000
3
158,976
360,000
Hydrogen Chloride
Hydrogen Fluoride
Oxygen % o
Temperature C Max. Volume Nm /hr Max. Volume Nm /day
st
nd
rd
Monitoring was not carried out in the 1 , 2 or 3 quarter due to the temporary closure of the facility. All emissions from the 4th quarter monitoring were within the set limits.
Prepared by: Q.E.D. Engineering Ltd, M-TEK Building 2, Armagh Road, Monaghan Tel: 047 72060, Fax: 047 72061
3
Flemings Fireclays Mfr. Ltd. The Swan, Athy, Co. Laois Annual Environmental Report 2009
IPPC Reg. No. P0527-01 Issue Date: 22/04/2010
2.2 Emissions to Surface Waters The licence requires that SW1, SW2, SW3, SW4 and SW5 are monitored quarterly for Suspended Solids and COD. A request was made by the agency in 2009 to conduct quarterly analysis of metals.
PARAMETER
UNITS
SW1
SW2
SW3
SW4
SW5
Env. Quality Standards for Surface Waters
Aluminium Arsenic Cadmium Chromium Iron Mercury Manganese Nickel Lead Antimony Selenium Boron Copper Sodium COD Suspended Solids
ug/l ug/l ug/l ug/l ug/l ug/l ug/l ug/l ug/l ug/l ug/l mg/l mg/l mg/l mg/l mg/l
797 13.4
