attachment no. e emissions table of · pdf filea2-09 kiln 3 grate cooler ... irish cement ltd...

Irish Cement Ltd Platin Works IPPC Licence Review Attachment No. E

E - 1 of 48

October 2009

ATTACHMENT No. E

EMISSIONS

TABLE OF CONTENTS

E.1. Emissions to Atmosphere ....................................................................................... 2 E.2. Emissions to Surface Waters ............................................................................... 6

E.3. Emissions to Sewer .................................................................................................. 9

E.4. Emissions to Ground ............................................................................................... 9

E.5. Noise Emissions ....................................................................................................... 9

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October 2009

E.1. Emissions to Atmosphere

E.1.1 Boiler Emissions There are no boiler emissions from the site associated with the cement manufacturing process.

E.1.2 Main Emissions A description of the main emissions to atmosphere is given in the Application Form Tables E.1(ii). The chemical characteristics of the main emissions are given in Tables E.1(iii).

The IPPC licensed main emission points at Irish Cement Ltd (ICL) are given in Table E.1 (refer also to Figure E.1).

Table E.1 IPPC Licensed Main Emission Points to Atmosphere

IPPC Licence Label

Description

A2-01 Raw Mill 1 & Coal Mill 1

A2-02 Kiln 2, Bypass, Raw Mill 2

A2-03 Coal Mill 2

A2-04 Cement Mill 1

A2-05 Cement Mill 2 and Separator


A2-07 Kiln 2 Grate Cooler

A2-08 Kiln 3, Bypass, Raw Mill 3, Coal Mill 3



Kiln 3 has been in operation since December 2008. Cement Mill 4 has been operational since September 2008.

Kiln 1 was decommissioned in October 2008 prior to commissioning of Kiln 3. ICL informed the Agency in advance, of the date of commencement of operation of Kiln 3 in accordance with the requirements of the IPPC Licence.

Kiln 1 emission point, A2-01 has been retained as an emission point for Raw Mill 1 and Coal Mill 1. Exhaust gases from the new Kiln 3 line may be used to dry limestone being milled for the production of CEM II cements. In this situation, it is proposed to vent the gas through the existing Kiln 1 chimney i.e. emission point A2-01. E.1.2.1 Main Emissions - Monitoring of Emissions to Atmosphere

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October 2009

Table E.2 lists the emission point A2-02 monitoring results for 2008 (post receipt of IPPC licence P0030-03) and compares them with IPPC licence limits.

Table E.2 Emission Point A2-02 Monitoring Results 2008 (post receipt of IPPC licence P003-03)

Parameter

2008 Average Concentration (post receipt of IPPC licence

P003-03)

(mg/Nm³@10%O2)

IPPC Licence Limits (mg/Nm³@10%O2)

Particulates 7 50

NOX 800* 1,000

SO2 0** 750

*NOX limit reduced to 800 mg/Nm3 @ 10% O2 after 6 months of receipt of new licence.

**2008 SO2 results were less than the limit of detection.

Table E.3 lists the emission point A2-08 monitoring results for 2009 and compares them with IPPC licence limits.

Table E.3 Emission Point A2-08 Monitoring Results 2009

Parameter 2009 (March 2009) Average

Concentration

(mg/Nm³@10%O2)

IPPC Licence Limits (mg/Nm³@10%O2)

Particulates 6 30

NOX 493 800

SO2 0* 400

*2009 SO2 results were less than the limit of detection.

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October 2009

Table E.4 lists the monitoring results for the other main emission points monitored for particulates emissions.

Table E.4 Other Particulates Monitoring Results 2008

Source Description 2008 Average Concentration

(mg/Nm³)

IPPC Licence Limits

(mg/Nm³)

A2-03 Coal Mill 2 37 50

A2-04 Cement Mill 1 33 75


29 50


3 50


17 100

A2-10 Cement Mill 4 1 30

Emissions are monitored in accordance with the frequencies stipulated in IPPC Licence Reg. No. P0030-03. E.1.2.2 Main Emissions – Description of Abatement Systems

Particulate emissions from the following sources are/will be abated using electrostatic precipitators: A2-01 Raw Mill 1 & Coal Mill 1 A2-02 Kiln 2, Bypass, Raw Mill 2 A2-04 Cement Mill 1 A2-07 Kiln 2 Grate Cooler A2-09 Kiln 3 Grate Cooler Particulates emissions from the following sources are/will be abated using bag filters: A2-03 Coal Mill 2 A2-05 Cement Mill 2 and Separator A2-06 Cement Mill 3 and Separator A2-08 Kiln 3/Bypass/Raw Mill 3/Coal Mill 3 A2-10 Cement Mill 4 NOX emissions from Kiln 2 and Kiln 3 can be abated using selective non-catalytic reduction (SNCR). SNCR involves injecting aqueous ammonia into the kiln exhaust gas to reduce NOX to N2. Further information on the abatement systems for emissions to atmosphere is provided in Attachment No. F.

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October 2009

E.1.3 Minor Emissions A minor emission is an emission, which on the basis of its concentration and mass emission is not considered environmentally significant. Therefore it is not classified as a main emission.

Some relevant minor emission points (e.g. extract from transfer points on materials handling systems) are abated using bag filters. Minor emission points and the abatement systems employed are detailed in Table E.1(iv). Minor emission points are shown in Figure E.2. Minor emission points associated with the proposed Alternative Fuels project are shown in Figure E.3.

E.1.4 Fugitive Emissions Fugitive dust emissions can occur from operations on-site. Every effort is made to minimise such emissions.

Dust management measures appropriate to modern cement manufacture are applied and are continually reviewed as part of the annual Environmental Management Plan for the site. All fugitive emission points are detailed in Table E.1(v).

Internal storage systems will be used for all the alternative fuels so there will be no new fugitive emission points associated with the alternative fuels.

E.1.5 Potential Emissions A potential emission point is an emission point that is not active under normal operations. Potential emissions and the malfunctions causing the emissions are identified in Table E.1(v).

There are no potential emission sources associated with the proposed Alternative Fuels project.

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October 2009

E.2. Emissions to Surface Waters E.2.1 Source of Emissions Details of all emissions to surface water are given Tables E.2(i) and (ii). A flow diagram of the process, surface water, domestic sewage effluent and groundwater conveyance is given in Figure E.4. The process, surface and groundwater conveyance system and emission points are shown in Figure E.5. The domestic sewage conveyance system is shown in Figure E.6. The domestic sewage treatment package plant is shown in Figure E.7. Management of process and storm water run-off on-site consists of a water collection system which delivers process and storm water into storm balancing tanks followed by sedimentation/settlement tanks, both of which are used to reduce the levels of suspended solids. Deep well water from the quarry is managed through continuous pumping of groundwater from the deep well in the quarry floor. It does not require any treatment. Domestic effluent is treated in a purpose built package waste water treatment plant on-site. Treated process and storm water run-off discharges from the sedimentation tank and confluences with deep well water from the quarry and treated domestic effluent to form the final treated effluent which discharges to the outfall point into the River Nanny via a designated pipeline. The treated final effluent is discharged through 2,637m of 610 mm pipeline which runs underground from the cement factory to the outfall point into the receiving waters of the River Nanny. The outfall pipe runs under roads and agricultural land and outfalls into the River Nanny south of the factory, just off the R150 regional road.

The proposed development will give rise to minor additional rainwater runoff as follows: - Roof of Solid Recovered Fuel store. - Roof of Chipped Tyre store

The total additional impermeable area from these buildings will be 0.20 ha. With an impermeable area of approx. 17.5 ha for the developed are of the full site this represents a minor increase of 1.14%. The runoff from the roofs of the two buildings will be collected in a storm water drain which will be connected to the overall site box drainage network. The proposed facilities will have no significant impact on the site storm water management system. The IPPC licensed emission points associated with emissions to surface waters are described in Table E.5.

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October 2009

Table E.5 IPPC Licensed Emission Points associated with Emissions to Surface Water

Emission Point Emission Type

SW-1 Treated process and storm water effluent from storm balancing and settlement tanks

SW-3 Treated domestic sewage effluent from wastewater treatment plant

SW-4 Combined effluent streams from SW-1, treated process and storm water effluent, SW-3, treated domestic effluent and potable excess quarry groundwater

E.2.2 Emissions to Surface Water Monitoring Results Continuous monitoring results of licensed emission parameters to surface water are given in Table E.6.

Table E.6 SW-4 Surface Water Emissions Monitoring Results 2008

Parameter 2008 Monthly Average Emission IPPC Licence Limit

BOD 0 mg/L* 6 mg/L

Suspended solids 13 mg/L 35 mg/L

Cu 0.0009 0.1 mg/L

Pb 0.0002 0.1 mg/L

Zn 0* 0.5 mg/L

pH 8 6-9

Flowrate (m3/day) 11,935 m3/day 28,000 m3/day

*less than detection limits

The Table E.7 below details monitoring frequency and methods used to monitor emissions from SW-4.

Table E.7 Monitoring of Emission Parameters from SW-4

Parameter Monitoring Frequency Analysis Method / Technique

Outlet flow Continuous On-line flow meter with recorders

pH Monthly pH electrode

Suspended solids Monthly Gravimetric method

Biochemical Oxygen Demand Monthly Standard method

Chemical Oxygen Demand Monthly Standard method

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October 2009

Parameter Monitoring Frequency Analysis Method / Technique

Total Cu Biannually Atomic absorption spectroscopy

Total Pb Biannually Atomic absorption spectroscopy

Total Zn Biannually Atomic absorption spectroscopy

Mineral oil Monthly Standard method

Conductivity Weekly Standard method

Visual inspection Weekly Sample and examine for colour and odour

Toxicity As may be required To be agreed with Agency

Note that: • Toxicity testing is carried out on instruction from the Agency • Mineral oils are also monitored in accordance with IPPC Licence requirements.

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October 2009

E.3. Emissions to Sewer E.3.1 Source of Emissions Foul water effluent from the facility is not discharged to the public sewer. Foul water is comprised of domestic wastewater and utilities wastewater from laboratories. Foul effluent from the works is discharged through a wastewater treatment package plant and thence to the common effluent discharge pipe for discharge to the River Nanny.

E.3.2 Characteristics of Foul Water Emissions The average flowrate from the wastewater treatment system is approximately 28 m³ per day (average from 2008 Annual Environmental Report) with a BOD loading of approximately 16.1 mg/L and suspended solids of 52 mg/L.

The wastewater treatment plant upgrade was agreed with the Agency. Technical details of the upgrade are provided in Attachment No. F.

E.4. Emissions to Ground

There are no direct emissions to ground from the site.

E.5. Noise Emissions

The details of the significant noise sources in terms of sound power level are given in the Noise Summary Sheets Tables E.5 (i). Existing noise sources are shown in Figure E.8.

The equipment associated with the proposed alternative fuels handling system will not affect current noise emission levels. The main sources of noise will be from comparatively small blowers. The combined sound power level of these units will not increase the total sound power level on-site above the current value. Consequently the operation of the proposal will not cause any increase in the sound pressure level at the nearest noise sensitive location, Synnott’s, 400 m to the east of the plant.

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E - 10 of 48 October 2009

IPPC Licence Application Tables

E.1(i)

E.1(ii)

E.1(iii)

E.1(iv)

E.1(v)

E.2(i)

E.2(ii)

E.3(i)

E.3(ii)

E.4(i)

E.4(ii)

E.5(i)

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Table E.1 (i) BOILER EMISSIONS TO ATMOSPHERE (1 Page for each emission point) Emission Point: Emission Point Ref. No:

Not Applicable

Location:

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

Vent Details

Diameter:

Height above Ground(m):

Date of commencement of emission:

Characteristics of Emission:

Boiler rating Steam Output: Thermal Input:

kg/hr

MW Boiler fuel Type: Maximum rate at which fuel is burned % sulphur content:

kg/hr

NOx mg/Nm3

0oC. 3% O2(Liquid or Gas), 6% O2(Solid Fuel) Maximum volume* of emission

m3/hr 0oC, 3 % O2 (liquid or gas), 6 % O2 (solid fuel)

Temperature

oC(max) oC(min) oC(avg)

* Volume flow limits for emissions to atmosphere shall be based on Normal conditions of temperature and pressure, (i.e. 0oC,101.3kPa), dry gas; 3% oxygen for liquid and gas fuels; 6% oxygen for solid fuels. (i) Period or periods during which emissions are made, or are to be made, including daily or seasonal variations (start-up/shutdown to

be included): Periods of Emission (avg)

min/hr hr/day day/yr

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TABLE E.1(ii) MAIN EMISSIONS TO ATMOSPHERE (1 Page for each emission point) Emission Point Ref. No:

A2-01

Source of Emission:

Raw Mill 1 & Coal Mill 1

Location:

Kiln 1 Stack in front of Building 185


306520E 271754N

Vent Details Diameter:

Height above Ground (m):

2.38m 98.01m

Date of commencement:

Post 2008


(i) Volume to be emitted: Average/day 1.08 x 10 6

Nm3/d Maximum/day 1.18 x 10 6 Nm3/d

Maximum rate/hour 49,000 Nm3/h Min efflux velocity Not available m.sec-1

(ii) Other factors Temperature 118oC (max) 76oC (min) 87 oC(avg)

For Combustion Sources: Volume terms expressed as: wet. ⌧ dry 10%O2

(iii) Period or periods during which emissions are made, or are to be made, including daily or seasonal variations (start-up

/shutdown to be included): Periods of Emission (avg)

60 min/hr 24 hr/day 365 day/yr

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A2-02

Source of Emission:

Kiln 2, Raw Mill 2 (ICL Plant No. 24601)

Location:

Kiln 2 Stack


306490E 271801N



3.70 103.04


1977




Maximum rate/hour 400,000 Nm3/h Min efflux velocity 8.9 m.sec-1

(ii) Other factors Temperature 148 oC(max) 103 oC(min) 121 oC(avg)

For Combustion Sources: Volume terms expressed as : wet. ⌧ dry @ 10 %O2




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A2-03

Source of Emission:

Coal Mill 2 (ICL Plant No. 22676)

Location:

Beside building 135


306599E 271737N



1.0 48.09


1982


(i) Volume to be emitted: Average/day 496,296 Nm3/d Maximum/day 744,000 Nm3/d



For Combustion Sources: Volume terms expressed as : wet. ⌧ dry @ 10 %O2




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A2-04

Source of Emission:

Cement Mill 1 Electrostatic Precipitator (ICL Plant No. 15222)

Location:

Building No. 152


306806E 271834N



0.704 28.64


1972


(i) Volume to be emitted: Average/day 376,032 Nm3/d Maximum/day 444,000 Nm3/d



For Combustion Sources: Volume terms expressed as : ⌧ wet @ actual % O2 dry




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A2-05

Source of Emission:

Cement Mill 2 and Separator Bag Filter (ICL Plant No. 25422)

Location:

Building No. 254


306791E 271840N



1.90 34.82


1978






For Combustion Sources: Volume terms expressed as : : ⌧ wet @ actual % O2 dry




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A2-06

Source of Emission:

Cement Mill 3 and Separator Bag Filter (ICL Plant No. 35622)

Location:

Adjacent to building No. 356 (Northside)


306761E 271881N



1.988 26.35


1990




Maximum rate/hour 135,000

Nm3/h Min efflux velocity 15.5 m.sec-1






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A2-07

Source of Emission:

Kiln 2 Grate Cooler (ICL Plant No. 24560)

Location:

East of Kiln 2


306722E 271867N



3.55 30.43


1998




Maximum rate/hour 210,000

Nm3/h Min efflux velocity 15.9 m.sec-1


For Combustion Sources: Volume terms expressed as : : ⌧ wet @ actual % O2 dry




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A2-08

Source of Emission:

Kiln 3, Raw Mill 3, Coal Mill 3, Kiln 3 By-pass

Location:

Kiln 3 stack


306602E 271675N



3.75 123


December 2008


(i) Volume to be emitted: Average/day 9.512616x10 6


Maximum rate/hour 410,000 Nm3/h Min efflux velocity 12 m.sec-1


For Combustion Sources: Volume terms expressed as : wet. ⌧ dry 10%O2




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A2-09

Source of Emission:

Kiln 3 Grate Cooler

Location:

Kiln 3 Grate Cooler stack


306707E 271707N



3.0 35.0


Planned for late 2008


(i) Volume to be emitted: Average/day 3.816288 x10 6


Maximum rate/hour 219,000Nm3/h Min efflux velocity 12.8 m.sec-1






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A2-10

Source of Emission:

Cement Mill 4 Bag Filter

Location:

Cement Mill 4 Stack


306802E 271928N



2.0 39


Planned for summer 2008


(i) Volume to be emitted: Average/day 2.64 x10 6



(ii) Other factors Temperature 130oC(max) 70 oC(min) 105 oC(avg)





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TABLE E.1(iii): MAIN EMISSIONS TO ATMOSPHERE - Chemical characteristics of the emission (1 table per emission point)

Emission Point Reference Number: A2-01 Raw Mill 1 & Coal Mill 1

Parameter Prior to treatment(1) Brief As discharged(1)

mg/Nm3 kg/h description mg/Nm3 kg/h. kg/year

Avg Max Avg Max of treatment Avg. Max Avg. Max Avg. Max

Particulates

60,000 60,000 270 2940 Exhaust gases cleaned by an Electrostatic Precipitator.

Type: F.L. Smidth

2FAA-363636-6080-1

Installed: 1971 ca

19 50 0.855 2.45 7,490 21,462

NOX 1267 1800 57 88 Lower NOX precalciner kiln and SNCR

750 1300 33.8 63.7 296,088 558,012

SOX 29 400 1.3 19.6 Absorption occurs in the preheater / raw mill

29 400 1.3 19.6 11,388 171,696

1. Concentrations should be based on Normal conditions of temperature and pressure, (i.e. 0oC,101.3kPa). Wet/dry should be the same as given in Table E.1(ii) unless clearly stated otherwise.

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TABLE E.1(iii): MAIN EMISSIONS TO ATMOSPHERE - Chemical characteristics of the emission (1 table per emission point)

Emission Point Reference Number: A2-02 - Kiln 2, Bypass, Raw Mill 2 (ICL Plant No. 24601)



Avg Max Avg Max of treatment Avg Max Avg Max Avg Max

Particulates 52950 52950 17130 21180 Exhaust gases are cleaned by electrostatic precipitator.

Type: F.L. Smidth

FAA-404040-15090-1 Installed: 1977

Electrostatic Precipitator extended in 2007.

24.2 50 7.8 20 68,489 175,200

NOX 1267 1800 410 720 Selective Non Catalytic Reduction in the Preheater Tower

Installed 2007

750 1000 243 400 2.1 x106 3.5x106

SOX 29 750 9.4 300 Absorption occurs in the preheater / raw mill

29 750 9.4 300 29784 2.6 x106


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TABLE E.1(iii): MAIN EMISSIONS TO ATMOSPHERE - Chemical characteristics of the emission (1 table per emission point) Emission Point Reference Number: A2-03 - Coal Mill 2 (ICL Plant No. 22676)




Particulates 60000 60000 940 1110 Exhaust gases are cleaned by a bag filter.

Type: F.L. Smidth

Installed: An Electrostatic Precipitator was originally installed in 1983. This was replaced by a Bag Filter in 2007.

10 50 0.207 1.55 1,812 13,578

NOX 1267 1800 26.2 55.8 Selective Non Catalytic Reduction in the Preheater Tower Installed 2007

750 1000 15.5 31.0 135780 271560

SOX 29 750 0.6 23.3 Absorption occurs in the preheater / raw mill

29 750 0.6 23.3 5256 203,670


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TABLE E.1(iii): MAIN EMISSIONS TO ATMOSPHERE - Chemical characteristics of the emission (1 table per emission point) Emission Point Reference Number: A2-04 - Cement Mill 1 Electrostatic Precipitator (ICL Plant No. 15222)




Particulates 60000 60000 940 1110 Exhaust gases are cleaned by electrostatic precipitator.

Type: F.L. Smidth

FAB-7100F

Installed: In 1972 Cement Mill 1 Electrostatic Precipitator was installed. In 1988 a

High Efficiency Separator and Bag Filter were installed. This Bag Filter is a minor emission point.

20.6 75 0.323 1 2826 12,155


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TABLE E.1(iii): MAIN EMISSIONS TO ATMOSPHERE - Chemical characteristics of the emission (1 table per emission point) Emission Point Reference Number: A2-05 - Cement Mill 2 Bag Filter (ICL Plant No. 25422)




Particulates 60000 6000 5065 7200 Exhaust gases are cleaned by air electrostatic precipitator/bag filter.

Installed: In 1978 Cement Mil 2 and an Electrostatic Precipitator were installed. In 1998 a

High Efficiency Separator and Bag Filter were installed. Since then the gases from the ESP are ducted into the High Efficiency Separator and Bag Filter.

14.3 50 1.203 6 10,538 52,560


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TABLE E.1(iii): MAIN EMISSIONS TO ATMOSPHERE - Chemical characteristics of the emission (1 table per emission point) Emission Point Reference Number: A2-06 - Cement Mill 3 Bag Filter (ICL Plant No. 35622)




Particulates 60000 60000 5565 8100 Exhaust gases are cleaned by a bag filter. Type: Redacam bag filter BI-GET 2DP

Installed: In 1978 Cement Mill 3 and an Electrostatic Precipitator were installed. In 1990 a High Efficiency Separator and Bag Filter were installed. Gases from the Electrostatic Precipitator are now ducted into the High Efficiency Separator and Bag Filter.

25.4 50 2.352 6.75 20,605 59,130


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TABLE E.1(iii): MAIN EMISSIONS TO ATMOSPHERE - Chemical characteristics of the emission (1 table per emission point) Emission Point Reference Number: A2-07 - Kiln 2 Grate Cooler (ICL Plant No. 24560)




Particulates 60000 60000 9349 12600 Exhaust gases are cleaned by an Electrostatic Precipitator

Installed: 1998

17.3 100 2.698 21 23,635 183,960


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TABLE E.1(iii): MAIN EMISSIONS TO ATMOSPHERE - Chemical characteristics of the emission (1 table per emission point) Emission Point Reference Number: A2-08 - Kiln 3, Raw Mill 3, Coal Mill 3 and Kiln 3 by-pass





10 30 4.0 12.3 34721 107748

NOX 1267 1800 502 738 Lower NOX Precalciner Kiln and SNCR

450 1300 178 533 1.6 x106

4.7 x106

SOX 29 400 11.5 164 Absorption occurs in the preheater / raw mill

29 400 11.5 164 100740 1.4 x106


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TABLE E.1(iii): MAIN EMISSIONS TO ATMOSPHERE - Chemical characteristics of the emission (1 table per emission point) Emission Point Reference Number: A2-09 - Kiln 3 Grate Cooler




Particulates 60000 60000 9541 13140 Exhaust gases are cleaned by an Electrostatic Precipitator.

10 30 1.6 6.6 13929 57553

1. Concentrations should be based on Normal conditions of temperature and pressure, (i.e. 0oC,101.3kPa). Wet/dry should be the same as given in Table E.1(ii) unless clearly stated otherwise

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TABLE E.1(iii): MAIN EMISSIONS TO ATMOSPHERE - Chemical characteristics of the emission (1 table per emission point) Emission Point Reference Number: A2-10 - Cement Mill 4





10 30 1.1 3.3 9636 28908


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TABLE E.1(iv): EMISSIONS TO ATMOSPHERE - Minor atmospheric emissions

Emission point Description Emission details1 Abatement system employed Reference Numbers material mg/Nm3

Wet (2)

kg/h. kg/year

A3-1 Limestone Crusher Limestone 50 2.1 8188 Bag Filter A3-2 New Limestone store -

loading point of extraction belt

Limestone 30 0.10 377 Bag Filter

A3-3 Top of Raw mill 2 & 3 limestone extromats

Limestone 30 0.37 2897 Bag Filter

A3-4 Homogenising (Top Floor Building 35)

Raw Meal 50 1.8 13920 Bag Filter

A3-5 Top of Raw mill 3 shale extromat

Shale 30 0.16 1272 Bag Filter

A3-6 Raw Mill 3 North wing (Millhouse)

Raw materials

30 0.45 3518 Bag Filter

A3-7 Raw Mill 3 North wing (Millhouse)

Raw materials

30 0.48 3730 Bag Filter

A3-8 Kiln 1 feed - on pump Raw Meal 50 0.5 3560 Bag Filter A3-9 Kiln 3 Feed Silo 4 Elevator

base Raw meal 30 0.21 1611 Bag Filter

A3-10 Clinker drag chain (5thfloor) Clinker 50 0.2 1076 Bag Filter A3-11 Road Clinker Hopper (Road

despatch) Clinker 50 0.5 3571 Bag Filter

A3-12 Clinker from silo's 1.2&3. (Building 48 5th floor)

Clinker 50 0.3 2108 Bag filter

A3-13 Department 48. 5th Floor Clinker to mills Drag Chain

Clinker 50 0.3 2108 Bag Filter

A3-14 CM1 Fluxo (1st floor CM 1) Cement 50 0.5 3898 Bag Filter A3-15 CM 1 Seapax Seperator Cement 50 0.3 2031 Bag Filter

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Wet (2)

kg/h. kg/year

(Cement Mill 1st floor) A3-16 Cement Mill 1 Additive

(Cement Mill 1st floor) Raw Meal 50 0.1 1029 Bag Filter

A3-17 New Type II Limestone bin Limestone 50 0.1 1004 Bag Filter A3-18 Kiln 3 Feed Silo 4 roof Raw meal 30 0.55 4352 Bag Filter A3-19 Cement Transport Screws

Tunnel (1st floor behind packing plant)

Cement 50 0.4 2796 Bag filter

A3-20 Rail Bulk Loading Cement 50 0.2 134 Bag Filter A3-21 Rail Bulk Loading Cement 50 0.2 134 Bag Filter A3-22 Rail Bulk Silo (Top) Cement 50 0.2 126 Bag Filter A3-23 Rail Bulk Loading Cement 50 0.2 149 Bag Filter A3-24 Shale Crusher (Replaced

12521 Old) (Beside Mansfield crusher)

Shale 50 0.6 2765 Bag Filter

A3-25 Raw mill 2 Elevator (spiral platform silo building 35)


A3-26 Kiln 2 feed 5th floor Raw Meal 50 0.4 3062 Bag Filter A3-27 kiln 2 Preheating Tower 2nd

floor back end Raw Meal 50 0.3 1963 Bag Filter

A3-28 Kiln 2 Preheating tower 3rd floor


A3-29 Kiln 2 Preheating tower 6th floor


A3-30 Kiln 2 Feed ground floor Raw Meal 50 0.4 2826 Bag Filter A3-31 Kiln 2 Grate Cooler (North) Clinker 50 0.5 4004 Bag Filter A3-32 kiln 2 Grate Cooler (South) Clinker 50 0.5 4004 Bag Filter A3-33 Clinker to silo's (bottom) Clinker 50 0.4 3297 Bag Filter

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Wet (2)

kg/h. kg/year

A3-34 Dedusting of Clinker silos 1, 2 & 3, Top Clinker Silo 1, replaced in Mar 08


A3-35 Clinker Silo 4 (top of silo) Clinker 50 0.6 4589 Bag Filter A3-36 Clinker Silo 5 (top of silo) Clinker 50 0.2 1255 Bag Filter A3-37 Clinker Silo 6 (top of silo) Clinker 50 0.2 1255 Bag Filter A3-38 Clinker 7 (top of Silo) Clinker 50 0.2 1255 Bag Filter A3-39 Clinker to silo's (top) Clinker 50 0.5 3519 Bag Filter A3-40 Kiln 2 & Kiln 3 Feed Building

135 Ground Raw meal 30 0.1 452 Bag Filter

A3-41 Clinker to mills Elevator (CM1 Top of building)


A3-42 Clinker feed Hopper CM1 (Top of building)

Clinker/Gypsum

50 0.5 3650 Bag Filter

A3-43 Clinker feed Hopper CM2 (Top Building)

Clinker/Gypsum


A3-44 Clinker feed Hopper CM3 (Top of building)

Clinker/Gypsum


A3-45 Clinker silo's 1.2&3. Btm (Opposite engineering build beside rail)


A3-46 CM2 Pneumex Pump (Roof) Cement 50 0.3 2151 Bag Filter A3-47 Kiln 2 back end coal feed

(Coal Silo) Preheater Tower 3rd floor

Coal 50 0.1 544 Bag Filter

A3-48 Kiln 2 & Kiln 3 Feed Building 135 Top

Raw meal 30 0.06 452 Bag Filter

A3-49 Coal Mill 2 Feed Cement 50 0.1 623 Bag Filter

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Wet (2)

kg/h. kg/year

A3-50 Fine Coal Hopper Kiln 2 Coal 50 0.2 1766 Bag Filter A3-51 Cement silo 3 (CM2 roof) Cement 50 0.4 2632 Bag Filter A3-52 Cement Silo 2 (Roof) Cement 50 0.5 3490 Bag Filter A3-53 Ferrous Sulphate Additive

Packaging and Despatch Plant 1st floor

Sulphate 50 0.1 188 Bag Filter

A3-54 Slag Loading bay (Packing plant walkway) Truck despatch

Slag Cement


A3-55 Slag screw conveyor Truck despatch

Slag 50 0.3 2000 Bag Filter

A3-56 Rail SR Cement Packing Plant

Cement 50 0.4 2904 Bag Filter

A3-57 Packing Plant No 1 Cement 50 1.4 2878 Bag Filter A3-58 Top of Slag Silo D2 GGBS/Slag 50 0.4 2868 Bag Filter A3-59 Packing Plant No 2 Cement 50 1.3 2742 Bag Filter A3-60 Road Dispatch 3rd Floor Cement 50 0.4 1504 Bag Filter A3-61 Road Bulk No. 1 Loading Cement 50 0.2 781 Bag Filter A3-62 Road Bulk No. 2 Loading Cement 50 0.2 1488 Bag Filter A3-63 Road Bulk No. 3 Loading Cement 50 0.2 1488 Bag Filter A3-64 Road Bulk No. 4 Loading Cement 50 0.2 1488 Bag Filter A3-65 Road Dispatch 1st Floor

(Road bulk elv.) Cement 50 0.4 1764 Bag Filter

A3-66 CM3 (Roof) Cement 50 0.2 1714 Bag Filter A3-67 Silo 7 Top floor filter Cement 50 2.0 14102 Bag Filter A3-68 Silo 8 Top floor filter Cement 50 2.0 14102 Bag Filter A3-69 Packing Plant Ground floor Cement 50 0.3 1050 Bag Filter A3-70 Silo 7 Btm Cement 50 0.2 1699 Bag Filter

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Wet (2)

kg/h. kg/year

A3-71 Silo 8 btm Bulk Rapid Cement


A3-72 K3 feed elevator (bottom) Raw meal 50 0.1 1137 Bag filter A3-73 Unassigned A3-74 Kiln 3 Preheater Tower Level

3 Raw meal 30 0.23 1837 Bag Filter

A3-75 Kiln 3 Preheater Tower Level 5

Raw meal 30 0.15 1145 Bag Filter

A3-76 Kiln 3 Burner Platform (Grate Cooler)


A3-77 North of Coal Mill 3 Bag Filter (Coal Mill 3 pump)

Coal dust 30 0.06 480 Bag Filter

A3-78 Top of fine coal bin supply to K3 Calciner


A3-79 Top of fine coal bin supply to Kiln 3


A3-80 Top of new Clinker kiln 3 Silo 8


A3-81 Kiln 3 Clinker Silo 8 - head of extraction conveyor


A3-82 Kiln 3 Clinker Silo 8 - head of extraction conveyor


A3-83 New Kiln 3 Clinker Elevator Clinker 30 0.33 2388 Bag Filter A3-84 Type II Limestone crusher -

east of new Limestone store Limestone 30 0.51 3657 Bag Filter

A3-85 Top of New Type II Limestone bins and Gypsum bins

Limestone/Gypsum

30 0.23 1678 Bag Filter

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Wet (2)

kg/h. kg/year

A3-86 Top of New Kiln 3 Clinker feed bin to cement mill


A3-87 Cement Mill 4 Materials Building Level 1 (Clinker Bin)

L/stone & Gypsum

30 0.40 2878 Bag Filter

A3-88 Cement Mill 4 Materials Building Level 1 (Elevator)


A3-89 Cement Mill 4 Department Level 2


A3-90 Top of Cement Mill 4 Fluxo pot


A3-91 Unassigned A3-92 Unassigned A3-93 Unassigned A3-94 Filter on SRF Pfister pre-

hopper (Calciner) SRF 30 0.15 1314 Bag filter

A3-95 Filter on MBM Silo 1 MBM 30 0.12 1058 Bag filter A3-96 Filter on MBM Silo 2 MBM 30 0.12 1058 Bag filter A3-97 Filter on MBM Pfister hopper MBM 30 0.02 146 Bag filter A3-98 Filter on SRF Pfister pre-

hopper (main burner) SRF 30 0.15 1314 Bag filter

1 The maximum emission should be stated for each material emitted, the concentration should be based on the maximum 30 minute mean. 2 Concentrations should be based on Normal conditions of temperature and pressure, (i.e. 0oC101.3kPa). Wet/dry should be clearly stated. Include reference oxygen conditions for combustion sources.

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TABLE E.1(v): EMISSIONS TO ATMOSPHERE – Fugitive and Potential atmospheric emissions

Emission point ref. no. (as per flow diagram)

Description Malfunction which could cause an emission

Emission details (Potential max. emissions)1

Material mg/Nm3 kg/hour

A4-1 (ICL Ref 16570) 21 Overpressure panels

Overpressure in system only Coal dust 30,000 10kg in total as plant will stop automatically

A4-2 (ICL Ref 16529) 1 Overpressure Diaphragm










A4-7 (ICL Ref 16546) 1 Overpressure flap

Overpressure in system or failure of spring fasteners

Coal dust 30,000 10kg in total as plant will stop automatically





A4-10 (ICL Ref 26670) 21 Overpressure panels





A4-12 (ICL Ref 24370) 4 Overpressure Overpressure in system or Coal dust 30,000 10kg in total as plant will stop

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flap failure of spring fasteners automatically













A4-22 (ICL Ref ) Spilled liquid surface in bund

Ammonia water spill into bund Ammonia vapour

N/A N/A

A4-23 (ICL Ref 14433) Kiln 1 stack Safety trip of ESP abatement system

Dust N/A If ESP filter is not rectified within several minutes the kiln is shut down.

A4-24 (ICL Ref 24450 ) Kiln 2 stack Safety trip of ESP abatement system

Dust N/A If ESP filter is not rectified within several minutes the kiln is shut down.

The Kiln 3 line was commissioned in December 2008. The associated potential emission points are as follows:

A4-20 (ICL Ref 463.BF550)

3 Overpressure flap



A4-21 (ICL Ref 463.BI600)

3 Overpressure flap



A4-17 (ICL Ref 463.EX460)

1 Overpressure flap



A4-18 (ICL Ref 6 Overpressure Overpressure in system or Coal dust 30,000 10kg in total as plant will stop

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463.BF300) flap failure of spring fasteners automatically

A4-19 (ICL Ref 463.BF530)

1 Overpressure flap



1 Estimate the potential maximum emission for each malfunction identified.

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TABLE E.2(i): EMISSIONS TO SURFACE WATERS (One page for each emission) Emission Point:

Emission Point Ref. No: SW-4 (ICL Ref. W4)

Source of Emission: Storm water, Process Cooling water, Domestic sewage water and Quarry ground water

Location : Adjacent to Quarry Gate Entrance

Grid Ref. (12 digit, 6E,6N): 306673E, 271226N

Name of receiving waters: River Nanny

Flow rate in receiving waters: Information not available m3.sec-1 Dry Weather Flow

m3.sec-1 95%ile flow

Available waste assimilative capacity:

kg/day

Emission Details:

(i) Volume to be emitted

Normal/day 12,000 m3 Maximum/day 28,000m3

Maximum rate/hour 1,167m3

(ii) Period or periods during which emissions are made, or are to be made, including daily or seasonal variations (start-up /shutdown

to be included):

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

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TABLE E.2(ii): EMISSIONS TO SURFACE WATERS - Characteristics of the emission (1 table per emission point) Emission point reference number : SW-4 (ICL Ref. W4)

Parameter Prior to treatment As discharged % Efficiency

Max. hourly

average (mg/l)

Max. daily average (mg/l)

kg/day kg/year Max. hourly average (mg/l)


Max. kg/day

Max. kg/year

Suspended solids 400 400 6000 2.2 x106 35 35 525 191,625 100

Oils, fats and greases 10 10 150 54,750 2.0 2.0 30 10,950 100

BOD 6.0 6.0 90 32,850 6.0 6.0 90 32,850 100

Lead 0.1 0.1 1.5 548 0.1 0.1 1.5 548 N/a

Copper 0.1 0.1 1.5 548 0.1 0.1 1.5 548 N/a

Zinc 0.5 0.5 7.5 2738 0.5 0.5 7.5 2738 N/a

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TABLE E.3(i): EMISSIONS TO SEWER (One page for each emission) Emission Point: Not Applicable

Emission Point Ref. No:

Location of connection to sewer:


Name of sewage undertaker:

Emission Details:


Normal/day m3 Maximum/day m3

Maximum rate/hour m3


to be included):

Periods of Emission (avg)

min/hr hr/day day/yr

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TABLE E.3(ii): EMISSIONS TO SEWER - Characteristics of the emission (1 table per emission point) Emission point reference number : Not Applicable


Max. hourly

average (mg/l)




kg/day kg/year

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TABLE E.4(i): EMISSIONS TO GROUND (1 Page for each emission point) Emission Point or Area: Not Applicable Emission Point/Area Ref. No:

Emission Pathway: (borehole, well, percolation area, soakaway, landspreading, etc.)

Location :


Elevation of discharge: (relative to Ordnance Datum)

Aquifer classification for receiving groundwater body:

Groundwater vulnerability assessment (including vulnerability rating):

Identity and proximity of groundwater sources at risk (wells, springs, etc):

Identity and proximity of surface water bodies at risk:

Emission Details:


Normal/day m3 Maximum/day m3

Maximum rate/hour m3


to be included):

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

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TABLE E.4(ii): EMISSIONS TO GROUND - Characteristics of the emission (1 table per emission point) Emission point/area reference number: Not Applicable


Max. hourly

average (mg/l)




kg/day kg/year

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Table E.5(i): NOISE EMISSIONS - Noise sources summary sheet – Kiln 2

Source Emission point

Ref. No

Equipment Ref. No

Sound Pressure1 dBA at

reference distance

Octave bands (Hz) Sound Pressure1 Levels dB(unweighted) per band

Impulsive or tonal qualities

Periods of

Emission

31.5 63 125 250 500 1K 2K 4K 8K Kiln 2 Booster Fan and Drive

N6 - 94@1m 89 86 83 88 91 87 87 86 79 None 24h/day

Kiln 2 Exhaust Fan and Drive

N7 - 95@1m 101 102 97 92 88 92 86 83 81 None 24h/day

Kiln 2 Exhaust Fan and Drive

N8 - 95@1m 101 102 97 92 88 92 86 83 81 None 24h/day

Raw Mill 2 Fan and Drive

N9 - 93@1m 100 98 92 91 88 89 86 79 72 None 24h/day

Raw Mill 2 Fan and Drive

N10 - 94@1m 100 99 97 91 91 90 90 86 80 None 24h/day

Kiln 2 Gantry Cooling Fans

N11 - 97@2m 88 89 96 98 95 92 87 80 73 None 24h/day

Cement Mill 3 Bag Filter Fan and Drive

N12 - 94@1m 87 85 93 94 91 90 83 78 74 None 24h/day

Kiln 2 Grate Cooler ESP Fan and Drive

N13 - 93@1m 88 86 82 86 90 87 86 85 77 None 24h/day

1. For items of plant sound power levels may be used.

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Table E.5(i): NOISE EMISSIONS - Noise sources summary sheet – Kiln 3

Source Emission point

Ref. No

Equipment Ref. No

Sound Pressure1 dBA at

reference distance

Octave bands (Hz) Sound Pressure1 Levels dB(unweighted) per band

Impulsive or tonal qualities

Periods of

Emission

31.5 63 125 250 500 1K 2K 4K 8K Kiln 3 Exhaust Fan and Drive

N14 - 95@1m 101 102 97 92 88 92 86 83 81 None 24h/day

Kiln 3 Raw Mill Fan and Drive

N15 - 94@1m 100 99 97 91 91 90 90 86 80 None 24h/day

Kiln 3 Booster Fan and Drive

N16 - 94@1m 89 86 83 88 91 87 87 86 79 None 24h/day

Kiln 3 Grate Cooler ESP Fan and Drive

N17 - 93@1m 88 86 82 86 90 87 86 85 77 None 24h/day

Kiln 3 Gantry Cooling Fans

N18 - 97@2m 88 89 96 98 95 92 87 80 73 None 24h/day

Cement Mill 4 Bag Filter Fan and Drive

N19 - 92@1m 87 86 82 85 88 88 86 80 77 None 24h/day

1. For items of plant sound power levels may be used.

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EPA Export 26-07-2013:16:18:14

A2-01

A2-02

A2-03

A2-04

A2-06

A2-10

A2-07

A2-08 A2-09

A2-05

Main Emissions to Atmosphere

Irish Cement Ltd Review of IPPC Licence Reg. No. P0030-03

D5374.41 October 2009 Figure E.1

0 metres 400

Scale 1:10,000

Not To Scale

0 kilometres 8

Scale 1:200,000

0 metres 60

Scale 1:1,500

Ordnance Survey Ireland Licence NumberEN 0002809 c Government of Ireland

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A3-68

A3-1

A3-84

A3-30A3-25A3-18

A3-71

A3-94

A3-70

A3-67

A3-64

A3-62

A3-65

A3-20

A3-23

A3-63

A3-61

A3-60

A3-55

A3-80

A3-58

A3-56

A3-54

A3-51

A3-52

A3-22

A3-19

A3-53

A3-57A3-69

A3-21

A3-27

A3-38

A3-14

A3-37

A3-49A3-26

A3-8A3-4

A3-72

A3-48

A3-48

A3-47

A3-29

A3-5

A3-3

A3-24

A3-36A3-39

A3-82A3-83

A3-34

A3-12

A3-33

A3-15

A3-42

A3-11

A3-10

A3-31A3-50

A3-17

A3-85

A3-28

A3-32

A3-81

A3-35A3-41

A3-44

A3-43

A3-46

A3-13 A3-45

A3-66

A3-50

A3-16

A3-59

A3-2

A3-88

A3-7

A3-87

A3-86

A3-9

A3-6

A3-74A3-75

A3-72

A3-78A3-76

A3-79

A3-89

A3-90

A3-82

A3-40

A3-77A3-95A3-96A3-97

A3-98

Minor Emissions Points to Atmosphere


D5374.41 Figure E.2October 2009

0 metres 400

Scale 1:10,000

Not To Scale

0 kilometres 8

Scale 1:200,000

0 metres 100

Scale 1:2,500


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A3-94

A3-95A3-96A3-97

A3-98

Alternative Fuels Project Minor Emissions Points



0 metres 400

Scale 1:10,000

Not To Scale

0 kilometres 8

Scale 1:200,000

0 metres 100

Scale 1:2,500


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EPA Export 26-07-2013:16:18:14

Process/Surface Water, Domestic Sewage and Groundwater Conveyance Flow Diagram



DomesticWasteWater

Deep Well PumpQuarry

SurfacePumping

StormWater

WTP forDomestic W.W.

Cooling/ConditioningRecirculationSystem

Cooling:Once through

Storm Balaning Tank(8 chambers)

Sedimentation Tanks

River NannySW1

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Duct MH

MH-02

03

MH-01

Process/Storm Water and Groundwater Conveyance, Treatment Plant and Emission Points



0 metres 120

Scale 1:3,000


Quarry Surface Water

Storm Balancing Tanks

Treated Process/surface Water Effluent

SW-4SW-3

SW-1

Quarry Groundwater

Settlement Tanks

Legend:

Quarry GroundwaterProcess/Surface Water

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Kiln 3

Limestone Store

Limestone Store

CementMill 4

Pet Coke Storage Area

NewEngineeringWorkshop

BauxiteStore

Raw MillTransport

Raw Mill 3

Coal Mill 3

Raw MillDepartment

New OfficeBuilding

ClinkerStore

Domestic Sewage Drainage System



To SewagePackage Plant

0 metres 100

Scale 1:2,500


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EPA Export 26-07-2013:16:18:14

Domestic Sewage Treatment Package Plant

Irish Cement Ltd review of IPPC Reg. No. P0030-03


0 metres 400

Scale 1:10,000

0 kilometres 8

Scale 1:200,000


Not To Scale

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N1

N2 N3

N11

N12

N4

N5

N13

N15

N16

N14

N17

N18

N19

N6

N7

N8

N9

N10

Noise Sources



0 metres 60

Scale 1:1,500


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EPA Export 26-07-2013:16:18:14

attachment no. e emissions table of · pdf filea2-09 kiln 3 grate cooler ... irish cement ltd...

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