Glanbia Fresh Pork Limited IPPC Review Documentation

9260n 00024 December 2005

Attachment NO' E l

(including E.l .A, E.l .B)

Emissions to Atmosphere

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Glanbia Fresh Pork Limited 9260n00024 IPPC Review Documentation December ZOO5

E.l.A Provide a summary of the emission points, together with maps and / or drawings and supporting documentation.

Background

The boiler, main and minor point emissions to atmosphere £torn Glanbia are as follows:

J New Boiler Stack, A1-2; J Original Boiler Stack, A1 - 1 ; J Odour Control Unit Stack, A2-I; J Vent from Blood Storage Tank, and

J General Extract

Tables E.l (i) - (ii) inclusive have been completed in the application form detailing all point emissions to

atmosphere.

Supporting Drawings:

Drawings E. I. I(A) Emissions to Atmospl~ere depicts the locations of the boiler and main emission points at the

facility. Drawings A953 Proposed Elevations of Boiler Stack and E.l.I(B) Odozir Control unit at Waste Water

Treatment Plant identify the elevations and the relevant roof heights of the boiler and odour control unit stacks.

Boiler Emissions to Atmosphere (Combustion Gases):

There are currently two boilers on-site. The boilers are used for the generation of process hot water

requirements. The new boiler, boiler A1-2 was installed and commissioned in 2004 while the original boiler,

A1 - 1 has been in operation since 199 1. It should be noted that only one boiler will be operated at a time with the

original boiler (A1-1) hnctioning as a standby. The boiler output of Al-1 is 3,500 kglhour and the output of the

new boiler (Al-2) is 6,800 kglhour with a rated thermal'input (nett) of 4.8 MW.

A 1 -2 - Main Boiler

Boiler A1-2 is a Cochran thermax stream boiler. A1-2 is located at approximately 3 m from Al-l (which is

located in the boiler house), grid reference 263373E, 233567N. Boiler A1-2 runs on light fie1 oil and the boiler stack has a diameter of 560rnm and is 15 m above ground. The boiler has a steam output.of 6,800 kglhr and.

produces 650 rng /~m3 ofNOx and operates at a temperature of 254 "C.

S.I. 394 of 2004:

With regard to Schedule I of S.I. 394 of 2004, the following listed substances are emitted fi-om the boiler stacks

on-site;

J Sulphur Dioxide;

J Oxides of Nitrogen; and

J Carbon Monoxide.

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GIanbia Fresh Pork Limited IPPC Review Documentation

9260n00024 December 2005

Maximum potential emissions for Sulphur Dioxide, Nitrogen Oxides, Total Particulate Matter and Carbon

Monoxide are specified hereunder in Table EI.1-Maximum Emission Values. These figures have been

normalised for oxygen, temperature, pressure and moisture content by the manufacturers of the boiler (BIB

Cochran Limited) as requested by the Environmental Protection Agency.

Table El.1: Maximum Emission Values

Specialist air dispersion modelling was conducted using the EPA AERMOD air dispersion model for the

emissions from A2-1. Modelling and a subsequent impact assessment was undertaken for Nitrogen Dioxide (as

NO*), Sulphur Dioxide (as SO*), Particulates (as PMlo) and Carbon Monoxide (as CO). A summary review and

copy of the technical report detailing the outcome of the modelling exercise, Determination of Emissions to

Atmosphere from a Boiler at Glanbia, Edenderry, County Offaly (AWV Consulting Limited, 2004) is included in

Attachment 11.

Determinand

so2 NO, Particulates

CO

The results of the air dispersion modelling exercise were compared with the Air Quality Standards Regulations,

2002 which are based on Council Directives 1999/30/EC and 2000169lEC. The existing height of the stack was

used as one of the inputs into the dispersion model and thus the results as presented hereunder reflect the

situation based on current site conditions.

Emission Concentration 1,020 mg/Nm3

650 mg/Nm3

125 mg/Nm3

150 mg/Nm3

A1 -1 - Secondary Boiler

Boiler Al-1 was commissioned in 1991 and is located in the boiler house on site (grid reference 263373E,

233567N). Boiler Al-1 runs on LPG fuel and the boiler stack has a diameter of 600mm and is 9 m above ground.

The boiler has a steam output of 3,500 kg/hr and produces 1 15 mg/Nm3 of NOx and operates at a temperature of

254 OC (527 Kelvin). .

This boiler acts as a standby to the main duty boiler emission reference A1-2.

Assessment of Compliance with BAT Guidance Limit

There are no specific Emission Limit Values for Combustion Gases from Boilers in the BAT Guidance Notes of

Best Available Technique for the Slaughtering Sector (EPA, December 2004). However it should be noted that

the conclusions from the duty boiler emissions modelling conducted were that the emissions from the duty

boiler would not result in any adverse impact beyond the site boundary.

Main Emissions to Atmosphere (Non Combustion Gases)

Odour Abatement System

In July 2003 Bord na M6na Technical Services was commissioned by Glanbia to carry out an odour impact

assessment at the Edendeny site (A Dispersion Modelling Assessment of Odorous Emissions from the Glanbia

Meats facility at Edendery, County Offal-v, Bord na Mdna Environmental Limited, December 2003) and a

summary review and copy of this report is included is included in Attachment 11. The purpose of the

assessment was to determine the potential of the facility for the generation of odour impact on the surrounding a Doc. Nr. 89260-N-R-01-B Page 2 of 6

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Glanbia Fresh Pork Limited IPPC Review Documentation

9260n00024 December 2005

a vicinity and provide adequate abatement measures if required. Potential odour sources were identified from a

site visit and were agreed by the Agency. These odour sources were used to construct the bases of the modelling

assessments. Odour rates/fluxes were calculated from site specific olfactometric data.

Bord na M6na installed a MdnaShell odour abatement system (emission point grid reference 263294E,

233497N) to minimise odours and reduce total sulphur compounds. It was commissioned in the summer of

2004. The unit is located adjacent to the balance tank in the waste water treatment plant. The odour control unit

extracts air from the headspace of the covered balance tank and the headspace of the covered dewatered sludge

holding tank. This air stream is sent through a calcareous shell media to minimise contaminants prior to release

through a stack. A detailed specification of this unit is included hereunder:

Process Description

Bio-oxidation of TRS compounds as a result of a combination of physical and bio-chemical processes:

1. Adsorption and absorption of the contaminants onto the packing and into the surrounding aqueous phase; and

2. Enhanced biological degradation of the sulphide compounds by micro-organisms particular to the M6naShell system and neutralisation of the microbial by-products by the unique nature of the packing.

Description of Specialised Filter Media

The shell media employed is selected and graded according to: Size, Shape, Calcium carbonate concentration and Density.

The shape of the media is ideal for highly efficient mass transfer of contaminants. In addition a large particle size is selected (typically 30mm-70mm) which gives an extremely low backpressure across the bed. The filter media is packed randomly and performs the following functions:

1. Acts as a carrier substrate for micro-organisms 2. Provides a supplementary nourishment for micro-organisms 3. Supports humidity stores 4. Provides adsorption surface for odorous 'components 5. Maintains Optimum pH. ,

Table E1.2: Process Details

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Glanbia Fresh Pork Limited 9260n 00024 IPPC Review Documentation December 2005

Table E1.3: Process Design - MONASHELL

Table E1.4: Mechanical Detail Specification

alvanised Steel

GRP or uPVC/GRP Wrap

Galvanised Stainless Steel

Stainless Steel or Plastic Submersible Pump 1 . 1

50 litreslmin @ 1 Om Head

ot Press Moulded GRP Platinum 22B 15 to BS

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Glanbia Fresh Pork Limited IPPC Review Documentation

9260n00024 December 2005

Table E1.5: Performances Guarantees and Conditions for the MONASHELL Odour Control System at Glanbia Meats, Edenderry

Odour Units ( Odour Removal Efficiency (ou/m3) 1 % >50,000 1 >99%

Due to background odours from irrigation water, these usually account for 50-100 odm3 at the outlet.

BAT Guidance Limits

After abatement, the odour produced at the waste water treatment plant is within the BAT Guidance Notes

limits. The BAT Guidance Limit for odour is set at 5 0uE/m3 as a 98 percentile of hourly average concentration

at the nearest odour sensitive receptor. However, the dispersion modelling completed has produced an odour

abatement system that was designed and commissioned to achieve an odour contribution of 3 O E U / ~ ~ as a 98

percentile at the nearest odour sensitive receptor. Therefore all odour emissions from the odour control unit,

A2-1 are within the BAT Guidance Limits of 5 0u/m3.

Minor Emissions

General Extract

The general extract removes air from the slaughtering, evisceration and deboning areas, the emissions from which are considered as insignificant.

E.l.B Fugitive and Potential Emissions

Fugitive and Potential Emissions

Sources and Control of Fugitive Emissions

Leaks from Valves, Pumps Seals and Flanges

Valve seals, pump seals and flanges are included in the scheduled maintenance and inspection programme - refrigeration systems.

Dust Emissionsfiom Solids Stored in the Open

No dusts are stored in the open

Loading and Unloading Operations

Slight particulate emissions may also occur during offloading of animals, and movement of vehicles within the

site.

Cleaning Operations

Slight emissions of particulates and water vapour may occur during cleaning of the yard.

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Glanbia Fresh Pork Limited 9260n00024 IPPC Review Documentation December 2005

Emissionsfrom the Waste Water Treatment Plant

Emissions from the waste water treatment plant are predominantly water vapour. Odour emissions from the

balancing tank and the sludge dewatered holding tank are controlled by the odour abatement system as specified

above.

Control of Nuisance 08-Site

As part of the preparatory works conducted by Bord na M6na Environmental Limited an odour monitoring

survey was carried out on 1.5'~ and 22nd August 2003 and included all the sources considered to be or have the

potential to be significant from an odour perspective. This list was approved by the Agency and included the

following sources;

Potential sources of odour include:

Lairage;

Sump;

Return fi-om Sludge PressIClarifier Sump;

Sludge Return Tank;

Dewatered Sludge Holding Tank;

Sludge Dewatering Building;

DAF Plant;

Balancing Tank;

Aeration Tank;

Gravity Settling Sludge Thickening Tank;

Blood Tank; and

Singe Stack.

Analysis of both the results and the odour emission rates for each of the sources was undertaken and inficated

that abatement for some of the odour sources was required. The Dewatered Sludge Holding Tank was

determined to be the largest potential on-site source of odour. From previous experience, Glanbia personnel

indicated that the Balance Tank was also a significant potential source of oclour. As a precautionary measure,

the odour control unit was installed and commissioned on-site to be-capable to extract the headspace air from

both the Dewatered Sludge Holding Tank, the Balance Tank and from the Sludge Dewatering Building.

The remainder of the list of potential sources as outlined above were not considered significant sources of odour

having regard to significant impact beyond the site boundary. Odour from these locations is anticipated to be

immediately localised to the source and not to present a significant contribution to odour levels detected beyond

the site boundary.

Council Directive 199911 3 E C

With regard to hgitive and potential emissions, there are no activities conducted on-site listed in the Schedule of

Council Directive 199911 3EC.

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1. READ THIS M W I N G IN CONJUNCTlON ml ALL OTHER RELEVANT I DRAWINGS & SPECIFICATIONS. 2. E.G.PETIIT MUST BE INFORMED IMMU)IATELY OF ANY DISCREPANCIES

BETWEEN DRAWINGS/CONTRACT DOCUMENlS AND SilE CONDmONS PRIOR TO COMMENCEMENT OF WORKS.

3. AU DIMDUSIONS ARE IN M I W M m E S UNLESS NOTED OTHERWISE. *, A l l LEVELS ARE IN METRES UNLESS NOTED OTHERWISE

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