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Quinn Cement Ltd.

January – December 2011

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 2011 - December 2011 ...................................................................................10 2.2.2 Dust Gauges .................................................................................................................11

2.2.2.1 Assessment of Directional Dust Deposition (graphs only for January – February)...................................................................................................................................12

2.3 Emissions to water..................................................................................................................15 2.3.1 Surface Water Emissions January 2011 – December 2011 ......................................15

2.3.1.1 Summary of Mass Emissions to Surface Water 2011 ......................................15 2.3.2 Groundwater Monitoring Summary.........................................................................15

2.4 Noise monitoring....................................................................................................................16 2.4.1 Noise monitoring Assessment ...................................................................................17

2.5 Waste Management ................................................................................................................18 2.6 Bund Testing Report ..............................................................................................................20 2.7 Environmental Incidents..............................................................................................................21 2.8 Complaints Summary ..................................................................................................................22 2.9 Environmental Management System...........................................................................................23

2.9.1 Report on Progress of Environmental Management Programme................................24 2.9.2 Schedule of Environmental Objectives and Targets 2012 ......................................26 2.9.3 Environmental Management Plan.............................................................................27

2.10 RMP and ELRA .................................................................................................................28 2.10.1 Residual Management Plan........................................................................................28 2.10.2 ELRA .............................................................................................................................28

2.11 AER Returns Worksheet ........................................................................................................29

Annex 1: Monitoring Locations:................................................................................................35 Dust Deposit Gauges .........................................................................................................................36 Noise:..................................................................................................................................................36 Surface water and Groundwater: .......................................................................................................36

Annex 2: Atmospheric Emission Points ..................................................................................37

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Air Emission Points ...........................................................................................................................38

Annex 3: Quinn Cement 14001 Accreditation.........................................................................39

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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 2011 – December 2011

Limestone/Silt/Shale 871,960

Gypsum/Iron-ore 30,705.94

2.1.2 Fuel usage

Fuel usage (per year) Fuel January 2011 – December 2011

Coal 82,353 tonne Diesel 321,974 litres Kerosene 1,500 litres

2.1.3 Electricity usage (kWh)

Electricity usage (kWh) January 2011 – December 2011

70,017,276

2.1.4 Water Consumption (m3)

Source Consumption (m3) Use Mains 5,063 Welfare

Groundwater 160,240 Process

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2.2 Emissions to Air

2.2.1 January 2011 - December 2011

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 206.2 3869 393,226 313.711 600 A2-01 – kiln Nitrogen Oxide 333.3 3869 393,226 507.095 1300 A2-01 – Kiln Particulates 5.5 3869 393,226 8.417 50 A2-02 - Grate cooler Particulates 5.5 3869 190,974 3.472 50 A2-03 - Coal mill Particulates 4.7 5004 36,721 0.666 50 A2-04 – Cement mill Particulates 9.5 3294 35,716 1.695 50 A2-05 – Sepax Filter Particulate 5.3 3294 144,392 3.840 50 1 An average figure taken from Air Assessment Reports Carried out by QED 2011.

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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 directional dust gauges were replaced at the beginning of March with single jar gauges.

The directional dust 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 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 February 2011.

Sample Site No Mg/m2/day

Site 1 Work shop

1 2 3 4

28.48 68.03

157.90 64.98

Site 2 Hilltop

1 2 3 4

43.92 42.24 70.54 47.18

Site 3 ESB

1 2 3 4

28.31 60.06 60.47 43.06

Site 4 Treacy’s Field

1 2 3 4

57.90 99.64 65.74 41.20

Site 5 Crusher

1 2 3 4

19.01 26.87 63.07 50.21

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

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The following results table provides averages for the five single jar gauges on site from March to December 2011.

Sample Site

Total Retained Water Measured

(ml)

Total Dried Undissolved

Matter Total

Solids mg/m2/day

Workshop DG1 611.5 70.79 35.149 181.442

Hilltop DG2 729.5 49.12 31.264 164.11 ESB DG3 584 55.91 25.664 134.576 Treacy’s Field DG4

600 47.5 21.48 110.488 Crusher DG5 630 57.07 31.912 161.232

2.2.2.1 Assessment of Directional Dust Deposition (graphs only for January – February). Site 1

0

50

100

150

200

mg/

m2/

day

Workshop - Directional Deposition Data

Series1 28.48 68.03 157.90 64.98

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.

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Site 2

0

20

40

60

80

mg/

m2/

day

Hill-top - Directional Deposition Data

Series1 43.92 42.24 70.54 47.18


The Plant is located to the east and south east of the monitor. The majority of the dust is emanating from 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.

Site 3

0

20

40

60

80

mg/

m2/

day

ESB - Directional Deposition Data

Series1 28.31 60.06 60.47 43.06


The Plant is located to the north and northeast of this monitoring location. The dust seems to be predominantly southerly and easterly, this would suggest influence from nearby vegetation rather than the activity of the plant.

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Site 4

0

20

40

60

80

100

mg/

m2/

day

Treacy's Field - Directional Deposition Data

Series1 57.90 99.64 65.74 41.20


The Plant is to the south east of this location. The majority of dust is coming from an easterly direction which would suggest results are influenced by traffic movements around the plant, in particular in the Bagging Plant area.

Site 5

0.00

20.00

40.00

60.00

80.00

mg/

m2/

day

Crusher - Directional Deposition Data

Series1 63.07 50.21 19.01 26.87


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 northern gauge is likely to be localised from the crusher.

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2.3 Emissions to water

2.3.1 Surface Water Emissions January 2011 – December 2011

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

2011 12.47 7.73 10.2 16.40 1.0 0.08 0.237 0.302 0.01 Limits 3000 6-9 - 35 10 - 0.05 0.2 -

2.3.1.1 Summary of Mass Emissions to Surface Water 2011

Year Flow (m3)

PH COD (Kg)

SS (kg)

BOD (kg)

NH4

(kg) Cr

(kg) Al

(kg) Mineral Oil

(kg) 2011 108186 7.73 1101 1774 108 9 26 33 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 25th October 2011 and the 9th November 2011. 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 1.03 No abnormal change Conductivity μS/cm 344 1000 Total Ammonia mg/l 0.1 0.15 Total Nitrogen mg/l 1.55 Chromium (Cr VI) mg/l <0.03 0.03 Aluminium mg/l 0.0078 0.2 Mineral Oil mg/l <10 Volatile Organic Compounds mg/l ND

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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 18th and 19th November 2011 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) –18th November 2011.

Location Date Time Leq L10 L90 Comments

NSL1 18th Nov’11 15.15 43.2 44.8 36.4 Plant inaudible at 36dBA

NSL2 18th Nov’11 14.45 45.9 46.7 40.5 Audible at 40dBA

NSL3 18th Nov’11 15.30 52.4 55.2 43.0 Mainly road traffic

NSL4 18th Nov’11 15.50 52.6 54.2 45.6 Audible at 45.5dBA, also road traffic

NSL5+ 18th Nov’11 16.15 61.2 61.8 60.3 Mid –site (truck idling nearby)

NSL6 18th Nov’11 14.15 47.1 46.2 45.1 Plant audible

Note + Not a noise sensitive location

Recorded night time noise levels dB(A) –19th November 2011.

Location Date Time Leq L10 L90 Comments

NSL1 19th Nov’11 01.00 43.6 43.9 34.8 Plant inaudible, road traffic

NSL2 19th Nov’11 00.15 45.8 44.5 35.1 Road traffic from town

NSL3 18th Nov’11 23.30 47.4 48.1 40.8 Road traffic and plant noise at 43.0dBA

NSL4 19th Nov’11 01.00 50.3 52.5 46.2 Plant noise at 46.2 dBA

NSL5+ 18th Nov’11 23.45 58.6 59.2 56.2 Mid site beside mill

NSL6 19th Nov’11 00.30 46.1 46.5 44.8 Plant noise audible at 44.8dBA and mountain

stream audible at 41dBA

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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 5, however this is not a noise sensitive location, this reading is taken from the middle of the site.

The night-time noise limit of Leq (15min) of 45 dBA was exceeded at locations NSL 3, 4, 5 and NSL 6, however the exceedence was only attributed to plant noise in NSL 4 at 46.2 dBA, slightly in excess of the limit at this location. However this house has been vacant for the past two years.

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

Noise reduction actions are ongoing. The next noise survey is due to take place in 2012.

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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

2011 mixed

municipal waste

150101, 150103, 200301

37.98

Wilton Waste

Recycling Ltd.

WCP/MH/08/0080-01 Wilton Waste Recycling Ltd.

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

Midland Waste Disposal Company Limited (131-

2) N/a

2011 Mixed C&D waste 170904 9.36

Wilton Waste

Recycling Ltd.


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


2) N/a

2011 Recyclable waste

150102 200139, 150101 200101

1.12

Wilton Waste

Recycling Ltd.


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


2) N/a

2011

Fluorescent Lamps

20 01 21 0.433

Irish Lamp recycling

WCP MH/2001/101C Irish Lamp Recycling Co. Ltd.

WL02/2000B Recovery Mercury contaminated filters and sludge; (EWC 060404): Claushuis Metaals, 3899AH Zeewolde, Holland for recycling. Permit MB/00.091030/A (GS van Flevoland) B620355

2011 Timber 20 01 38 19.65

Pallet Supplies Limited

WCP/MH/2001/53D Pallet Supplies Ltd., Mountain Lodge, Cootehill, Co. Cavan

WFP-CN-10-0002-01

Recovery Pallet Supplies Ltd., Mountain Lodge, Cootehill, Co. Cavan f

N/a

24/03/2011 Solid oily waste 150202

0.38 (6 barrels solid oily waste) Enva

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

B620680

2011 Waste Oil 130208 1500 litres Enva

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

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29/06/2011 WEEE 200135 2.99

Irish Lamp recycling

WCP MH/2001/101C Irish Lamp Recycling Co. Ltd.

WL02/2000B Recovery Irish Lamp Recycling Co. Ltd. B620349

29/06/2011 Mixed metals 170407 2.86

MSM Recycling WCP-DC-08-1118-01 MSM Recycling WL79-1

Recovery

MSM Recycling N/a

25/08/2011 Oily rags

15 02 02 2*240l bins Enva

WCP-DC-08-1116-01 Enva Ireland Ltd. WL184-1 Recovery Enva Ireland Ltd. B620696

23/09/2011 Scrap Metal (media balls)

17 04 05 10.4

Hegarty Metal Recycling WCP-LK-08-589-01

Hegarty Metal Processors(International) Ltd., Ballysimon Road, Limerick

WFP-LKC-11-001-01 Recovery

Hegarty Metal Processors(International) Ltd., Ballysimon Road, Limerick

N/a

24/10/2011

Hazardous waste (Sylobead, empty drums and lab waste)

15 01 10, 16 03 04, 18 02 05

0.358 Waste packaging 2.208 Sylobead 0.098 Potassium Dichromate SRCL WCP/DC/09/1178/01 SRCL WL 55-2

Disposal Lindenschmidt, Germany O'Toole Composting, Carlow B620417

07/12/2011

4* oily rags 1* aerosols 1* grease cartridges 150202 0.5 Enva

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

B559076

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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 :

a. Gas Oil Bund

b. Grinding Aid Bund

c. Waste Segregation Area

d. Raw Mill Hydraulic Pump Sump

e. Mobile Oil and Chemical Bunds.

Was carried out in December 2010 and was completed in February 2011. Testing was completed in February 2011 as severe weather conditions hampering tests in December, the Agency were informed on the 20/12/2010.

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; all bunding was pass as fit for purpose.

The next bund integrity test is scheduled for Quarter 4 of 2013.

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2.7 Environmental Incidents

The following is a list of environmental incidents experienced at Quinn Cement during the period January 2011 to December 2011.

Date Nature of Incident Action Taken Authorities Contacted

September

Fitz Environmental high SO2 on Main Stack

Reported by the EPA to QC, QC Commented

EPA

December

High Al

Reported to EPA by phone and fax.

EPA

November

High SS weekly 30/11, high monthly Al


EPA

October

High SS and Al, high EPA result for Al


EPA

October

High SS in weekly SW 12/10, 19/10, 27/10/2011, monthly 25/10


EPA

September

High Aluminium 27/09


EPA

05/09/2011

ESP trip for 48 minutes due to a power dip.


EPA

August

High Aluminium 04/08, 16/08

Reported to EPA by phone and fax, to be investigated in conjunction with ongoing investigation.

EPA

July

High Aluminium 06/07

Reported to EPA by phone and fax, to be investigated in conjunction with ongoing investigation.

EPA

June

High Chromium in June

Reported to EPA (08/07/2011) by phone voicemail left to be investigated in conjunction with ongoing investigation. Reported by Fax 20/07/2011.

EPA

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24/05/2011

ESP Trip caused by fluctuations in incoming power.

Precip restarted when possible

EPA

20/01/2011

EPA sample 20/01/2011 was non compliant with the Aluminium limit

Investigation into causes and report

EPA

2.8 Complaints Summary

There were no complaints received by Quinn Cement during the period January 2011 to December 2011.

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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.

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2.9.1 Report on Progress of Environmental Management Programme

Licence objectives Licensee Targets Progress

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.

The majority of items on the Noise Improvement Programme

have been completed or are in progress. Items which have not

been fully closed out have been transferred to 2012 Objectives

and Targets.

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.

This is a long term Objective and is still being progressed. This

Objective has been transferred to 2012 Objectives and Targets

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.

Numerous requests for information were submitted and a

Proposed Determination was issued early 2012. This is a long

term Objective and is still being progressed. This Objective has

been transferred to 2012 Objectives and Targets.

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

in 2010 with accreditation to 14001. To maintain accreditation.

Accreditation has been maintained.

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.

This Objective has been progressed, Integration with the EMS

has commenced. Energy Efficiency projects and investigations

are ongoing and training for management staff has been

undertaken.

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

Certification audit scheduled for March 2012.

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. Completed

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. Completed

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2.9.2 Schedule of Environmental Objectives and Targets 2012

Licence Objectives Licensee Targets

Noise

Continued implementation of Noise Improvement

Programme

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.

New IPPC License (P0378-02)

For the operation of the proposed Alternative Fuels

project a new IPPC licence is required. Application for a new licence was submitted in 2010.

BES 6001

To achieve accreditation to BES 6001 sustainability

standard across the supply chain.

P0378-02 IPPC Licence

Implement new conditions within PO378-02 and

incorporate into ISO 14001 system. Implement infrastructural and operational changes as required by

the Licence

ISO 50001

To continue development of the energy management

system

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2.9.3 Environmental Management Plan

Objectives & Targets Means of Achievement/Action Necessary Person Responsible Time frame for Achievement

Noise Continued implementation of Noise

Improvement Programme

Plant Engineer, Maintenance Manager, Environmental Advisor

December 2012

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 2015

New IPPC License (P0378-02)

For the operation of the proposed Alternative Fuels project discussed above, a new IPPC

licence is required. Application for a new licence was submitted in 2010.

Environmental Advisor, Project Management June 2012

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

Environmental Advisor and Cement Management Team March 2012

P0378-02 IPPC Licence

Implement new conditions within PO378-02 and incorporate into ISO 14001 system. Implement

infrastructural and operational changes as required by the Licence

Environmental Advisor and Cement Management Team

Within 1 year of granting of the Licence

ISO 50001 To continue development of the energy management system.

Environmental Advisor and Cement Management Team 2013

28

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.

29

2.11 AER Returns Worksheet

| PRTR# : P0378 | Facility Name : Quinn Cement Limited | Filename : P0378_2011.xls | Return Year : 2011 | 4159 30/03/2012 15:30

Guidance to completing the PRTR workbook

Version 1.1.13REFERENCE YEAR 2011

1. FACILITY IDENTIFICATIONParent Company Name Quinn Cement Limited

Facility Name Quinn Cement LimitedPRTR Identification Number P0378

Licence Number P0378-01

Waste or IPPC Classes of ActivityNo. class_name

10.1 The production of cement.

Address 1 Quinn CementAddress 2 ScotchtownAddress 3 BallyconnellAddress 4 Co Cavan

CavanCountry Ireland

Coordinates of Location -7.57841 54.1311River Basin District GBNIIENW

NACE Code 2351Main Economic Activity Manufacture of cement

AER Returns Contact Name Anna McNallyAER Returns Contact Email Address [email protected]

AER Returns Contact Position Environmentak AdvisorAER Returns Contact Telephone Number 0499525200

AER Returns Contact Mobile Phone NumberAER Returns Contact Fax Number 0499525201

Production Volume 0.0Production Volume Units

Number of Installations 0Number of Operating Hours in Year 0

Number of Employees 0User Feedback/Comments

Web Address

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

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

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

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

used ?

AER Returns Workbook

30

4.1 RELEASES TO AIR Link to previous years emissions data | PRTR# : P0378 | Facility Name : Quinn Cement Limited | Filename : P0378_2011.xls | Return Year : 2011 | 30/03/2012 15:308 11 19 19 27 27 6 10 6 6 6 6 11

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 Emission Point 2 Emission Point 3 Emission Point 4 Emission Point 5 T (Total) KG/YearA (Accidental) KG/Year

F (Fugitive) KG/Year

03 Carbon dioxide (CO2) C ETS 497581000.0 0.0 0.0 0.0 0.0 497581000.0 0.0 0.008 Nitrogen oxides (NOx/NO2) M PER IS EN 14792 507095.0 0.0 0.0 0.0 0.0 507095.0 0.0 0.011 Sulphur oxides (SOx/SO2) M PER IS EN 14791 313711.0 0.0 0.0 0.0 0.0 313711.0 0.0 0.086 Particulate matter (PM10) M ALT ISO 9096 8417.0 3472.0 666.0 1695.0 3840.0 18090.0 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


RELEASES TO AIR

RELEASES TO AIRMETHOD

POLLUTANT METHOD

RELEASES TO AIRPOLLUTANT METHOD

Method Used

Method Used

Method UsedPOLLUTANT

31

4.2 RELEASES TO WATERS Link to previous years emissions data | PRTR# : P0378 | Facility Name : Quinn Cement Limited | Filename : P0378_2011.xls | Return Year : 2011 | 30/03/2012 15:308 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 only coPlease 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 ALT ISO 17025 26.0 26.0 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 ALT ISO 17025 33.0 33.0 0.0 0.0238 Ammonia (as N) M ALT ISO 17025 9.0 9.0 0.0 0.0303 BOD M ALT ISO 17025 108.0 108.0 0.0 0.0306 COD M ALT ISO 17025 1101.0 1101.0 0.0 0.0324 Mineral oils M ALT ISO 17025 1.0 1.0 0.0 0.0331 Organohalogens M ALT ISO 17025 0.0 0.0 0.0 0.0240 Suspended Solids M ALT ISO 17025 1774.0 1774.0 0.0 0.0363 Total Dissolved Solids M ALT ISO 17025 22153.0 22153.0 0.0 0.0

RELEASES TO WATERS

RELEASES TO WATERS

Method Used

POLLUTANTMethod Used

POLLUTANT

POLLUTANTRELEASES TO WATERS

Method Used

32

4.3 RELEASES TO WASTEWATER OR SEWER Link to previous years emissions data | PRTR# : P0378 | Facility Name : Quinn Cement Limited | Filename : P0378_2011.xls | Return Year : 20 30/03/2012 15:308 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

33

4.4 RELEASES TO LAND Link to previous years emissions data | PRTR# : P0378 | Facility Name : Quinn Cement Limited | Filename : P0378_2011.xls | Return Year : 2011 | 30/03/2012 15:308 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

POLLUTANT METHODMethod Used

RELEASES TO LAND

RELEASES TO LAND

POLLUTANT METHODMethod Used

34

5. ONSITE TREATMENT & OFFSITE TRANSFERS OF WASTE | PRTR# : P0378 | Facility Name : Quinn Cement Limited | Filename : P0378_2011.xls | Return Year : 2011 | 30/03/2012 15:305 13 Please enter all quantities on this sheet in Tonnes 13

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 Quanti ty 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)

To Other Countries 15 02 02 Yes 0.38

absorbents, filter materials (including oil filters not otherwise specified), wiping cloths, protective clothing contaminated by dangerous substances R13 M Weighed Abroad ENVA Ireland,WL184-1

Clonminam Ind. Est. , Portlaoise ,Co. Laois,.,Ireland

Lindenschmidt ,Reg.no. E97095037,Kreuztal,.,.,.,Germany Kreuztal,.,.,.,Germany

Within the Country 13 02 08 Yes 1.35 other engine, gear and lubricating oils R9 M Weighed Offsite in Ireland ENVA Ireland,WL184-1


Enva Ireland,WL184-1 ,Clonminam Industrial Estate ,Portlaoise ,Co. Laois,.,Ireland

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


absorbents, filter materials (including oil filters not otherwise specified), wiping cloths, protective clothing contaminated by dangerous substances R13 E Volume Calculation Abroad ENVA Ireland,WL184-1



To Other Countries 15 01 10 Yes 0.358packaging containing residues of or contaminated by dangerous substances D15 M Weighed Abroad Eco Safe Systems,54-2

1A Allied Industrial Estate,Kylemore Road,Dublin 10,.,Ireland


To Other Countries 18 02 05 Yes 0.98chemicals consisting of or containing dangerous substances D15 M Weighed Abroad Eco Safe Systems,54-2

1A Allied Industrial Estate,Kylemore Road,Dublin 10,.,Ireland



laboratory chemicals, consisting of or containing dangerous substances, including mixtures of laboratory chemicals R13 M Weighed Abroad ENVA Ireland,WL184-1


SBH ,D-74238,Austrasse 5 ,Krautheim ,.,.,Germany

Austrasse 5 ,Krautheim ,.,.,Germany

To Other Countries 20 01 21 Yes 0.433fluorescent tubes and other mercury-containing waste R4 M Weighed Abroad

Irish Lamp Recycling,WL02/2000B

Woodstock Industrial Estate ,Kilkenny Road ,Athy ,Co. Kildare,Ireland

Claushuis Metaals for recycling. Permit ,MB/00.091030/A,3899AH Zeewolde ,.,.,.,Netherlands

3899AH Zeewolde ,.,.,.,Netherlands

Method Used

35

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

quinn cement ltd. - environmental protection · pdf fileproportioned quantities of each...

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