aer 2011 therm - environmental protection agency · hse officer /mgt rep aine osojca ... suspended...

Quinn Therm Ltd

Environmental Manual- Annual Environmental Report

Submitted March 2012

Issue No 05

Prepared by Áine Osojca

Annual Environmental

Report

Quinn Therm Limited

IPPC No P0739-01

Annual Environmental Report

2011

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AER P0739-01 Contents: 1.0 Company Details........................................................................................3 1.1 Process Overview:.................................................................................................. 4

2.0 Overview ..................................................................................................5 3.0 Environmental Management .................................................................6 3.1 Progress Meetings.................................................................................................. 6

4.0 Environmental Objectives and Targets ............................................................8 5.0 Emissions...............................................................................................10 5.1 Emissions from the installation........................................................................... 10 5.2 Emissions to Atmosphere and Sewer................................................................. 10 5.3 Emissions to Water .............................................................................................. 10 5.4 Pollution Emissions Register .............................................................................. 11 5.5 Waste Management .............................................................................................. 11 5.6 Recycling & REPAK.............................................................................................. 15 5.7 Water Usage .......................................................................................................... 15 5.8 Energy Usage........................................................................................................ 15

6.0 Environmental Performance........................................................................17 6.1 Annual Reporting.................................................................................................. 17 6.1.1 Noise Monitoring Report Summary ...........................................................17 6.1.2 Ambient Monitoring Summary ..............................................................18 Table 1.0 ...................................................................................................18 6.1.3 Air Emissions Monitoring Summary.......................................................20 Table 2.0 ...................................................................................................20

6.2 Resource Consumption Summary ...................................................................... 21 Table 3.0 ...................................................................................................21

6.3 Complaints Received............................................................................................ 21 6.4 Wastes off Site ...................................................................................................... 21 6.5 Notifications and Reported Incidents to the Agency during 2011.................... 22 6.6 Tank and pipeline testing..................................................................................... 22 6.7 Risk Mgt Programmes .......................................................................................... 22

7.0 Environmental Management Programme .......................................................23 7.1 Residual Management Plan................................................................................... 23 7.2 ELRA ...................................................................................................................... 23 7.3 Bund Integrity ....................................................................................................... 23 7.4 Environmental Prevention Measures and Remedial Actions............................ 24

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3

1.0 Company Details

Company Name: Quinn Therm Limited Licence Register Number: P0739-01 Address: Scotchtown, Ballyconnell, Co. Cavan Managing Director Bernard Farrell Divisional Manager Joseph Donegan Contact Numbers: Phone 049 9525600 Fax 049 9525601

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4

1.1 Process Overview: Quinn Therm Ltd is located in Scotchtown, Ballyconnell, Co. Cavan. It manufactures

Polyioscyanurate board for the construction Industry. The combination of technology and

chemistry lends itself to the creation of an insulation board which has zero ODP, low thermal

conductivity, high insulation value with class 1 fire rating surface spread of flame. Cost-effective

and environmentally sensitive solutions are a strong feature of the company. Its products do

not readily absorb water, making them suitable for use in damp environments. They are also

light, robust and easy to handle. All products are manufactured to withstand the service life of a

building. The process consists of a main production area, laboratory, dust extraction, chemical

blending and storage areas, raw material and final product storage, pentane tank storage, off

loading area, spray cage, offices, toilets and car parking facilities.

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2.0 Overview

Quinn Therm Ltd is located in Scothchtown, Ballyconnell, Co. Cavan. This annual

environmental report summarises the environmental performance for the year Jan 2011 –

December 2011. This report has been compiled in accordance with the EPA Guidance note for

Annual environmental report: Standardised Reporting Guidance and also using template

spreadsheets from the Office of Environmental Enforcement.

During 2011, the company strove to improve compliance with conditions of its IPPC licence

while also maintaining its ISO 14001:2004 accreditation.

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3.0 Environmental Management The Divisional Manager is responsible for the implementation of the Environmental Policy, overall

environmental management of the site and allocation of resources. Designated EHS Officers are responsible

for the day-to-day operations of the site, and the management of the IPPC licence.

The Ground Staff are responsible for the day-to-day operation of the installation and implementing good

environmental practice and training.

Environmental communication is essential to the Quinn Therm Ltd ethos and as such Quinn Therm Ltd

communicates any environmental issues to its staff, via meetings, memos, notice boards, presentations etc.

Quinn Therm Ltd also communicates to the general public via websites, brochures, emails etc.

Quinn Therm EMS is accredited to 14001 standard.

Applicable Documents

Quinn Therm Ltd Environmental Organizational Chart (See Page 7)

3.1 Progress Meetings Production progress meetings are carried out weekly, where environmental issues are also addressed.

Dedicated Environmental Meetings are held monthly to discuss improvements, actions in progress,

environmental management programs, objectives and targets, waste management issues/ controls and to

discuss environmental audits, energy management etc. This meeting is attended by the divisional manager,

plant manager, production manager, polymer engineering manager and quality systems supervisor along with

the CIS (Construction Industry Supply) Group environmental management department. Information is passed

on to significant team members as appropriate. Any issues, improvements or comments from members of staff

regarding environmental performance were communicated through the system and acted upon.

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Divisional Mgr Joseph Donegan

Office Manager Sinead Casey

Sales Manager Rose Mullally

Sales UK Leo Mc Elgunn

Manufacturing Mgr Peadar Maguire

P. Eng Mgr UK&Irl HSE Officer /Mgt Rep

Aine Osojca

Office Supervisor Charlene Mc Kiernan

Production Supervisors

Terry Mc Govern / Darren Murphy

Operators Office Staff

Dispatch Kevin Mc Barron

Lorry Drivers

Group Depts. IT, HR, Technical

Sales, Stores

Group Environmental Mgr

Fintan Coyle

Maintenance Dept Gordon Wiggins /

Barry Owens

Plant Mgr Norman Whyte

Warehouse Supervisor/

Production Planner Vincent Costello

Quality Sys Supervisor

HSE Officer/Mgt Rep Joanne Willis

FLT Drivers

Group Environmental

Advisor Stephen Linden

EHS Representative Terry Mc Govern

Graduate Polymer Engineer/ Sinead

Kelly

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4.0 Environmental Objectives and Targets

Environmental Objectives and Targets were revised in September 2011 following the annual

environmental review, with Quinn Therm Ltd being reviewed on a monthly basis at the

environmental meeting in conjunction with the Quinn Group CIS environmental management

team. Objectives and Targets are focussed on the environmental aspects which Quinn Therm

Ltd have influence over and which would have a significant impact on the environment.

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Applicable Documents:

EMP’s incorporating Objectives and Targets see page 10

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5.0 Emissions

5.1 Emissions from the installation

Independent monitoring of plant emissions is carried out by QED Engineering, Monaghan.

Cyclones and bag filters are used in the dust extraction system to reduce particulate emissions

from the installation.

5.2 Emissions to Atmosphere and Sewer

All activities on site are carried out responsibly to ensure that there were minimal odours or air

emissions released from the site. There are now four emission points to air from the production

process, three of these points are reportable as part of the conditions set out in the IPPC

licence. The fourth emission point, located at the plasterboard assembly point (A2-4), was

added in early 2010. The agency was informed about this new emission point in March 2010.

Quinn Therm Ltd are measuring this point, however emissions from this point are very low, this

emission point is not part of the IPPC licence reporting and so is exempt from

monitoring/reporting. No process effluent is generated from activity of the plant. The waste from

the toilets and the canteen are released into the site sewerage system which is pumped to the

local wastewater treatment plant. The emissions to sewer are domestic in nature and do not

require a discharge licence and is exempt from monitoring.

5.3 Emissions to Water

There are no emissions to water of environmental significance from the plant. Storm water

emissions were inspected weekly for odour and colour by Quinn Therm staff and samples were

taken and analysed by Euro Environmental Services Ltd for pH and COD quarterly and total

suspended solids on a quarterly basis.

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5.4 Pollution Emissions Register

Quinn Therm Ltd do not emit any of the chemicals listed on the PRTR reporting list, therefore

no report for the year has been completed, as of the revised reporting online spreadsheets

devised by the Agency.

5.5 Waste Management

The company has a number of waste streams arising on site that were recovered or disposed

of offsite, please refer to spreadsheets attached.

All wastes were collected and disposed of by approved and licensed contractors, which are

periodically audited by Quinn Therm Ltd.

Haz Waste Removed 2011

Non Haz waste Removed 2011

Foam waste Removed 2011

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Recyclable Waste removed.

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5.6 Recycling & REPAK

Where possible, all waste packaging from the production floor is recycled. Quinn Therm Ltd

recycles wood, baled plastic, plastic drums, baled cardboard, cardboard cores, steel and paper.

Quinn Therm Ltd subscribes to REPAK membership number 4250, which involves declaring

the amount of packaging waste on our products sold within the Republic of Ireland. A bi-annual

fee is then paid to REPAK based upon the waste quantities declared.

5.7 Water Usage

Water usage analysis is carried out on a monthly basis. Analysis is made with regards to

volume of water used against working hours. This report is sent to the Group’s Environmental

Manager and reviewed at the monthly environmental meetings. Any abnormalities from this

report will lead to an investigation being carried out and corrective actions issued if required.

There were no significant issues within 2011.

5.8 Energy Usage

Energy usage for the year 2011 was analysed on a monthly basis, there are dedicated energy

management programs in place in Quinn Therm Ltd, which are designed to reduce the amount

of energy used on the Therm Ltd site. Therm Ltd uses the SEI Energy Tracker as a tool to aid

with energy management. An energy audit review was carried out during 2011, a copy of which

is available on-site.

All monthly analysis is reviewed at the monthly environmental meeting and any abnormalities

are discussed and corrective actions issued if required.

A reduction in fuel oil consumption in 2011 can be seen due to the installation of a new boiler in

2010.

Reference:

Energy Management Programs see next page.

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6.0 Environmental Performance

6.1 Annual Reporting

Reports were submitted to the agency in full and to the specifications laid out in the IPPC

licence.

6.1.1 Noise Monitoring Report Summary

A day and night noise survey of the plant was carried out by QED Engineering Ltd, October

and November of 2011. Five monitoring points were located for the day-time and night-time

noise survey. The five points are the noise sensitive locations for Quinn Therm Ltd as per our

IPPC licence. Due to Quinn Therm Ltd being situated between two other industrial sites and

across a busy road (R205 / B127) from a cement manufacturing plant it is extremely hard to

distinguish noise sources. NSL1 is situated particularly close to the Quinn Packaging plant and

NSL3 is in close proximity to the Quinn Cement plant. NSL5 is the nearest noise location to the

Therm Ltd plant and the readings at this location both day and night were well within limits set

in the IPPC licence. Based on the last survey it can be assumed that Quinn Therm Ltd is not

contributing environmental noise that may be considered nuisance. No complaints relating to

noise have been issued to the company in 2010. Three copies of this report were furnished to

the EPA and are available onsite.

1. Rakeelan filling Station/Shop NSL2

2. Cassidy’s Shop NSL1

3. McKiernan’s Residence NSL 3

4. Doon Heights NSL 4

5. River Bank NSL 5

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6.1.2 Ambient Monitoring Summary

Groundwater monitoring wells are located on site under condition 3.12 of the IPPC licence 739.

Samples for storm water were taken and sent to QED Engineering for evaluation on behalf of

the EPA. Ground water is annually tested and storm water is quarterly tested. Quinn Therm Ltd

ground water tests and storm water tests were carried out by QED Engineering &

Environmental Efficiency. All results are within the guidelines. Following are the most recent

results from monitoring.

Ground Water

Table 1.0

Date Parameter Units

Results

GWS1-

B

Results

GWS-3

Results

GWS-4

November 2011 pH pH units 7.6 7.7 7.7

COD mg/l 8 8 8

Conductivity µS/cm 410 448 361

VOCs µg/l 0 0 0

Storm Water

Table 1.1

Date Parameter Units Results

21/03/2011 pH pH units 7

COD mg/l 47.20

Suspended Solids mg/l <5


29/06/2011 pH pH units 7.2

COD mg/l 35

Suspended Solids mg/l -


27/09/2011 pH pH units 7.9

COD mg/l <8

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Suspended Solids mg/l <5


06/12/2011 pH pH units 7.6

COD mg/l 21

Suspended Solids mg/l -

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6.1.3 Air Emissions Monitoring Summary

Five emission points are located on site to monitor emissions to atmosphere as per schedule

C.1 (ii) of the licence. This work was carried out by QED Engineering and Environmental

Efficiency in 2011. Results from this report state the combustion efficiency of the boilers is high

and all emission results are within the IPPC Emission Limit Values.

Air Emissions monitoring results

Table 2.0

Date Parameter Substance to

be monitored Units

Limit

emissions Results

08/06/2011 A1-2 (a) Boiler Combustion

efficiency mg/Nm3 ----- 94.8%

A1-2 (b) Combustion

efficiency mg/Nm3 Must be high 88.5%

A2-1 (Dust

extraction System)

Particulates

Test 1 mg/Nm3 10 1.03

Particulates

Test 2

1.5

A2-2 (Chemical

Laydown

Extraction system)

MDI mg/Nm3 0.1 <0.01

A2-3 (Pentomat

Extraction

System)

MDI mg/Nm3 0.1 <0.01

Date Parameter Substance to

be monitored Units

Limit

emissions Results

06/12/2011 A1-2 (a) Boiler Combustion

efficiency mg/Nm3 ----- na

A1-2 (b) Combustion

efficiency mg/Nm3 Must be high na

A2-1 (Dust

extraction System)

Particulates

Test 1 mg/Nm3 10 1.47

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Particulates

Test 2 20.96

A2-2 (Chemical

Laydown

Extraction system)

MDI mg/Nm3 0.1 <0.008

A2-3 (Pentomat

Extraction

System)

MDI mg/Nm3 0.1 <0.007

6.2 Resource Consumption Summary

The following table summarises the volumes of fuel and electricity purchased and utilised at

Quinn Therm Limited during January 2011 to December 2011.

Table 3.0

Resource Amount

Electricity 1,676,765kWh

Fuel for heating 70,510.0 Litres

Fuel for fork trucks 37,190.2Litres

6.3 Complaints Received

There were no complaints received at the plant regarding operations at the plant in 2011.

6.4 Wastes off Site All wastes that are transported off site are recorded as per requirements of Quinn Therm Ltd

IPPC licence. This includes the tonnage of waste produced, destination of waste, name of

transporters and the EWC code. All waste contractors used by Quinn Therm Ltd have the

required permits and licences. All hazardous waste is disposed of in the correct manner by

approved contractors. Waste contactors are periodically audited where applicable with regards

their permits and how they carry out the removal of the waste.

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6.5 Notifications and Reported Incidents to the Agency during 2011.

Minor incidents are recorded internally as of the recording requirements of ISO 14001, but

these incidents had no potential for risk to the wider environment that would necessitate

communication to the Agency.

6.6 Tank and pipeline testing As part of the preventative maintenance plan in Quinn Therm Ltd, pipe work, tanks, chemical

storage area etc are inspected on a daily/weekly basis for any leaks pressure changes any

abnormalities. All issues are documented and kept on file. The underground pentane tank is

connected to an alarm sensor, in the case of a pressure drop the alarm will sound and the line

will cut out. This alarm system is checked periodically by an approved contractor.

6.7 Risk Mgt Programmes Currently there are no risk management programs in place; this is going to be reviewed at the

annual environment management review to see if status has changed.

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7.0 Environmental Management Programme

A proposal for the year running from Jan 2011 to Dec 201 was decided upon in Jan 2011 and

again reviewed at the environmental management review meeting. These are ongoing with

review at the monthly environmental management meeting to view status. Refer to

environmental management programs.

Applicable Documents:

Environmental Management Program including Objectives and Targets as seen previously

7.1 Residual Management Plan

The residual management plan was originally submitted in March 2007 to the EPA for approval.

Quinn Therm Ltd reviewed this ERLA in August 2010. A copy of this reviewed document is

kept on file at Quinn Therm Ltd. No significant changes have been made to this document.

7.2 ELRA

The ELRA was submitted to the agency during the year 2007 and reviewed in August 2010. A

copy of this reviewed document is kept on file at Quinn Therm Ltd. No significant changes

have been made to this document.

7.3 Bund Integrity

Permanent bunds are checked by an external agency (Adcon Consultants Ltd, Belturbet, Co.

Cavan) every 3 years, as per IPPC licence requirements. Reports are kept on file at Quinn

Therm Ltd. Next external check is due in July 2014. Visual checks are carried out internally on

all mobile bunds with the relevant reports being kept on file at Quinn Therm Ltd.

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7.4 Environmental Prevention Measures and Remedial Actions

Quinn Therm Ltd has maintained ISO 14001:2004 certification of the site EMS for the duration

of 2011, as well as maintaining a fully operational EMS system.

The following actions have been carried out in 2011 and will feature heavily in 2012, in order to

ensure the successful operation of the EHS Management System in accordance with the IPPC

licence and ISO14001:2004

• Environmental Aspects are being reviewed and updated to reflect production activities.

• Waste Management practices are in place in Quinn Therm Ltd, only approved

contractors are used.

• Environmental issues are discussed at the weekly progress meeting and also at the

monthly environmental meeting.

• Energy management system in place, targets were given for energy reduction. These

targets are reviewed on a monthly basis.

• Looking at attaining A+ rating on Quinn Therm Ltd insulation product.

• Evacuation Drills are carried out on all shifts bi-annually and results are evaluated so

that corrective actions can be put in place.

• Training to be given to employees in terms of Fire training and chemical spill training,

pentane awareness training.

Moving forward regular external audits will be carried out to ensure that the EMS and ISO

14001:2004 are implemented maintained and is operational throughout the plant. ISO 14001:,

some of these will take the form of full systems audits along with full process audits. Re-

certification to 14001 was successfully carried out in March 2011. Quinn Therm Ltd has an

ongoing commitment to ensure that all operations are carried out in an environmentally friendly

way and that the aspects are controlled and monitored in order to assess environmental

improvements on an ongoing basis. As per new guidelines received from the EPA in October

2010, any contractor carrying out air monitoring for Quinn Therm Ltd will be requested to prove

their accreditation status against ISO 17025, otherwise they will need to provide competency

records.