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Annual Environmental Report 2009
ANNUAL ENVIRONMENTAL REPORT 2009 (Ref. IPPC Licence Register No. P0530-01)
Annual Environmental Report 2009
ANNUAL ENVIRONMENTAL REPORT 2009 (Ref. IPPC Licence Register No. P0530-01)
Prepared By: A.McDonald, Operations Manager.
Date : 23rd March 2010.
Annual Environmental Report 2009
Table of Contents
1.0 Introduction
2.0 Summary Information
2.1 Emissions to Atmosphere
2.2 Ambient Dust Deposition Monitoring
2.3 Emissions to Surface Waters
2.4 Waste Management
2.5 Resource Consumption
2.6 Noise Monitoring
2.7 Environmental Incidents and Complaints
2.8 Tank and Pipeline Testing and Inspection
2.9 Review of Residuals Management & Quarry Restoration Plan
3.0 Management of the Activity
3.1 Schedule of Environmental Objectives and Targets
- Environmental Management Programme Proposal 2010
- Environmental Management Programme Report 2009
3.2 Pollution Emission Register Proposal 2010
3.3 Pollution Emission Register Report 2009
4.0 Licence-Specific Reports
None.
APPENDICES 1 - 5
Annual Environmental Report 2009
1.0 Introduction
Licence Register No.: P0530-01
Company Name: Ormonde Brick Limited.
Location: Ardra, Castlecomer, Co.Kilkenny.
Description of Activity: Manufacture of fired-clay facing bricks from locally occuring shale
and fireclay extracted mainly from quarries at Coolbawn and Gurteen,
Castlecomer, Co.Kilkenny. The shale is crushed in a jaw crusher, the
shale / fireclay is ground in a dry pan-mill, screened and mixed with
water to provide wet clay for shaping. The wet clay is extruded and
wire-cut to the required size and shape. The wet brick is dried in chamber
driers by utilising hot air from the kiln roof and kiln cooling zone.
After drying, the product is automatically set on refractory kiln cars for
firing to approximately 1000oC in a tunnel kiln.
Finally, the fired product is sorted and packed automatically by machine
or by hand into packs bound with steel or plastic strapping and covered
with plastic packaging.
Environmental Policy: A copy of the company Environmental Policy is shown in Appendix 1.
The company Environmental Management System is approved to
ISO 14001 by C.I.C.S.Ltd.
Organisation: The Operations Manager is the Person in Charge in relation to contacts
with the Agency concerning the IPPC Licence and Environmental issues.
The Operations Manager also has the role of Quarry Manager and is
responsible for environmental issues relating to the quarries located
locally at Coolbawn & Gurteen.
Annual Environmental Report 2009
2.1 EMISSIONS TO ATMOSPHERE
2.1.1 General
There was no production in the Works during 2009. Kiln no. 2 was shut down at end of December
2008 and was not re-commissioned during 2009.
2.1.2 Summary of Monitoring during 2009
There was no emission monitoring carried out during 2009 as the Kiln and Works operations were
shut down for the entire period.
2.1.3 Summary of Mass Emissions during 2009
As stated above, the Kiln did not run during 2009 and hence there were no mass emissions
to report for the year.
2.1.4 Continuous HF Monitor
There were no continuous HF Monitor readings during 2009 as the Kiln was out of commission.
2.1.5 Herbage Analysis
At the request of the Agency, a programme of grass sampling for fluorides commenced in April
2005. The results of Herbage Analysis for 2009 are shown in Table 1 below. Sampling was carried
out in April only. Herbage sampling has ceased, by agreement with the Agency, due to the Kiln and
Productiuon operations being out of commission. (A new site will have to be located before sampling
resumes as the current site will not be made available to the Company).
The tolerance level identified for domesticated animals is 30 mgF/kg of herbage.
Location Date of Sampling
06-Apr 30-May 27-Jun 23-Jul 01-Sep 03-Oct 29-Oct Average
GS1 4.0 --- --- --- --- --- --- 4.0
GS2 --- --- --- --- --- --- --- ---
GS3 3.2 --- --- --- --- --- --- 3.2
GS4 2.7 --- --- --- --- --- --- 2.7
Notes: (i) Sampling carried out during the growing season from April to October.
(ii) Not possible to sample GS2 due to poor growth and bad ground conditions.
Table 1 : Herbage Analysis for Fluorides
Annual Environmental Report 2009
2.1.6 Agency Monitoring and Enforcement 2009
During 2009, there was no monitoring of emissions to atmosphere carried out by the Agency.
2.2 AMBIENT DUST DEPOSITION MONITORING
2.2.1 Dust monitoring is normally required to be carried out during the months of May to September.
However, due to the shutdown of both Factory and Quarry operations it was agreed with the Agency
that there was no requirement to carry out dust monitoring during 2009.
2.3 EMISSIONS TO SURFACE WATERS
2.3.1 Surface water and groundwater are discharged from the site at ref. point SW3F. The main discharge
is from groundwater springs at the rear of the facility, roof run-off, yard run-off including storm
events and run-off from adjoining forestry lands.
2.3.2 The results of sampling and analysis by BHP Laboratories for monitoring as required for 2009 are
shown in Table 2 below. The monthly records for the daily Visual Inspections for 2009 are shown in
Appendix 2.
Parameter Units Month
Average Jan Feb Mar Apr May Jun Jul Aug Sept Oct Nov Dec
B.O.D. mg/l 3 1 1 7 3 4 11 6 3 7 12 5 5
Conductivity µS/cm @ 20oC 433 611 433 355 514 475 322 279 501 267 285 443 410
Ammonia mg/l NH4 0.04 0.01 0.01 0.09 0.01 0.01 0.01 0.02 0.01 0.01 0.01 0.01 <0.02
Nitrite mg/l NO2 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05
Nitrate mg/l NO3 0.1 5.05 5.48 5.35 11.2 7.8 2.4 5.12 7.6 3.8 11.1 4.7 5.81
pH pH units 8.15 7.90 7.61 8.02 8.16 8.11 7.54 7.22 6.56 6.56 7.13 7.72 7.56
Suspended
Solids mg/l 1 4 2.8 20.4 1 1 13 6 1 23 56 3 11.0
Table 2 : Summary Table for Surface Water Discharge Monitoring
Notes: (i) In our IPPC Licence, there are no Emission Limit Values in Schedule 3(i) Surface
Water Discharge Monitoring.
(ii) Overall, the water quality at SW3F has remained consistent in comparison to the
previous year 2008.
(iii) There is no volumetric measure on the discharge at SW3F and therefore no summary
for Mass Emissions can be provided.
Annual Environmental Report 2009
2.4 WASTE MANAGEMENT
2.4.1 The summary for Non-Hazardous Waste is shown in Table 11.1 and the summary for Hazardous Waste is shown in Table 11.2. and further
monthly
waste analysis is shown in Tables 11.3 (a) & 11.3 (b). The Waste Contractors and Permit / Register Numbers employed are shown in Table 11.4.
Table 11.1 : Summary Table for Non-Hazardous Waste
Information on each waste stream EWC Code as per
2001/118/EC
HAZ
Yes/No
Description of
Waste
Quantity (tonnes/annum)
Method of
Disposal/Recovery
Location of
Disposal/Recovery
Name of Waste Disposal
/Recovery Contractor
1 0 1 2 0 1 No Green Brick 0 Returned to process
where possible (D1)
Used in restoration of
quarry.
Wholesale Suppliers Ltd.
1 0 1 2 0 8 No Waste fired brick 0 Construction fill (R0) n/a
2 0 0 3 0 1 No Domestic &
Canteen Waste
7.64 Landfill (D1) Kilkenny County
Council.
Greenstar Noble
1 6 0 1 0 3 No Tyres 0 Re-cycled (R3) Crumb Rubber Ltd,
Dundalk.
Kieran Mooney Haulage
2 0 0 1 3 8 No Wood (Broken
Pallets)
0 Re-cycled (R3) Erwin Cobbe,
Portarlington.
Greenstar Noble
2 0 0 1 4 0 No Waste metal 4.69 Re-cycled (R4) ACB, Spain. A1 Metal Recycling
1 5 0 1 0 1 No Paper & Cardboard 5.42 Re-cycled (R3) Kilkenny County
Council.
Greenstar Noble
1 5 0 1 0 2 No Plastic Wrap 3.72 Re-cycled (R5) Eurokey Recycling,
UK.
Greenstar Noble
2 0 0 3 0 4 No Sludge from Septic
Tank
0 Pumped into sewage
treatment plant (D8)
Purcellsinch Water
Treatment Works,
Kilkenny
Quick Sharp Ltd.
1
7 0 1 0 7 No Construction &
Demolition Waste
0 Landfill (D1) Kilkenny County
Council.
Greenstar Noble
Annual Environmental Report 2009
Information on each waste stream EWC Code as per
2001/118/EC
HAZ Yes/No
Description of
Waste
Quantity
Method of
Disposal/Recovery
Location of
Disposal/Recovery
Name of Waste Disposal /
Recovery Contractor
1 4 0 6 0 3* Yes Degreasing
Solvents
0 litres Re-cycled (R2) Safety Kleen Ltd.
Sheffield, England.
Safety Kleen Ireland Ltd.
1 5 0 1 1 0 Yes Pigment Bags 0 Landfill (D1) KTK Landfill, Shannon. Enva
2 0 0 1 2 1* Yes Fluorescent Tubes 0 kg Recycled (R4/R5) (i) Glass – Quinn Glass, IRL.
(ii) Mercury Contaminated
Filters & Sludge
- Claushuis Metaals, NL.
(iii) Aluminium End Caps
- A1 Metal Recycling.
Irish Lamp Recycling.
1 6 0 6 0 4 Yes Primary Batteries 0 Re-cycled (R4/R5) (i) Acid neutralised
(ii) Lead & Plastic exported
to smelting plant for re-use.
Returnbatt Ltd.
1 6 0 2 0 9* Yes Capacitors &
Transformers
0 PCB Disposal
Contractor (D10)
R.F. Winder Electrical Ltd. R.F. Winder Electrical Ltd.
1 3 0 8 9 9* Yes Waste Oils 2,000 litres Re-cycled (R8) Enva, Portlaoise, Co.Laois. Enva
1 6 0 1 0 7* Yes Oil Filters 0 Re-cycled (R3) Hegarty Metal Recycling,
Limerick
Enva
1 3 0 8 9 9* Yes Solid Oily Waste 250 kg Re-cycled (R1) Solid oily extract exported
to Germany for re-cycling.
Enva
1 3 0 7 0 1* Yes Contaminated
Water
0 Re-cycled (R9) Enva, Portlaoise, Co.Laois. Enva
1
7 0 6 0 5* Yes Construction Waste
containing Asbestos
0 Landfill (D1) Germany BIS Willich Industrial
Services Ltd
Notes:
(1) Engine, hydraulic and gear waste oils were mixed in the same waste oil storage container.
(2) Contaminated water was water which was contaminated with diesel oil within a bund, hence the EWC number is for diesel oil.
Table 11.2 : Summary Table for Hazardous Waste
Annual Environmental Report 2009
Month Degreasing
Solvents
Litres
Pigment
Bags
No.
Fluorescent
Tubes
Kg
Primary
Batteries
Litres
Capacitors &
Transformers
No.
Waste
Oils
Litres
Solid
Oily
Waste
Kg
Oil
Filters
Litres
Construction
& Demolition
Waste
Tonnes
Construction
Waste
Containing
Asbestos
Tonnes
Tyres
Tonnes
Waste
Metal
Tonnes
Jan 0 0 0 0 0 0 0 0 0 0 0 4.69
Feb 0 0 0 0 0 0 0 0 0 0 0 0
Mar 0 0 0 0 0 0 0 0 0 0 0 0
Apr 0 0 0 0 0 0 0 0 0 0 0 0
May 0 0 0 0 0 0 0 0 0 0 0 0
June 0 0 0 0 0 0 0 0 0 0 0 0
July 0 0 0 0 0 0 0 0 0 0 0 0
Aug 0 0 0 0 0 0 0 0 0 0 0 0
Sep 0 0 0 0 0 0 0 0 0 0 0 0
Oct 0 0 0 0 0 0 0 0 0 0 0 0
Nov 0 0 0 0 0 0 0 0 0 0 0 0
Dec 0 0 0 0 0 2,000 250 0 0 0 0 0
Total 0 0 0 0 0 2,000 250 0 0 0 0 4.69
Table 11.3 (a) : Summary Table for Waste Analysis
Annual Environmental Report 2009
Month Sludge from
Sediment
Trap
@ SW3F
Tonnes
Sludge from
Septic Tanks
Tonnes
Green Brick
Tonnes
Waste Fired
Brick
Tonnes
Domestic &
Canteen
Waste
Tonnes
Timber
(Broken
Pallets)
Tonnes
Cardboard
& Paper
Tonnes
Plastic Wrap
Tonnes
Contaminated
Water
Litres
Jan 0 0 0 0 0 0 0.06 0 0
Feb 0 0 0 0 0 0 0.06 0 0
Mar 0 0 0 0 0 0 0.06 0 0
Apr 0 0 0 0 0 0 0.06 0 0
May 0 0 0 0 3.98 0 0.06 0 0
June 0 0 0 0 0 0 0.06 0 0
July 0 0 48 0 0 0 0.62 3.72 0
Aug 0 0 36 0 0 0 0.06 0 0
Sept 0 0 48 0 3.66 0 0 0 0
Oct 0 0 60 0 0 0 0.06 0 0
Nov 0 0 72 0 0 0 0 0 0
Dec 0 0 24 0 0 0 0 0 0
Total 0 0 288 0 7.64 0 1.1 3.72 0
Table 11.3 (b) : Summary Table for Waste Analysis
Annual Environmental Report 2009
Table 11.4 : Summary Table for Waste Contractors and Permit / Register Numbers
Waste Contractor / Broker Permit / Register Number Issuing Authority
Greenstar WCP/KK/053/02 Kilkenny County Council
A1 Metal Recycling WMP 007 Kilkenny County Council
Quick Sharp Ltd. WCP/KK/126(A)/05 Kilkenny County Council
Safety Kleen Ltd. W0099-01 Environmental Protection Agency
Security in Shredding WCP/KK/225/04 Kilkenny County Council
Irish Lamp Recycling WCP/KK/030(A)/05 Kilkenny County Council
Returnbatt Ltd. WCP/KK/001/02 Kilkenny County Council
Enva WCP/KK/059(A)/07 Kilkenny County Council
Wholesale Suppliers Ltd. WCP/KK/122/02 Kilkenny County Council
Irish Environmental Services Transit Station Licence no. 40/1 Environmental Protection Agency
RILTA Environmental Transit Station Licence no.192/2 Environmental Protection Agency
KTK Landfill Ltd. W0081-03 Environmental Protection Agency
Crumb Rubber Ireland Ltd. WCP/KK/143(A)/07 Kilkenny County Council
Kieran Mooney Haulage Ltd. WCP/KK/386/07
WCP/OY/525/07
Kilkenny County Council
Offaly County Council
Annual Environmental Report 2009
2.5 RESOURCE CONSUMPTION
2.5.1 Energy Consumption
The energy consumption figures for 2009 are shown in Table 3 below.
Energy Type Consumption Converted to MWhr
Natural Gas 0 kWhr 0
LPG (Propane) 7,540 litres 56
Diesel Oil (for Mobile Plant) 2,000 litres 24
Gas Oil (for Kiln firing) 0 litres 0
Electricity 190,000 kWhr 190
Table 3 : Summary Table for Energy Consumption
2.5.2 Water Consumption
The water consumption figures for 2009 are shown in Table 4 below.
The utilisation of on-site ground water was 0% in 2009 (in comparison to 18% for 2008).
Source Consumption (m3)
On-site Ground Water 0
Municipal Supply 5,644
Table 4 : Summary Table for Water Consumption
Annual Environmental Report 2009
2.6 NOISE MONITORING
The Annual Noise Survey was not completed in 2009 as both the Factory and Quarry operations
were closed down for the year.
2.7 ENVIRONMENTAL INCIDENTS AND COMPLAINTS
2.7.1 Environmental Incidents
There were no environmental incidents in 2009.
2.7.2 Environmental Complaints
There were no environmental complaints received during 2009.
2.8 TANK AND PIPELINE TESTING AND INSPECTION
2.8.1 Tank and Pipeline Testing and Inspection
A leak test was completed in August 2005 on the main LPG line from the storage tanks. A
further leak test had been scheduled for 2009 – was completed in Feb 2010.
2.8.2 Inspection of Overground Flanges and Valves
Due to the Factory shutdown since December 2008 the frequency of inspections has been reviewed
on the over ground flanges and valves at the Diesel Tank supplying mobile plant, Generator, Clay
Conditioner line, Slop Manganese line, Tank Farm at rear of Factory and the LPG line. These
installations are now inspected on a monthly basis.
Sample reports for Week 28/2008 & 43/2008 are included in Appendix 3 and no problems were
recorded during 2009.
Annual Environmental Report 2009
2.9 REVIEW OF RESIDUALS MANAGEMENT & QUARRY RESTORATION PLAN
2.9.1 The Residuals Management & Quarry Restoration Plan as required by Condition 12 of our IPC Licence
was completed in March 2002 and submitted as part of the 2001 AER.
2.9.2 The following is a review of progress in 2009 in the reinstatement of worked out quarry areas:
Quarry Ref.P.811/89, Coolbawn
Considerable progress was achieved on the Top-soil reinstatement of Phase 1. Work was also carried
out on the sloping of Shale faces in Phase 2 .
Quarry Ref. P.312/88, Gurteen
Work was carried out on creating a drainage sump using rejected fired bricks. Earth-moving work was
also carried out in progressing Sub-soil and Top-soil reinstatement on site.
Annual Environmental Report 2009
3.0 MANAGEMENT OF THE ACTIVITY
3.1 Schedule of Environmental Objectives and Targets
The Environmental Management Programme - Proposal 2010 and the Environmental Management
Programme - Report 2009 are shown on the following pages.
Annual Environmental Report 2009
Emissions to Atmosphere (1)
Operation Emission Target Objective Target
Date
Responsible
Person
Comments
Emissions from
Kiln stack
AS2-1BF
10 mg/Nm3
(AS2-1BF)
Minimise
Hydrogen Fluoride
emissions from
Kiln No.2 to
< 10 mg/Nm3
Continue with the Process Abatement
Project.
Ongoing
A.McDonald
In the event of the Kiln being
re-commissioned, proposals similar to
those outlined in Proposal 2009 will be
actioned,namely,
- Further increase of CaCo3
addition to clay mixes
- further increase of
perforation size
- further improvement of Kiln
seals
Document Approved By:
Ormonde Brick Limited
Ardra, Castlecomer,
Co.Kilkenny.
Revision: 0
Page: 1 of 11
Issued: 20.03.10 Operations Manager
Title:
Environmental Management Programme – Proposal 2010
Annual Environmental Report 2009
Document Approved By:
Ormonde Brick Limited
Ardra, Castlecomer,
Co.Kilkenny.
Revision: 0
Page: 2 of 11
Issued: 20.03.10
Operations Manager
Title:
Environmental Management Programme – Proposal 2010
Emissions to Atmosphere (2)
Operation Emission Target Objective Target
Date
Responsible
Person
Comments
Emissions from
Kiln stack AS2-
1BF
10 mg/Nm3
(AS2-1BF)
Ensure ground level
concentration of
Fluorides < 30mg/kg.
Continue with Monthly ‘Herbage
Sampling’ programme during the
growing season from April –
October.
Ongoing
A.McDonald
Resume herbage sampling to verify
ground level concentrations from HF
emissions
Fugitive Dust
Emissions
Not
determined
Reduction in fugitive
dust emissions from
Factory and Quarry
sites.
Continue with 2 weekly visits by
contractor Yard Sweeper / Washer
and more frequently if necessary
Ongoing
A.McDonald
Resume increased frequency of Yard
Sweeping activities to control fugitive
dust emissions.
Emissions from
Dust Filters
-
Ensure that dust
emissions are
controlled.
Carry out Annual Supplier
Inspections of dust filters DF1, DF2
& DF5.
Ongoing
A.McDonald
Resume Supplier Inspections & Audits
to compliment in-house maintenance
checks.
Annual Environmental Report 2009
Document Approved By:
Ormonde Brick Limited
Ardra, Castlecomer,
Co.Kilkenny.
Revision: 0
Page: 3 of 11
Issued: 20.03.10 Operations Manager
Title:
Environmental Management Programme – Proposal 2010
Emissions to Atmosphere (3)
Operation Emission Target Objective Target
Date
Responsible
Person
Comments
All
Atmospheric
Emissions
Not
determined
Ensure that air
emissions/odour do
not impair
significantly the
amenity value of the
environment beyond
the site boundary.
Continue with daily visual and
olfactory checks of impact of
emissions on amenities adjacent to
the site boundary as part of EMS..
Ongoing
A.McDonald
To ensure there is no impact on
local air quality due to emissions
from the facility.
Compliance
Monitoring
-
Continue Monitoring
Schedule as per
Condition 5.2 of the
IPC licence # 530.
Provision of satisfactory system of
measurement and monitoring of
emissions to ensure compliance in
accordance with schedule 1 (ii)
Monitoring of Emissions to the
atmosphere.
Ongoing
A.McDonald
To provide regular monitoring of
emissions to atmosphere.
Annual Environmental Report 2009
Document Approved By:
Ormonde Brick Limited
Ardra, Castlecomer,
Co.Kilkenny.
Revision: 0
Page: 4 of 11
Issued: 20.03.10 Operations Manager
Title:
Environmental Management Programme – Proposal 2010
Emissions to Surface Waters
Operation Emission Target Objective Target
Date
Responsible
Person
Comments
Surface water
Discharge of
Hazardous Materials
Loading and unloading
of
Hazardous Materials
Compliance
Monitoring
Not
determined
Not
Determined
-
The assurance that no
potentially polluting
substance discharges
from the site into the
receiving surface
water medium.
Minimise the risk of
Accidental discharges
of hazardous
materials to surface
waters
Continue Monitoring
Schedule as per
condition 8.1.2 of the
IPPC Licence # 530
Fortnightly inspections, cleaning
and preventative maintenance as
required of the sediment trap to be
recorded as part of site EMS.
Clean out Sediment Trap at SW3F
Arrange staff training in the general
awareness of the dangers in the
handling of hazardous materials and
the procedure to be followed in the
event of a spillage occuring.
Provision of satisfactory system of
measurement/monitoring of
emissions to ensure compliance with
Schedule 3(i)
Ongoing
Ongoing
Ongoing
A.McDonald
A.McDonald
A.McDonald
Annual Environmental Report 2009
Emissions to Ground Waters (1)
Operation Emission Target Objective Target
Date
Responsible
Person
Comments
Chemical Storage
on-site
Incidental
To protect
ground/surface waters
in the event of a
spillage from the
storage of hazardous
materials stored on-
site
(i) Monthly inspection of all bunds
to ensure that any leaks or spills
are detected.
(ii) Strictly operate the procedure
for the emptying of bunds in
an environmentally responsible
manner.
Ongoing
Ongoing
A.McDonald
A.McDonald
To provide for the protection of
groundwater / surface water in the
event of a spillage from the
chemical storage area.
Piping of chemicals
on-site
Incidental
To protect
ground/surface waters
in the event of a
spillage from the
piping of chemicals
on-site.
Fortnightly inspection and log of all
over-ground pipes and flanges
carrying materials other than water.
Carry out leak test on LPG line
Feb 2010
A.McDonald
A.McDonald
Inspections carried out on a less
frequent basis as plant was not in
operation.
Document Approved By:
Ormonde Brick Limited
Ardra, Castlecomer,
Co.Kilkenny.
Revision: 0
Page: 5 of 11
Issued: 20.03.10 Operations Manager
Title:
Environmental Management Programme – Proposal 2010
Annual Environmental Report 2009
Document Approved By:
Ormonde Brick Limited
Ardra, Castlecomer,
Co.Kilkenny.
Revision: 0
Page: 6 of 11
Issued: 20.03.10 Operations Manager
Title:
Environmental Management Programme – Proposal 2010
Emissions to Groundwaters (2)
Operation Emission Target Objective Target
Date
Responsible
Person
Comments
Foul water emissions
2.85 kg/day
BOD
To protect the
subsurface and
underlying
groundwater
from sewage
contamination.
Carry out 6-monthly checks on the
LRD50 Treatment System.
Ongoing
A.McDonald
Maintenance contract in place
with Enviropak Ltd for 6 monthly
checks on the performance of the
system.
Brick Cutting
Operation
Not
determined
To protect the
subsurface and
underlying
groundwater from
wastewater discharges
generated at the Brick
Cutting Operation.
Control and maintenance of the
sedimentation tanks as part of the
site EMS.
Omgoing
A.McDonald
The system installed eliminates
discharges of dirty cutting-saw
water to ground.
Annual Environmental Report 2009
Document Approved By:
Ormonde Brick Limited
Ardra, Castlecomer,
Co.Kilkenny.
Revision: 0
Page: 7 of 11
Issued: 20.03.10 Operations Manager
Title:
Environmental Management Programme – Proposal 2010
Emissions as Noise
Operation Emission Target Objective Target
Date
Responsible
Person
Comments
Annual Noise Survey
-
To survey the noise
generated on-site
(i) Submit notification to the
Agency confirming that Noise
Survey will be completed in
accordance with the
Environmental Noise Survey
Guidance Document.
(ii) Carry out Noise Survey at
Factory and Quarry Sites.
Sep 2010
Oct 2010
A.McDonald
A.McDonald
Assuming normal operations have
resumed at the Quarries and Factory;
To assess the impact of noise on the
surrounding environment.
Annual Environmental Report 2009
Document Approved By:
Ormonde Brick Limited
Ardra, Castlecomer,
Co.Kilkenny.
Revision: 0
Page: 8 of 11
Issued: 20.03.10 Operations Manager
Title:
Environmental Management Programme – Proposal 2010
Utilities and Energy Consumption
Operation Emission Target Objective Target
Date
Responsible
Person
Comments
Water Usage
Plant Wide
As
wastewater
Mininmise water
wastage plant wide.
(i) Continue with monthly reading
of water meter on supply from
site well.
(ii) Identify, implement appropriate
water conservation measures.
Ongoing
Ongoing
A.McDonald
A.McDonald
Assuming normal operations resume at
the Factory;
To assess water volumes used from
site well which is supplied from
groundwater springs.
Power Consumption
Plant Wide
Not
Applicable
Minimise energy
wastage plant wide.
Continue with implementation of
energy conservation programme by
ensuring that all electrical
equipment is fitted with control
devices (e.g. Thermostats,
lights, occupancy sensors etc.) to
minimise power consumption.
Omgoing
A.McDonald
Annual Environmental Report 2009
Emissions as Solid / Hazardous Waste (1)
Operation Emission Target Objective Target
Date
Responsible
Person
Comments
All wastes generated on-
site
To be
accurately
determined
Develop and
implement a waste
management strategy
for the site.
(i) Log and control all waste
generated on-site, the final
destination of this waste, the
method of treatment and
details of the contracted party.
(ii) Ongoing training of staff on the
types of waste generated on-
site.
Ongoing
Ongoing
A.McDonald
A.McDonald
Volume and number of distinct waste
streams will be directly related to the
level of operations at the Factory;
To provide control and tracking of all
waste generated on site.
Training of staff is ongoing.
Document Approved By:
Ormonde Brick Limited
Ardra, Castlecomer,
Co.Kilkenny.
Revision: 0
Page: 9 of 11
Issued: 20.03.10 Operations Manager
Title:
Environmental Management Programme – Proposal 2010
Annual Environmental Report 2009
Document Approved By:
Ormonde Brick Limited
Ardra, Castlecomer,
Co.Kilkenny.
Revision: 0
Page: 10 of 11
Issued: 20.03.10 Operations Manager
Title:
Environmental Management Programme – Proposal 2010
Emissions as Solid / Hazardous Waste (2)
Operation Emission Target Objective
Target
Date
Responsible
Person
Comments
Hazardous Waste
Generation
Not
determined
Reduction in quantity
of fluorescent tubes
for disposal.
Installation of longer life lighting.
Ongoing
A.McDonald
Routine replacement of fluorescent
tube lighting with halogen bulb
lighting.
General Packaging
Waste
To be
quantified
accurately
To reduce the quantity
of packaging waste
generated on-site.
(i) Report on progress in achieving
reduction in quantities of refuse
and minimisation of waste
plastic, steel strapping,
cardboard and timber pallets
sent for recycling.
(ii) Provide ongoing training of
staff in procedure relating to
waste management.
Dec 2010
A.McDonald
A.McDonald
To target reductions in quantity of
waste generated in the Works.
Annual Environmental Report 2009
Document Approved By:
Ormonde Brick Limited
Ardra, Castlecomer,
Co.Kilkenny.
Revision: 0
Page: 11 of 11
Issued: 20.03.10 Operations Manager
Title:
Environmental Management Programme – Proposal 2010
Residuals Management & Quarry Site Restoration
Operation Emission Target Objective
Target
Date
Responsible
Person
Comments
Reinstatement of Quarry
Sites
-
To restore worked out
quarry areas.
Complete top-soil in Phase 1 of
Quarry ref. P811/89, Coolbaun.
Aug 2010
A.McDonald
To ensure that worked out areas of
the quarry are reinstated as asoon as
practicable.
Annual Environmental Report 2009
Document Approved By:
Ormonde Brick Limited
Ardra, Castlecomer,
Co.Kilkenny.
Revision: 0
Page: 1 of 10
Issued: 20.03.10 Operations Manager
Title:
Environmental Management Programme – Report 2009
Emissions to Atmosphere (1)
Operation Emission Target Objective Responsible
Person
Comments
Emissions from
Kiln stack
AS2-1BF
10 mg/Nm3
(AS2-1BF)
Minimise Hydrogen
Fluoride emissions
from Kiln No.2 to
< 10 mg/Nm3
Continue with the Process Abatement Project.
E.Power
Due to significant reduction in demand
for brick products Kiln 2 was shut
down in Dec 2008 and was not re-lit
during 2009. The Agency was advised
of closure in Dec 2008 and of decision
not to re-commission during 2009.
Emissions from
Kiln stack AS2-
1BF
10 mg/Nm3
(AS2-1BF)
Ensure ground level
concentration of
Fluorides <
30mg/kg.
Continue with Monthly ‘Herbage Sampling’
programme during the growing season from
April – October.
E.Power
Herbage was sampled in April 2010
and was compliant. No further
sampling carried out
- No factory emissions
- Land owner has asked Company
to stop monitoring on current site
Fugitive Dust
Emissions
Not
determined
Reduction in
fugitive dust
emissions from
Factory and Quarry
sites.
Continue with 2 weekly visits by contractor
Yard Sweeper / Washer and more frequently if
necessary
E.Power
Requirements reviewed due to Quarry
and Works operations shutdown. Yard
sweeper available as required.
Annual Environmental Report 2009
Document Approved By:
Ormonde Brick Limited
Ardra, Castlecomer,
Co.Kilkenny.
Revision: 0
Page: 2 of 10
Issued: 20.03.10
Operations Manager
Title:
Environmental Management Programme – Report 2009
Emissions to Atmosphere (2)
Operation Emission Target Objective Responsible
Person
Comments
Emissions from
Dust Filters
-
Ensure that dust
emissions are
controlled.
Carry out Annual Supplier Inspections of dust
filters DF1, DF2 & DF5.
E.Power
Supplier Inspections & Audits on hold
pending resumption of Works operation
All Atmospheric
Emissions
Not
determined
Ensure that air
emissions/odour do
not impair
significantly the
amenity value of the
environment
beyond the site
boundary.
Continue with daily visual and olfactory checks
of impact of emissions on amenities adjacent to
the site boundary as part of EMS.
E.Power
Daily checks on hold pending
resumption of Kiln operation.
Compliance
Monitoring
-
Continue
Monitoring
Schedule as per
Condition 5.2 of the
IPC licence # 530.
Provision of satisfactory system of
measurement and monitoring of emissions to
ensure compliance in accordance with schedule
1 (ii) Monitoring of Emissions to the
atmosphere.
E.Power
Monitoring schedule on hold pending
resumption of Kiln operation.
Annual Environmental Report 2009
Emissions to Surface Waters
Operation Emission Target Objective Responsible
Person
Comments
Surface water
Discharge of
Hazardous
Materials
Not
Determined
The assurance that
no potentially
polluting substance
discharges from the
site into the
receiving surface
water medium.
Fortnightly inspections, cleaning and
preventative maintenance as required of the
sediment trap to be recorded as part of site
EMS.
Clean out Sediment Trap at SW3F
E.Power /
A.McDonald
Inspections carried out on a less
frequent basis. No issues raised.
Not completed. Extend to July 2010.
Loading and
unloading of
Hazardous
Materials
Not
determined
Minimise the risk
of accidental
discharges of
hazardous materials
to surface waters.
Continue staff training in the general
awareness of the dangers in the handling of
hazardous materials and the procedure to be
followed in the event of a spillage occuring.
E.Power /
A.McDonald
Yard staff and supplier are well briefed
re occasional delivery of Diesel.
Compliance
Monitoring
-
Continue
Monitoring
Schedule as per
Condition 8.1.2 of
the IPC licence #
530.
Provision of a satisfactory system of
measurement and monitoring of emissions to
ensure compliance, in accordance with
Schedule 3(i) Surface Water Discharge
Monitoring.
E.Power /
A.McDonald
Inspections completed as required and
monthly analyses carried out.
Document Approved By:
Ormonde Brick Limited
Ardra, Castlecomer,
Co.Kilkenny.
Revision: 0
Page: 3 of 10
Issued: 20.03.10 Operations Manager
Title:
Environmental Management Programme – Report 2009
Annual Environmental Report 2009
Document Approved By:
Ormonde Brick Limited
Ardra, Castlecomer,
Co.Kilkenny.
Revision: 0
Page: 4 of 10
Issued: 20.03.10 Operations Manager
Title:
Environmental Management Programme – Report 2009
Emissions to Groundwaters (1)
Operation Emission Target Objective Responsible
Person
Comments
Chemical Storage on-site
Incidental
To protect ground /
surface waters in
the event of a
spillage from the
storage of
hazardous materials
stored on-site
(i) Monthly inspection of all bunds
to ensure that any leaks or spills
are detected.
(ii) Strictly operate the procedure
for the emptying of bunds in
an environmentally responsible
manner.
E.Power /
A.McDonald
Inspections completed on a less
frequent basis as plant was not in
operation.
Procedure strictly enforced.
Bund Integrity test carried out on
Slop Mangalox / Clay Conditioner
Bund Area
Diesel Tank Bund - Bulk of
remaining contents in Gas Oil Tanks
removed.
Piping of chemicals on-site
Incidental
To protect ground /
surface waters in
the event of a
spillage from the
piping of chemicals
on-site.
Fortnightly inspection and log of all over-
ground pipes and flanges carrying materials
other than water.
Carry out leak test on LPG line
E.Power /
A.McDonald
Inspections carried out on a less
frequent basis as plant was not in
operation.
Pressure test delayed due to lack of
availabilty of experienced Engineer .
(Test completed early 2010 )
Annual Environmental Report 2009
Document Approved By:
Ormonde Brick Limited
Ardra, Castlecomer,
Co.Kilkenny.
Revision: 0
Page: 5 of 10
Issued: 20.03.10 Operations Manager
Title:
Environmental Management Programme – Report 2009
Emissions to Groundwaters (2)
Operation Emission Target Objective Responsible
Person
Comments
Foul water
emissions
2.85 kg/day
BOD
To protect the
subsurface and
underlying
groundwater
from sewage
contamination.
Carry out 6-monthly checks on the LRD50
Treatment System.
E.Power /
A.McDonald
Integrity test carried out on 3 no.
Enviropak Tanks to ensure no leakage.
Brick Cutting
Operation
Not
determined
To protect the
subsurface and
underlying
groundwater from
wastewater
discharges
generated at the
Brick Cutting
Operation.
Control and maintenance of the
sedimentation tanks as part of the
site EMS.
E.Power /
A.McDonald
No maintenance required during 2009
due to minimal activity.
Annual Environmental Report 2009
Document Approved By:
Ormonde Brick Limited
Ardra, Castlecomer,
Co.Kilkenny.
Revision: 0
Page: 6 of 10
Issued: 20.03.10 Operations Manager
Title:
Environmental Management Programme – Report 2009
Emissions as Noise
Operation Emission Target Objective Responsible
Person
Comments
Annual Noise
Survey
-
To survey the noise
generated on-site
(i) Submit notification to the Agency
confirming that Noise Survey will
be completed in accordance with the
Environmental Noise Survey
Guidance Document.
(ii) Carry out Noise Survey at Factory
and Quarry Sites.
E.Power /
A.McDonald
E.Power /
A.McDonald
Annual Noise Survey not carried out, in
agreement with the Agency, as both
Quarry and Factory were not in
operation at any time during the year.
All Activities
Not
Determined
Reduce the noise
generated from high
noise site activities
Continue with Noise Abatement
Programme.
E.Power / A.McDonald
Programme on hold pending
re-commissioning of Factory
operation.
Annual Environmental Report 2009
Document Approved By:
Ormonde Brick Limited
Ardra, Castlecomer,
Co.Kilkenny.
Revision: 0
Page: 7 of 10
Issued: 20.03.10 Operations Manager
Title:
Environmental Management Programme – Report 2009
Utilities and Energy Consumption
Operation Emission Target Objective Responsible
Person
Comments
Water Usage
Plant Wide
As
wastewater
Mininmise water
wastage plant
wide.
(i) Continue with monthly reading
of
water meter on supply from
site well.
(ii) Identify and implement
appropriate
water conservation measures.
E.Power /
A.McDonald
No water taken from site well for process during 2009.
Conservation programme on hold pending re-commissioning
of Factory operation
Power
Consumption
Plant Wide
Not
Applicable
Minimise energy
wastage plant
wide.
Continue with implementation of
energy conservation programme
by ensuring that all electrical
equipment is fitted with control
devices (e.g. Thermostats,
lights, occupancy sensors etc.) to
minimise power consumption.
E.Power /
A.McDonald
Energy conservation initiatives carried out in office area
Factory based initiatives on energy conservation on-hold
pending re-commissioning.
Annual Environmental Report 2009
Document Approved By:
Ormonde Brick Limited
Ardra, Castlecomer,
Co.Kilkenny.
Revision: 0
Page: 8 of 10
Issued: 20.03.10 Operations Manager
Title:
Environmental Management Programme – Report 2009
Emissions as Solid / Hazardous Waste (1)
Operation Emission Target Objective Responsible
Person
Comments
All wastes
generated
on-site
To be
accurately
determined
Develop and
implement a waste
management
strategy for the site.
(i) Log and control all waste
generated on-site, the final
destination of this waste, the
method of treatment and
details of the contracted party.
(ii) Ongoing training of staff on
the types of waste generated
on-site.
E.Power /
A.McDonald
E.Power /
A.McDonald
All waste streams identified – only packaging and domestic
waste applied during 2009.
Yard and office staff are well briefed on correct handling of
applicable waste streams.
Annual Environmental Report 2009
Document Approved By:
Ormonde Brick Limited
Ardra, Castlecomer,
Co.Kilkenny.
Revision: 0
Page: 9 of 10
Issued: 20.03.10 Operations Manager
Title:
Environmental Management Programme – Report 2009
Emissions as Solid / Hazardous Waste (2)
Operation Emission Target Objective Responsible
Person
Comments
Hazardous
Waste
Generation
Not
determined
Reduction in
quantity of
fluorescent tubes
for disposal.
Installation of longer life lighting.
E.Power /
A.McDonald
Routine replacement of fluorescent tube lighting with
halogen bulb lighting.
General
Packaging
Waste
To be
quantified
accurately
To reduce the
quantity of
packaging waste
generated on-site.
(i) Report on progress in
achieving reduction in
quantities of refuse and
minimisation of waste plastic,
steel strapping, cardboard &
timber pallets sent for
recycling.
(ii) Provide ongoing training of
staff in procedure relating to
waste management.
E.Power /
A.McDonald
E.Power/
A.McDonald
Low level of operations – low volumes of packaging waste
produced.
Annual Environmental Report 2009
Document Approved By:
Ormonde Brick Limited
Ardra, Castlecomer,
Co.Kilkenny.
Revision: 0
Page: 10 of 10
Issued: 20.03.10 Operations Manager
Title:
Environmental Management Programme – Report 2009
Residuals Management & Quarry Site Restoration
Operation Emission Target Objective
Responsible
Person
Comments
Reinstatement
of Quarry
Sites
-
To restore worked
out quarry areas.
Reinstate top-soil in Phase 1 of
Quarry ref. P811/89, Coolbaun.
E.Power /
A.McDonald
Reinstatement of top-soil in Phase 1 is now well advanced.
Grading of excavation slopes carried out on phase 2.
Annual Environmental Report 2009
3.2 Pollution Emission Register Proposal 2010
It is proposed , when the Kiln and Production Operations are re-commissioned, to continue with the existing PER for the monitoring of Hydrogen
Fluoride and Hydrogen Chloride emissions on the following basis:-
- Hydrogen Fluoride (HF) is a significant pollutant being emitted in the kiln exhaust gases.
The Company has expended significant resources in order to accurately quantify the amount of this emission. A continuous HF monitor is in place
since March 2004 and HF profiles are being logged for all the clay mix types and firing conditions. The Company is committed to the reduction of
HF by process abatement techniques in accordance with GG166 in order to comply with the ELV of 10mg/m3 which applied from January 2006.
Project work was completed on the kiln in July 2005, based on the Lingl proposal for exhaust gas recirculation, which has succeeded in further
reducing HF concentration levels in emissions. In conjunction with this strategy, body additive trials using finely ground calcium carbonate were
completed and all clay mixes now contain calcium carbonate since 1st April 2006. Based on emission results, adjustments are made to the calcium
carbonate addition rates to clay mixes as required. Sampling and analysis for Fluorine in the input raw materials and the finished fired-bricks has
also been completed.
- Hydrogen Chloride (HCl) which is also emitted in the kiln exhaust gases, is mainly derived from the use of Clay Conditioner (contains approx.
5% Barium Chloride) which is used in all products and PDV Salt (Sodium Chloride) which is used on the surface of some products for
appearance purposes. There is ongoing assessment of the usage rate of Clay Conditioner and there has been a reduction in the volume of PDV Salt
consumed per unit of production and product development work is on-going in order to reduce the use of PDV Salt, which can also lead to rejects
due to fluxing in the kiln.
3.3 Pollution Emission Register Report 2009
The Pollution Emission Register for 2009 is shown overleaf.
The following are some explanatory notes :
Hydrogen Fluoride (HF)
- the Gross Usage as reported is the total Fluorine estimated in the clay raw materials consumed in the process based on analysis carried out
between 2002 & 2006.
- the mass emission of HF reported in section 2.1.3 for 2009 was 0 tonnes compared to 0.9 tonnes in 2008.
- the Process Optimisation Project is ongoing in accordance with GG166 and the CaCO3 addition rates
for all clay mixes were increased further in July 2008. Coupled with Exhaust Gas Re-circulation and
ongoing process modifications, the average Concentration / average Mass Emission of HF are
decreasing satisfactorily year on year.
Annual Environmental Report 2009
Hydrogen Chloride (HCl)
- the two inputs associated with HCl are Barium Chloride (Clay Conditioner) and Sodium Chloride
(PDV Salt) and classified as inputs of Chloride.
- the products manufactured all contain Clay Conditioner but only some of those contain PDV Salt.
- the mass emission of HCl reported in section 2.1.3 for 2009 was 0 tonnes compared to 2.2 tonnes
in 2008.
- there is no Liquid Waste for PDV Salt, Liquid Waste for Clay Conditioner is that which is in product
rejected before firing and Solid Waste is PDV Salt also on rejected product.
Annual Environmental Report 2009
FACILITY IDENTIFICATION
Facility Name Ormonde Brick Limited
IPC Register No. 530
National Grid Reference 2542E, 1735N
Reporting Period January 2009 to December 2009
Production Units tonnes
Employee No.
POLLUTANTS SUMMARY Pollutant Name CAS No. Input Gross
Usage
Outputs Unaccounted Eco-
Productivity
Indices
Air MOM Liquid
Waste
MOM Solid
Waste
MOM Product MOM Recovery IGEE INEE
Hydrogen Fluoride - Fluorine
(in Shale and Fireclay)
7782-41-4
0
0
0
M
0
0
B
0
M
0
0
0
0
Hydrogen Chloride - Chloride (in Clay Cond.)
- Chloride (in Salt)
10361-37-2
7647-14-5
0
0
0
0
0
M
0
B
0
B
0
0
0
0
0
0
0
0
* Data on HF in Product Output is variable, which questions it’s reliability
MOM – Method of Measurement
This refers to the method used in determining losses to Air, Water and Land. The following codes are to be used to demonstrate the method used:
Method Code
Direct Measurement M
Material Balance B
Not Determined ND
Engineering Estimates E
Other O
Environmental Form
Ormonde Brick Limited
Ardra, Castlecomer, Co.Kilkenny.
Document : PER 2009
Document Approved By:
_____________________________________
A.McDonald, Operations Manager.
Revision: 1
Page: 1 of 1
Issued: 23rd March 2010
Title:
2009 Pollution Emissions Register Tracking List