attachment d · 2015-02-17 · attachment d waddock composting epa licence application page 9 of 22...

Attachment D

Waddock Composting EPA Licence Application of 22

Attachment D

Infrastructure & Operation

Attachments in this section include:

D.1 Operational Information Requirements

D.2 Additional Requirements for Waste Activities not Covered Above or Elsewhere

D.2.1 Wastes to be Accepted

D.2.2 Waste Acceptance Procedures

D.2.3 Waste and Material Outputs from Waste Activities

D.2.4 Principles of Self Sufficiency and Proximity

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Attachment D


Attachment D.1: Operational Information Requirements Development History Established in 2005, Waddock Composting Facility, Ltd. is a Local Authority permitted and

Department of Agriculture Animal By Products approved composting facility utilising in-vessel

batch tunnel technology to produce high-quality compost for agricultural, horticultural,

landscaping and gardening markets. Located in north County Carlow, the facility is 6 KM off

of the new M9 motorway from Exit 4 for Castledermot making it easily accessible from the

Midlands, Leinster and parts of Munster.

In 2010, the facility was upgraded to increase capacity and improve environmental

performance and management, especially in relation to odour control. The facility utilises a

state-of-the-art process control system that allows the Operator to fully manage the

composting process and track batches through the facility for traceability purposes.

The upgrade included a state-of-the-art tipping building and mixing area, six purpose-

built sealed composting tunnels, upgraded process control, ventilation and odour control

systems and fire retention tanks complete with rainwater harvesting.

In September 2011, Waddock Composting was issued with an updated permit for this site

from Carlow County Council, register number WFP-CW-11-05-01. This permit outlines the

scope of activities permitted on site in accordance with the Third Schedule, Part I, of the

Waste Management (Facility Permit and Registration) Regulations 2007 as amended.

In 2013, Waste Facility Permit Number WFP-CW-13-1 was issued to Waddock Composting by

Carlow County Council. The permitted tonnage under this permit is 24,999 tonnes per annum.

The following attachment describes the plant, methods, processes and operations of

Waddock Composting Facility Ltd.

Facility Design Hardstand and Drainage The entire facility and perimeters of the waste buildings are paved in impermeable concrete

hardstand with the exception of the car parking area and an area at the back of the facility

which is hard standing.

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Attachment D


Photograph1:

The waste building is completely

surrounded by drainage infrastructure at

all areas where potential foul run off may

be emitted. This is in the form of ACO

drains on all hardstanding areas

highlighted in the photograph 1 above.

A concrete “moate” style drainage channel

between the car parking area and the

adjacent side of the building as highlighted

in the photograph below diverts clean

rainwater to the surface water drainage.

Photograph 2:

Sewerage and Surface Water Drainage Infrastructure Leachate from within the composting building is diverted to the underground leachate

collection holding tank. This leachate is fed back and reused in the composting process. In the

event that any excess leachate runoff that is not reused in the process arises, this is sent to

Athy Waste Water Treatment Plant. All rainwater runoff from the site area beyond the ACO

drains is diverted to the surface water pipework which drains into the stream running along

the eastern boundary of the facility and feeds into the Aghalona River. See Facility Layout Plan

Drawing 2.

As part of this licence application it is proposed to install a Class 1 full retention interceptor

at the facility. Once this interceptor is installed, all surface water runoff will be diverted to the

interceptor prior to discharge to the surface water stream.

The only foul water at the facility is from the facility offices. This waste water is diverted to

the on-site septic tank.

Please refer to attached drawing numbers Drawing 1, Drawing 2, Drawing 3, and Drawing 4

for details of existing and proposed drainage infrastructure at the facility as well as roof water

collection system layout.

Site Security The site is bounded on all sides by security stock proof fencing and concrete block walls. The site entrance is via locked security gates and all buildings are secured with roller shutter doors and Security lights that come on at night.

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Attachment D


Site Access The facility is well serviced with road networks and is located close to the M9 motorway and is accessed along the R418.

Design and Location of Fuel Storage Areas

Fuels stored on-site include diesel, engine and hydraulic oils. All fuels and oils used at the

facility are stored in bunded areas. The diesel tank on-site is a self bunded diesel bouser. All

oils are stored in a locked storage container in bunds. Material Safety Data Sheets are

maintained on-site for all fuels and chemicals. Sufficient absorbent materials and spill kits are

maintained on-site to deal with any potential or accidental spillages or leaks. Designated staff

are trained in the use of spill kits and how to handle a fuel or oil spill.

Waste Inspection Area

Waste tipping and inspection areas have been designated in the reception building. All waste

is inspected upon arrival at the weighbridge prior to tipping into one of three submerged

tipping bunkers where the waste is inspected to ensure that the material conforms to the

waste acceptance criteria. The waste inspection and tipping area can be seen on the attached

Site Layout Plan Drawing 1. A procedure for waste acceptance SOP#01 is attached to Section

C of this application. This describes the criteria for waste acceptance and procedure for

checking all loads prior to and following acceptance.

All waste is inspected upon entry and upon tipping to ensure that the waste is acceptable.

Any non-acceptable items identified are rejected from the facility at this stage and reloaded

back onto the same receptacle/container.

Composting Infrastructure Tables 1 and 2 below set out the principal processing plant and equipment on-site:

Table 1. Principal Processing Plant and Equipment

Machine Make Model Registration Serial Number

Loading Shovel JCB 437 HT 141 CW 704

Loading Shovel JCB 414 S 12 CW 892 1242623

Trommel Screen Redwood Systems WAD280313 2013 WAD280313

Power Washer Honda GX 340 (Red)

Electric Steam Washer

Karcher HDS-10/20-4M 010988

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Attachment D


Table 2. Environmental Equipment Log:

Equipment Type

Ventilation Fan 22 KW

Primary Composting Bay 1,2 & 3 Inlet Fan 15 KW

Primary Composting Bays Extraction Fan 37 KW

Scrubber Pump 7.5 KW

ABP 1,2,3 & 4 Inlet & Outlet Fans 4 KW

Temperature Probes PT100 3 Wire

Manual Temperature Probe Reotemp

Leachate Recirculation pump Submersible pump

Manual PH metres Oakton

Fire Extinguishers Aenor

Process Control Software Program Scada

The main composting infrastructure currently consists of a waste intake area with three

tipping bays, temporary storage area, six primary composting bays, four ABP composting

tunnels, six footbaths, screening plant, biofilter and ancillary equipment as detailed in the

table above.

The tipping area is totally enclosed with three rolling doors at the back of the facility to allow

collection or delivery vehicles to tip their loads from the delivery area into one of three

submerged or below-grade bunkers within the enclosed reception shed.

The tipping area has sufficient space to store fresh bulking materials (wood chips, hay,

sawdust, etc.) and oversized materials from the screening process. By tipping and storing

different materials in their own individual areas, the operator has the ability to control the

mixing and blending process.

The inside dimensions of the composting tunnels are 20 x 5.7 x 5m (l*w*h). Each of the

tunnels are controlled by the Redwood composting process control system. This The

Redwood process computer is located in the operator’s control room located in the main

facility offices. The custom designed software allows dynamic control and pre-programming

of process key setpoints for each composting activity or unit. All results are monitored,

recorded and displayed on the computer screen on a continual basis. Recorded results are

compared to setpoint data simultaneously.

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Attachment D


Based on this comparison and the range tolerance specified for process variables, the

computer adjusts air and water flows and conditions affecting the tunnels, the building area,

the scrubbers and the biofilter. Access to the Redwood System is tightly controlled and is

restricted to Managers with in depth knowledge of the composting process are trained on

and have access to the Redwood software control system.

The Operating Manual for the Redwood system is attached to this section.

The Maintenance of Machinery & Environmental Equipment is set out in SOP#12 attached in

Section C of this application.

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Attachment D


Processes Composting Process – Waste Acceptance and Treatment Standard Operating Procedure SOP#02 in Section C of this application details all of the processing steps necessary to produce a pasteurised and safe compost product in accordance with Conditions for Approval and Operation of Composting Plants Treating Animal By-Products in Ireland, EU Regulation (EC) No. 1774/2002 and Waste Facility Permit No. WFP-CW-13-1. The processing of animal by-products by the Waddock Composting Facility consists of the following ten steps:

1. Feedstock reception 2. Feedstock preparation 3. Temporary storage of blended feedstocks 4. Primary tunnel composting 5. Turning and primary tunnel composting repeated 6. Screening to 12mm 7. Pasteurisation tunnel composting (1st barrier) 8. Turning and pasteurisation tunnel composting (2nd barrier) 9. Pathogen testing 10. Maturation, product storage and release

These steps are described in detail in Standard Operating Procedure SOP #02 and Odour Management Plan attached in Section C of this application. Cleaning of Delivery Area, Intermediate Area and Trucks Leaving the Facility The facility is designed with clean, intermediate and dirty areas in line with Animal By Product

Regulations as per the process flow diagram Drawing 6 below (a larger version of Drawing is

also attached.

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Attachment D


Drawing 6, Process Flow Diagram

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Attachment D


A power wash is in place at the facility in accordance with the requirements of the Animal By

Products Regulations and is a critical aspect of the on-site HACCP Plan. The power washer is

connected to rain water harvesting system firstly and is backed up by the mains water supply.

All vehicles tipping in the delivery area must be washed down if necessary.

If a machine or equipment needs to exit the reception building for Maintenance, repair,

replacement, etc. they are washed with a steam power washer or a cold powerwasher with

Jet 5 Hydrox 5 or similar disinfectant (active ingredient is peroxyacetic or peracetic acid) and

recorded on LOG #18 Machinery & Equipment Existing Reception Shed Cleaning Log.

Standard Operating Procedure SOP#03 attached in Section C describes in detail the procedure

for cleaning the delivery area. Standard Operating Procedure SOP#15 attached in Section C

describes the procedures in place for cleaning plant and vehicles leaving the shed.

Standard Operating Procedure SOP#06 attached in Section C describes the procedures for

ABP Tunnel Inspection, Filling, Sealing within the pasteurization tunnels & Cleaning of the

Intermediate Area. This procedure includes layout plans of the clean, intermediate and dirty

areas of the facility.

Abatement The necessary pieces of environmental abatement equipment at the facility are the biofilter and the silt trap and proposed interceptor. Biofilter An open-vessel biofilter system consisting of a media bed containing contaminant degrading microorganisms, a media support structure, a foul air distribution system, and a sprinkler system method of controlling the biofilter moisture content is in place at the facility. The media can consist of various materials including soil, woodchip, peat, compost, sand or synthetic material (plastic packing material). Typically, the foul airstream to be treated is distributed over the bottom of the biofilter bed and forced upward through the media. The moist filter media provides physical and chemical conditions appropriate for the transfer of the contaminants from the vapour phase and supports microbial biodegradation of the adsorbed and absorbed contaminants. A full specification of the biofilter is attached to this section. Figure 1 below is a simplified schematic of Waddock Composting Facility’s biofilter.

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Attachment D


Figure 2 - Biofilter Schematic

A foul airstream containing biodegradable organic and inorganic odorous compounds passes through an air-distribution system underneath the filter medium. The air piping system is set on cement blocks to raise it off the ground so the air can be evenly distributed under the pipe. A medium such as chip wood with a particle size up to 100mm is spread loosely and evenly over the air distribution system. The old woodchip is screened along with the new woodchip at a rate of 4:1 through a 12mm trommel and the >12mm woodchip is placed around the pipes up to a height of 1.5m and then the 0 – 100mm is placed to the full height of 3m. By mixing the new with the old woodchip, reintroduction of the bacteria into the new media bed takes place. The media provides an environment for microorganisms that biologically degrade the odorous compounds. Interceptor It is proposed to install a Class 1 Full Retention Interceptor at the facility the details of which are attached labelled “Interceptor Data Sheet”. The proposed location of this is detailed in Drawing 2 attached.

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Attachment D


Ancillary Processes Traffic Control A traffic management system is in place at the facility. All vehicles enter and exit the facility

via the main entrance facility which is outlined in Drawing 6 above. Due to the location of the

site entrance there is sufficient vehicle queuing space for all vehicles.

A speed limit of 10km/hr is in place at the facility. Vehicles are directed to the tipping area by

the weighbridge operative who control the volume of vehicles to each of the buildings.

All Other Services

Other services at the facility include ESB which is supplied from the National Grid Network.

Water is supplied to the facility from the mains. Rain water is also harvested on site.

A telecommunications service is set up at the facility offices. This enables external

communications to be made by phone, fax or email.

Site Accommodation On-site accommodation includes facility offices, welfare facilities and a staff canteen as

outlined in the site layout plan Drawing 1.

Fire Control System A system for fire control is in place at the facility. Fire extinguishers are placed at fire point

locations throughout the facility and are serviced on an annual basis (or as used) by an

external contractor. All staff are trained in fire safety.

Fire fighting water retention tanks have been installed at the facility. These tanks are concrete

tanks with a capacity of 13,948 gallons per tank. Two tanks have been installed at the facility

giving a total of 27,896 gallons of available water that can be used for fire fighting in the event

of a fire at the facility.

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Attachment D


D.2 Additional requirements for waste Activities (not covered above or elsewhere) (All Class 11

of the First Schedule of the EPA Act 1992, as amended)

D.2.1 Wastes to be accepted

The maximum annual tonnage of waste to be handled at the site and the year to which the quantity

relates is indicated as follows:

Maximum Annual Tonnage (tonnes) 24,900

Year 2015

Table 3. Attachment D.2 details the waste types to be accepted

EWC Code

Waste Description Waste description

Tonnes per annum (2013)

Tonnes per annum (2014)

Tonnes per annum Proposed 02 01

Wastes from agriculture, horticulture, aquaculture, forestry, hunting and fishing.

(the actual description of the waste, not the text accompanying the EWC code)

02 01 01 Sludges from washing and cleaning

Washings 64.56 0 100

02 01 02 Animal tissue waste 20

02 01 03 Plant tissue waste 20

02 01 05 Animal faeces, urine and manure (including spoiled straw), effluent 780

02 01 07 Waste from forestry 20

02 02

Wastes from the preparation and processing of meat, fish and other foods of animal origin

02 02 01 Sludges from washing and cleaning 20

02 02 02 Animal tissue waste 20

02 02 03 Materials unsuitable for consumption or processing 20

02 02 04 Sludges from on-site effluent treatment

Factory Sludge 1,399.78 1129.44 20

02 02 99 Wastes not otherwise specified Monashell 3.04 10

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Attachment D


02 03

Wastes from fruit, vegetables, cereals, edible oils, cocoa, coffee, tea and tobacco preparation and processing; conserve producton; yeast and yeast extract production, molasses preparation and fermentation

02 03 01 Sludges from washing, cleaning, peeling, centrifuging and separation 20

02 03 04 Materials unsuitable for consumption or processing

Fruit & Veg 81.8 0 100

02 03 05 Sludges from on-site effluent treatment 20

02 03 99 Wastes not otherwise specified 20

02 04 Wastes from sugar processing

02 04 03 Sludges from on-site effluent treatment 20

02 05 Wastes from the dairy products industry

02 05 01 Materials unsuitable for consumption or processing (from dairy industry)

Whey/Milk Products

100.18 68.12 150


Dairy Sludge 95.72 30.6 50

02 06 Wastes from the baking and confectionary industry

02 06 01 Materials unsuitable for consumption or processing (from baking and confectionary) 20


Factory Sludge 760.28 1360.32 1200

02 07 Wastes from the production of alcoholic and non-alcoholic beverages

02 07 01 Wastes from washing, cleaning and mechanical reduction or raw materials 20

02 07 02 Wastes from spirit distillation Brewers Grain 163.04 190.94 200

02 07 04 Materials unsuitable for consumption or processing

Kieseluhr 42.86 0 50


Distillation Sludge 0 13.46 100

02 07 99 Waste not otherwise specified 20

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Attachment D


03 01 Wastes from wood processing and the production of panels and furniture

03 01 01 Waste bark and cork 20

03 01 05 Sawdust, shavings, cuttings, wood, particle board and veneer 20

03 03 Wastes from pulp, paper and cardboard production and processing

03 03 01 Waste bark and wood 20

03 03 05 De-inking sludges from paper recycling 20

03 03 08 Wastes from sorting of paper and cardboard destined for recycling 20

03 03 11 Sludges from on-site effluent treatment other than those mentioned in 03 03 10 20

04 02 Wastes from the textile industry

04 02 10 Organic matter from natural products (for example grease, wax) 20


07 05 Wastes from the MFSU of chemicals


07 05 14 Solid wastes other than those mentioned in 07 05 13 20


15 01 Packaging (including separately collected municipal packaging waste)

15 01 03 Wooden Packaging 20

1502 Absorbents, filter materials, wiping cloths and protective clothing

15 02 03 Absorbents, filter materials, wiping cloths and protective clothing 20

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Attachment D


17 02 Wood, glass and plastic

17 02 01 Wood 20

19 02 Waste from the physico/chemical treatment of wastes

19 02 06 Sludges from physico/chemical other than those mentioned in 19 02 05

20

19 06 Wastes from the anaerobic treatment of waste

19 06 06 Digestate from anaerobic treatment of animal and vegetable manure 20

19 08 Wastes from water treatment plants not otherwise specified

19 08 05 Sludges from treatment of urban waste water

Sewer Sludge 1,958.72 1127.66 20

19 08 09 Grease and oil mixture from oil/water separation containing only edible oil and fats

Sludge 220.3 150.92 200


19 09

Wastes from the preparation of water intended for human consumption or water from industrial use

19 09 01 Solid waste from primary filtration and screenings 20

19 09 02 Sludges from water clarification Alumn Sludge 1,641.26 1975.96 1200

19 09 04 Spent activated carbon Sludge 20

19 12 Wastes from the mechanical treatment of waste not otherwise specified.

19 12 07 Wood other than those mentioned in 19 12 06 600

19 12 12

Other wastes (including mixtures of materials) from mechanical treatment of waste other than those mentioned in 19 12 11 20

20 01 Seperately collected fractions

20 01 01 Paper and Cardboard 20

20 01 08 Biodegradable kitchen and canteen waste

Food Waste 10,978.81 15,388.30 18500

20 01 25 Edible oil and fat Grease Trap 392.02 593.06 800

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20 02 Garden and park waste

20 02 01 Biodegradable waste (garden and park wastes)

Green waste 18.18 4.4 100

20 03 Other municipal wastes

20 03 01 Mixed municipal waste 0 0 20

20 03 04 Septic tank sludge Septic Sludge 2.4 8.36 20

TOTAL 17922.95 22041.54 24900

Certain wastes to be accepted are classified as animal by-products in accordance with Regulation

1069/2009.

The following table 4 shows the waste types to be accepted at the facility which are classified as animal by-products:

Table 4: Waste types to be accepted at the Facility which are classified as ABP

Waste Description

EWC Code

ABP

Designation

Hazardous

Waste (Yes or

No)

Food Waste 20 01 08 Yes No

Animal Tissue Waste 02 01 02 Yes No

Animal faeces, urine and manure

(including spoiled straw), effluent

02 01 05 Yes No

Sludges from Washing and Cleaning 02 02 01 Yes No

Animal Tissue Waste 02 02 02 Yes No

Materials unsuitable for consumption or processing

02 02 03 Yes No

Sludges from onsite effluent treatment 02 02 04 Yes No

Dairy Sludge 02 05 02 Yes No

Whey/Milk Products 02 05 01 Yes No

Mixed Municipal Waste 20 03 01 Yes No

Other wastes (including mixtures of materials) from mechanical treatment of waste other than those mentioned in 19 12 11

19 12 12 Yes No

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Attachment D


D.2.2 Waste Acceptance All materials are accepted at the facility in accordance with the Waste Acceptance Procedure

SOP#1 attached and the Procedure for Facility Operation and Efficient Process Control SOP#2

attached in Section C. Prior to entry to the waste buildings details of the load are recorded on

the weighbridge docket, including vehicle registration, waste type, EWC code, date, time,

haulier, customer and the gross weight of the load. Once these details have been recorded

and an initial waste inspection is carried out, the driver is directed to the correct tipping area

for the particular waste type.

Once the waste has been tipped in the waste inspection area, has been subject to inspection

and considered to be acceptable the driver is directed back onto the weighbridge for second

weighing after the vehicle has been washed. Once the vehicles un-laden weight is recorded a

nett weight is generated, a ticket is printed. Tickets for all loads are printed on quadruplicate

dockets. One copy is given to the driver, one is retained for invoicing and one is placed in the

Batch Profile Folder as records for inspection from regulatory bodies such as the County

Council; Department of Agriculture, Fisheries and Food or the EPA. The fourth copy is placed

into a separate folder for future reference once all the necessary logs have been completed.

If a load arrives at the facility which is deemed to contain unacceptable material, the load is

not accepted and is rejected at the gate to the facility.

Where a load has been tipped and non-conforming materials are found to be present in the

load, the non-conforming material is reloaded and is removed off-site to an appropriately

licenced treatment facility as soon as practicable. The supplier of the non-conforming waste

is informed.

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Attachment D


D.2.3 Waste and material outputs from waste activities

Waste Outputs

The following residual waste outputs are generated at the facility and account for approximately

12% of the overall intake tonnage. Currently, the residual waste is sent to Powerstown Landfill or

Drehid Landfill.

Table 5: Residual Waste Outputs

Waste Description

EWC Code

Hazardous

(Yes or No)

Non Composted Fraction 19 05 01 No

Overs 19 05 99 No

Sewer Sludge Removed 19 08 05 No

Catering Waste Returned 20 01 08 No

Material Outputs

Approximately 88% of the output from the facility is high-quality compost material for agricultural,

horticultural, landscaping and gardening markets.

The requirements of article 28 of the European Communities (Waste Directive) Regulations 2011

are addressed as follows:

The end product produced at the facility is in strict compliance with the Compost Quality Standard

set out in the waste facility permit which states:

No sample shall exceed 1.2 times the quality limit values set. The following criteria (where they apply to compost) are

deemed a quality standard for the use of compost as a soil improver and should not be deemed as criteria for fertiliser.

In addition N, P, K, NH4-N, NO3-N, pH and dry matter content should also be measured.

A. Compost Maturity

The state of the curing pile must be conducive to aerobic biological activity.

Compost shall be deemed to be mature if it meets two of the following groups of requirements or other maturity test

as may be agreed by the Council:

1. Specific Oxygen Uptake Rate < 13 mmol O2/kg OS/h (Bord Na Mona Test Method)

2. Compost will not re-heat upon standing to greater than 20 oC above ambient temperature and compost must

be cured for at least 21 days.

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Attachment D


Compost from Stabilised Biowaste, with non source segregated biowaste feedstock, shall meet the following

requirement:

1. AT4 test value of <10 mg O2/g DM

B. Trace Elements Concentration Limits (notes 1,2,3,7)

Parameter (mg/kg, dry mass) Compost Quality StandardsNote 5 Stabilised Biowaste Note 5

Class 1 Class 2

Cadmium (Cd) 0.7 1.5 5

Chromium (Cr) 100 150 600

Copper (Cu) 100 150 600

Mercury (Hg) 0.5 1 5

Nickel (Ni) 50 75 150

Lead (Pb) 100 150 500

Zinc (Zn) 200 400 1500

PolyChlorintated Biphenyls (PCB’s) - - 0.4

Polynuclear Aromatic Hydrocarbons (PAH’s) - - 3

Impurities >2mm Note 6 <0.5% <0.5% <3%

Gravel and Stones >5mm Note 6 <5% <5% -

Note 1: These limits apply to the compost just after the composting phase and prior to mixing with any other materials.

Note 2: Incoming sludges (other than sewage sludges) shall be monitored quarterly (on a client by client basis) for the

parameters outlined in this table in addition to Selenium (Se) and Molybdenum (Mo).

Note 3: Monitoring of Arsenic (As) is required if waste timber is used in the composting process.

Note 4: The above alone should not be taken as an indication of suitability for addition to soil as the cumulative metal

additions to soil should be first calculated.

Note 5: Normalised to 30% organic matter content

Note 6: Compost must not contain any sharp foreign matter measuring over a 2 mm dimension that may cause damage

or injury to humans, animals and plants during or resulting from its intended use.

Note 7: Standards from Working Document on Biological Treatment of Biowaste, second edition 2001.

C. Pathogens

Each compost batch shall be monitored to ensure compliance with the following:

Pathogenic organism content must not exceed the following limits:

Salmonella sp. Absent in 25g n=5

Faecal Coliforms 1000 Most Probable Number (MPN) in 1g n=5

Where: n = Number of samples to be tested.

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Attachment D


Faecal coliforms should be sampled after the pasteurisation process.

D. Other Test Requirements

Where sewage sludge is part of the compost feedstock, and compost will be landspread, the test requirements outlined

in the following document are required: “Code of Good Practice for the use of Biosolids in Agriculture” DEHLG.

Where bio-stabilised waste is to be deposited at landfill it must meet the following standards:

Offensive odours are minimised and that the Respiration Activity after four days (AT4) is <10 mg O2/g DM (until 1-1-

2016), and <7 mg O2/g DM thereafter.

One test is required every 1,000 tonnes of stabilised biowaste.

In the event that there is an inadequate supply of biodegradable waste for composting Waddock

Composting Facility Ltd. proposes to accept MSW for drying/stabilisation. This material will be

handled in the exact same manner as the biodegradable waste and will be subject to the same

‘composting’ processes. There will be no mixing of this waste type and biodegradable waste in the

tunnels. Following stabilisation the compost like output (fines) will be screened from the bulk

material and used for landfill engineering. The residual fraction will be sent off site for manufacture

into Solid Recovered Fuel (SRF) or Refuse Derived Fuel or possibly for landfill. Because Waddock

Composting Facility Ltd has three waste acceptance bays the two waste streams can be accepted

without crossover and should Waddock Composting Facility Ltd. propose to accept MSW they will

provide a storage plan to the Agency prior to acceptance. This will detail where and how the

material will be stored prior to being stabilised and will also detail how the products from this

process will be stored on site prior to removal.

D.2.4 Principles of self-sufficiency and proximity

Waddock Compost Facility Ltd. is committed to the recycling of organic waste from all sources

including Household, Commercial and Industrial, and where appropriate Construction and

Demolition. Waddock Compost Facility Ltd. wishes to utilise its state of the art technology to

capacity and therefore requires an Industrial Emissions Licence to reflect the classes of waste

activity proposed. By doing this WCFL will contribute significantly to the national composting

tonnage capacity available to waste operators necessary to enable the diversion of biodegradable

waste from landfill.

This will contribute to Ireland’s efforts to meet EU targets of biodegradable municipal waste

(BMW) accepted at landfill for disposal as set out by the EU Landfill Directive (1999/31/EC).

The EU Landfill Directive (1999/31/EC) prescribes a staged reduction in the quantities of

biodegradable municipal waste (BMW) allowed to landfill.

The Landfill Directive imposes restrictions on the consignment of certain wastes to landfill. Landfill

operators must demonstrate that all waste accepted has been subjected to pre-treatment

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Attachment D


effective from 16th July 2009 for facilities commenced since 16th July 2001. Article 5 of the

Directive sets mandatory targets for diversion of biodegradable municipal waste (BMW) from

landfill. It is now mandatory to reduce biodegradable municipal wastes (BMW) going to landfill to

35% of the total amount (by weight) that was produced in 1995 (427,000t) by 2016. An assessment

of risk carried out by the EPA in 2012 has found that Ireland is at risk of not meeting these statutory

obligations. The report also anticipates that municipal waste arising’s will increase by 825,000

tonnes (to 3.7m tonnes) within the next 15 years and found that; “the predicted growth of

municipal waste within the coming decade will necessitate investment in waste management

infrastructure”. The report also highlighted the need for much more rapid progress in the

provision of sustainable alternatives.

This subject development will provide a vital cog in the wheel of Ireland achieving these

mandatory targets by continuing to provide a processing facility for biodegradable material that

can be accepted for composting and treatment at the facility. Policy documents from the EU such

as ‘The Resource Efficiency Roadmap’ and the Governments document ‘A Resource Opportunity-

Waste Management Policy in Ireland’ highlight a sea change in opinion which now views BMW as

a valuable resource with a huge economical potential. They highlight that Ireland must also now

plan more fundamentally for alternative approaches that will allow us to effectively eliminate our

use of landfill within the next decade. The proposed development will contribute some of the

necessary infrastructure required to do this. Through the recycling and composting of organic

material at the subject development far more productive products (such as compost) are created

then would be the case if the facility did not exist and the material was simply landfilled.

Despite this looming landfill deadline of 2016 the recovery and recycling of organic waste in

Ireland is currently well below par. While the most pressing immediate driver must remain

compliance with the landfill Directive limits, the DEHLG policy document Waste Management

Policy in Ireland 2012 states that; ‘Ireland must also now plan more fundamentally for alternative

approaches that will allow us effectively to eliminate our use of landfill within the next decade’.

If permitted the subject proposal will recycle up to 24,900 tonnes of biodegradable waste and as

such will become an important player in helping to meet Ireland’s diversion targets and

requirement for progressive waste management infrastructure.

The location of the proposed development adjacent to the M9 Dublin to Waterford Motorway on

the Carlow Kildare border has the following advantages;

The existing land use policies for the site support the development of the subject

application and subsequently there are no non-conforming land uses immediately

surrounding the site. Most importantly the subject site is fundamentally suitable for

the location of the proposed development.

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Attachment D


It is in close proximity to a large customer base, both from the South East Region and

from the Greater Dublin Area. The proximity (ca. 6km) of the M9 Dublin to Waterford

motorway means ease of access from significant customer base.

Its location on the site of the existing facility will mean that existing infrastructure can

be utilised to maximum capacity without the need for major structural development.

The existing site already has good quality infrastructure in place such as roads, services

(water and foul sewers), and telecommunications to support the subject

development.

There is no requirement for any additional construction at the facility.

Figure 3: Site Location

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Redwood Systems Operations & Technical Manual for

Waddock Composting Facility,

Killamaster,

Co. Carlow

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Contents Computer Operations ........................................................................................................................................................... 3

PLC Wiring .......................................................................................................................................................................... 24

PLC Input/Output List ...................................................................................................................................................... 31

Technical Data .................................................................................................................................................................... 36

Performance of Composting System at Waddock Composting, Killamaster, Co. Carlow ................................................... 37

Aeration System .......................................................................................................................................................... 37

Extraction System ........................................................................................................................................................ 37

Ventilation System ...................................................................................................................................................... 37

Bio Filter ...................................................................................................................................................................... 38

Scrubber...................................................................................................................................................................... 39

Overview of the Aeration and Extraction Systems of the Six tunnels. ........................................................................... 40

Fan Performance Data ........................................................................................................................................................ 41

List of Parts ......................................................................................................................................................................... 43

Aeration System .............................................................................................................................................................. 44

Extraction System ........................................................................................................................................................... 44

Ventilation System .......................................................................................................................................................... 44

Scrubber ......................................................................................................................................................................... 44

Dampers ......................................................................................................................................................................... 44

Probes............................................................................................................................................................................. 44

Control System ................................................................................................................................................................ 45

PLC Software ................................................................................................................................................................... 45

PLC Card Layout .............................................................................................................................................................. 46

Drawings ............................................................................................................................................................................. 47

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Computer Operations

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On start up of the CitectScada system, this is the screen that you are presented with which is called the Overview. This will give you the basic information on the performance of each bay; the inlet fan speed, the position of the damper, the controlling temperature of that bay and the outlet fan speed. On the bottom of the screen you are presented with 8 options which will give you further details on the control and management of the system. To access any of these you must have a Log In username and password.

OVERVIEW

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This view gives a detailed description of each bay. From here you have full access and control to the running of the system. You can turn the motors on or off; change the speed of the motors, the position of the dampers and whether to run the system in manual or automatic. This is where you would enter the starting parameters for the automatic sequence (explained in Parameters).

PRODUCTION UNITS

Click here to change damper position

Click here to change motor speed

Pile number displayed here

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To change anything in this section simply click on the item and, if it is amendable, you will be presented with a pop up window. For example if you are changing the position of the damper and you will be asked at what percentage you wish the damper to be open. Enter the number on the key pad and the damper will move to that position. Note: If a Bay is running in automatic you can still override the parameters in manual mode.

PRODUCTION UNITS

Click here to alter between manual and auto

Click here to enter parameters for automatic sequence

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To create a new pile number click on one of the boxes as shown above. Once you click New Pile No. it is generated and stored in the database. The pile numbers are generated automatically in sequence. You can enter all the relevant information about that pile here i.e. description, screening date, mixing date etc. To move the pile from area to area click on the Target, select where you would like it moved to and click “move pile”. NB When making any changes ensure to press save pile.

Click here to enter information for a pile number.

Invoice no/ weighbridge no. goes here.

Description of product

Click here to generate a new pile number.

PRODUCTION UNITS

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A batch number is generated only in the ABP bays and is done so automatically as soon as the auto sequence is started.

PRODUCTION UNITS

Batch number generated in auto cycle on ABP bays.

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When an alarm is generated a detailed list appears in the Alarms section. From here you can see what and where the alarm is. To acknowledge an alarm double click it and it will turn a deeper red. Anything not acknowledged will remain a brighter orange colour. The alarm will continue to generate however, if the problem has not been resolved. A full history of alarms will continue to store here and can be viewed at any time

ALARMS

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At any time you can view the trend history of the bays. You will be presented with a split screen which will enable you load the information from 2 different bays, the same bay at different time intervals etc.

TRENDS

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By clicking on the folder as shown above you will be presented with a list of pre defined Bay trends containing all relevant parameters for that bay. The subsequent graph that is displayed is shown in real time with a default display of 10 minutes.

TRENDS

Click here to open up the pop up box shown

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TRENDS

Click here to manually enter probes/alarms

Click here to show the individual information boxes (in yellow)

Moving this time line will give you a detailed description of the time interval selected.

Time interval displayed here

Click here to manually enter dates and times

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When you choose the automatic mode you will be asked to enter a set of parameters for that sequence. On the first page a list of default operating limits for the inlet motor speeds will be on your left. Under that you have the option of setting offsets to the outlet speed for that production unit and damper for that bay. On the right is displayed the current Bay and 3 options. To change the set enter the appropriate bay and click Read Set. When you click the following pages the parameters for that bay can be seen. If you make any changes to the parameters for a Bay you must click Save Set to save them. Warning! By clicking Clear Set you will erase all parameters for that bay.

PARAMETERS

Default motor operating limits

Outlet and Damper offsets

Current Bay parameters

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On the second page of the Parameters you will have an option of delaying the automatic start up in days, hours and minutes. You also have further options; to start on the delayed time entered only, or to start when either the delay time had expired or the product has reached a certain temperature.

Enter start up delay here

Enter temperature delay here

PARAMETERS

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On the third page of the Parameters you have the option of selecting the motor speeds for each temperature zone reached. In this example only one zone is displayed which instructs the fan to operate at 1250rpm up to a temperature of 15⁰C. If the temperature rises above this a further automatic sequence will begin (settings for which are on the next page). You can choose up to 5 different zones. For instance zone 2 could be: up to 25⁰C run at 1500rpm, zone 3 could be: up to 30⁰C run at 1750rpm and so on. Once the temperature rises above the last zones settings, the automatic sequence will follow on to the next step.

Enter cycle and duty times here

Choose number of zones here

Enter temperature and rpm settings here

PARAMETERS

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You have a further option of having the fan come on for set periods of time and then off again by utilising the cycle/duty option. If Always On is selected the fan will remain on for the duration of the sequence. If Timed is selected then the fan will still follow the auto sequence however it can be configured to only come on for say 10 minutes and off for 50 minutes. It will continue to do this repeatedly until deselected.

PARAMETERS

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On the fourth page of the Parameters is where you can specify the system to process at specific times and temperatures, and within a certain range of motor speeds. In the process duration enter the temperature you would like the product to process at and the length of time which it is to be processed for; for example 70C for 1 hour.

PARAMETERS

Enter temperature and time settings here

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On the final page of the Parameter settings you have the option of a shutdown delay. This refers to the shutdown of the automatic sequence so you still have the option of keeping the motors running after a sequence has finished as specified in the previous page. You can enter a time delay in days, hours and minutes and the rpm at which it is to run at when shutdown happens. You have a further 3 options on how it shuts down: Delay only will shut down on the specified time only; Delay or Temp will shut down on either the specified time or when a specific temperature has been reached; Delay or Temp and Maintain will shut down on delay or when a specific temperature has been reached and will maintain that temperature. Note: Remember to Save Set when changing any parameter.

Enter time delay and rpm settings here

Enter temperature and time delay settings here

PARAMETERS

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In the Engineering page this is where the operating limits for the outlet fan are. This is also where you can set the temperature and time parameters for the pasteurisation zone.

Engineering

Set pasteurisation parameters here

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When an automatic cycle has finished, a detailed description of that cycle is stored in the History database. By using the system manually the relevant information for each pile is also available however it will have to be obtained manually e.g. searching for the appropriate trend time frame.

HISTORY

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HISTORY

Click here to transfer data to Selected Record

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For example locate the pile number you want in the list. Click on the box next to the pile number and it will highlight that line. Now click on download and all the information for that process will be loaded into the Selected Record on the left, as shown above. By clicking on the arrow pointing to each process and selecting process temp or pasteurisation temp, a trend is automatically generated for that process.

Click here to highlight a particular process

HISTORY

Indicates if process parameters have been met as defined in Engineering.

Select either one to display the trends for that period.

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By selecting either process or pasteurise for a particular bay you will be presented with the screen above. All information about that pile number including the trend for that chosen period is displayed.

HISTORY

Trend showing the time period for the process highlighted.

Description of everything for that pile contained on the chart

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PLC Wiring

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TERMINAL BLOCK 1

1

ABP1 Inlet Fan Running 49

High level scrubber

2

ABP1 Inlet Fan Tripped 50

Low level scrubber

3

ABP1 Inlet Fan Hand

51

Not Used

4

ABP1 Inlet Fan Auto

52

Not Used

5

ABP1 Inlet Fan E Stop 53

Not Used

6

ABP1 Outlet Fan Running 54

Not Used

7

ABP1 Outlet Fan Tripped 55

Not Used

8

ABP1 Outlet Fan Hand 56

Not Used

9

ABP1 Outlet Fan Auto 57

Not Used

10

ABP1 Outlet Fan E Stop 58

Not Used

11


Not Used

12


Not Used

13

ABP2 Inlet Fan Hand

61

Not Used

14

ABP2 Inlet Fan Auto

62

Not Used

15


Not Used

16


Not Used

17


ABP1 Inlet Run

18


ABP1 Inlet Reset 19


ABP1 Inlet Leache Valve

20


ABP1 Outlet Run 21


ABP1 Outlet Reset

22


ABP1 Outlet Leache Valve 23

ABP3 Inlet Fan Hand

71

ABP2 Inlet Run

24

ABP3 Inlet Fan Auto

72

ABP2 Inlet Reset 25



26


ABP2 Outlet Run 27


ABP2 Outlet Reset

28


ABP2 Outlet Leache Valve 29


ABP3 Inlet Run

30


ABP3 Inlet Reset 31



32


ABP3 Outlet Run

33

ABP4 Inlet Fan Hand

81

ABP3 Outlet Reset 34

ABP4 Inlet Fan Auto

82

ABP3 Outlet Leache Valve

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35


ABP4 Inlet Run 36


ABP4 Inlet Reset

37


ABP4 Inlet Leache Valve 38


ABP4 Outlet Run

39


ABP4 Outlet Reset 40


ABP4 Outlet Leache Valve

41

Vent 1 open selector

89

Ventilation local/remote lamp

42

Vent 2 open selector

90

Scrubber pump Run

43

Ventilation VSD speed1 91

Scrubber pump Reset

44


Not Used

45


Not Used

46

Ventilation local/remote button 94

Not Used

47

Scrubber pump running 95

Not Used

48

Scrubber pump tripped 96

Not Used

1 97

Bio Filter Damper 1

98

Bio Filter Damper 2 99

Bio Filter Damper 3

100

Bio Filter Damper 4 101

Bio Filter Damper 5

102

Not Used 103

Not Used

104

Not Used 105

Not Used

106

Not Used 107

Not Used

108

Not Used 109

Not Used

110

Not Used

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TERMINAL BLOCK 2

1

41

0V

2

42

24V Inlet Damper Bay 4 3

43

I+

4

44

COMM 5

45

0V

6

46


47

I+

8

48

COMM 9

49

0V

10

50


51

I+

12

52

COMM 13

53

0V

14

54

24V

Not Used

15

55

I+ 16

56

COMM

17

57

0V

18

58

24V Not Used

19

59

I+ 20 0 - 24V DC

60

COMM

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

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TERMINAL BLOCK 3

White(+)/Red/Red - [Wire from white connector in probe head to be wired to 1st slot (closest to back plate).

Red terminals in slots 2 and 3

1

PT 100 Bay1 PT100 1 49 0V

2

PT 100 Bay1 PT100 2 50 24V Outlet Damper Bay 5

3

PT 100 Bay2 PT100 1 51 I+ 4

PT 100 Bay2 PT100 2 52 COMM

5

PT 100 Bay3 PT100 1 53 0V

6

PT 100 Bay3 PT100 2 54 24V Outlet Damper Bay 6

7

PT 100 Bay4 PT100 1 55 I+ 8


9

PT 100 Bay5 PT100 1 57 0V

10

PT 100 Bay5 PT100 2 58 24V Ventilation Damper 1

11

PT 100 Bay6 PT100 1 59 I+ 12


13

PT 100 ABP1 PT100 1 61 0V

14

PT 100 ABP1 PT100 2 62 24V Ventilation Damper 2

15

PT 100 ABP1 PT100 3 63 I+ 16

PT 100 ABP1 PT100 4 64 COMM

17

PT 100 ABP1 PT100 5 65

0V

18

PT 100 ABP2 PT100 1 66

24V ABP1 Inlet Fan Speed

19

PT 100 ABP2 PT100 2 67

I+ 20

PT 100 ABP2 PT100 3 68

COMM

21

PT 100 ABP2 PT100 4 69

0V

22

PT 100 ABP2 PT100 5 70


23

PT 100 ABP3 PT100 1 71

I+ 24

PT 100 ABP3 PT100 2 72

COMM

25

PT 100 ABP3 PT100 3 73

0V

26

PT 100 ABP3 PT100 4 74


27

PT 100 ABP3 PT100 5 75

I+ 28

PT 100 ABP4 PT100 1 76

COMM

29

PT 100 ABP4 PT100 2 77

0V

30

PT 100 ABP4 PT100 3 78


31

PT 100 ABP4 PT100 4 79

I+ 32

PT 100 ABP4 PT100 5 80

COMM

33 1 black 0V

81 0V

34 2 Red 24V Outlet Damper Bay 1 82 24V ABP1 Outlet Fan Speed

35 3 white I+

83 I+

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36 5 orange COMM

84 COMM

37 0V

85

0V

38 24V Outlet Damper Bay 2 86

24V ABP2 Outlet Fan Speed

39 I+

87

I+ 40 COMM

88

COMM

41 0V

89

0V



43 I+

91

I+ 44 COMM

92

COMM

45 0V

93

0V



47 I+

95

I+ 48 COMM

96

COMM

4 97

0V

98


I+

100

COMM 101

0V

102


I+

104

COMM 105

0V

106


I+

108

COMM 109

E

110

U 111

V Scrubber Pump

112

W 113

U

114

V 3F15 115

W

116

U 117

V 2F15

118

W 119

U

120

V 1F15 121

W

122

U 123

V 1F22

124

W 125

U

126

V 1F37

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127

W 128

N

129

E

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PLC Input/Output List

Digital Inputs Rack Slot Channel

0 2 0 X40 ABP1_IF_RUN ABP1 Inlet Fan Running 1 X41 ABP1_IF_TRIP ABP1 Inlet Fan Tripped 2 X42 ABP1_IF_HAND ABP1 Inlet Fan Hand

3 X43 ABP1_IF_AUTO ABP1 Inlet Fan Auto 4 X44 ABP1_IF_ESTOP ABP1 Inlet Fan E Stop

5 X45 ABP1_OF_RUN ABP1 Outlet Fan Running 6 X46 ABP1_OF_TRIP ABP1 Outlet Fan Tripped 7 X47 ABP1_OF_HAND ABP1 Outlet Fan Hand 8 X48 ABP1_OF_AUTO ABP1 Outlet Fan Auto

9 X49 ABP1_OF_ESTOP ABP1 Outlet Fan E Stop A X4A ABP2_IF_RUN ABP2 Inlet Fan Running B X4B ABP2_IF_TRIP ABP2 Inlet Fan Tripped C X4C ABP2_IF_HAND ABP2 Inlet Fan Hand

D X4D ABP2_IF_AUTO ABP2 Inlet Fan Auto E X4E ABP2_IF_ESTOP ABP2 Inlet Fan E Stop

F X4F ABP2_OF_RUN ABP2 Outlet Fan Running

0 3 0 X50 ABP2_OF_TRIP ABP2 Outlet Fan Tripped 1 X51 ABP2_OF_HAND ABP2 Outlet Fan Hand

2 X52 ABP2_OF_AUTO ABP2 Outlet Fan Auto 3 X53 ABP2_OF_ESTOP ABP2 Outlet Fan E Stop 4 X54 ABP3_IF_RUN ABP3 Inlet Fan Running 5 X55 ABP3_IF_TRIP ABP3 Inlet Fan Tripped 6 X56 ABP3_IF_HAND ABP3 Inlet Fan Hand

7 X57 ABP3_IF_AUTO ABP3 Inlet Fan Auto 8 X58 ABP3_IF_ESTOP ABP3 Inlet Fan E Stop

9 X59 ABP3_OF_RUN ABP3 Outlet Fan Running A X5A ABP3_OF_TRIP ABP3 Outlet Fan Tripped

B X5B ABP3_OF_HAND ABP3 Outlet Fan Hand C X5C ABP3_OF_AUTO ABP3 Outlet Fan Auto D X5D ABP3_OF_ESTOP ABP3 Outlet Fan E Stop E X5E ABP4_IF_RUN ABP4 Inlet Fan Running F X5F ABP4_IF_TRIP ABP4 Inlet Fan Tripped

0 4 0 X60 ABP4_IF_HAND ABP4 Inlet Fan Hand 1 X61 ABP4_IF_AUTO ABP4 Inlet Fan Auto

2 X62 ABP4_IF_ESTOP ABP4 Inlet Fan E Stop 3 X63 ABP4_OF_RUN ABP4 Outlet Fan Running 4 X64 ABP4_OF_TRIP ABP4 Outlet Fan Tripped 5 X65 ABP4_OF_HAND ABP4 Outlet Fan Hand 6 X66 ABP4_OF_AUTO ABP4 Outlet Fan Auto

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7 X67 ABP4_OF_ESTOP ABP4 Outlet Fan E Stop 8 X68 VENT1_OPEN_SWITCH Vent 1 open selector

9 X69 VENT2_OPEN_SWITCH Vent 2 open selector A X6A VENT_FAN_SPD1 Ventilation VSD speed1

B X6B VENT_FAN_SPD2 Ventilation VSD speed2 C X6C VENT_FAN_SPD3 Ventilation VSD speed3 D X6D VENT_LOCAL_REM Ventilation local/remote button E X6E SCRUBBER_RUN Scrubber pump running F X6F SCRUBBER_TRIP Scrubber pump tripped

0 5 0 X70 SCRUBBER_HL High level scrubber 1 X71 SCRUBBER_LL Low level scrubber

2 X72

3 X73 4 X74 5 X75 6 X76 7 X77 8 X78

9 X79

A X7A

B X7B

C X7C D X7D E X7E

F X7F

Digital Outputs Rack Slot Channel

0 6 0 Y80 ABP1_INLET_FAN_RUN_CMD ABP1 Inlet Run 1 Y81 ABP1_INLET_FAN_RESET_CMD ABP1 Inlet Reset 2 Y82 ABP1_INLET_LEACHATE_VALVE ABP1 Inlet Leache Valve

3 Y83 ABP1_OUTLET_FAN_RUN_CMD ABP1 Outlet Run 4 Y84 ABP1_OUTLET_FAN_RESET_CMD ABP1 Outlet Reset 5 Y85 ABP1_OUTLET_LEACHATE_VALVE ABP1 Outlet Leache Valve

6 Y86 ABP2_INLET_FAN_RUN_CMD ABP2 Inlet Run 7 Y87 ABP2_INLET_FAN_RESET_CMD ABP2 Inlet Reset 8 Y88 ABP2_INLET_LEACHATE_VALVE ABP2 Inlet Leache Valve

9 Y89 ABP2_OUTLET_FAN_RUN_CMD ABP2 Outlet Run

A Y8A ABP2_OUTLET_FAN_RESET_CMD ABP2 Outlet Reset B Y8B ABP2_OUTLET_LEACHATE_VALVE ABP2 Outlet Leache Valve

C Y8C ABP3_INLET_FAN_RUN_CMD ABP3 Inlet Run D Y8D ABP3_INLET_FAN_RESET_CMD ABP3 Inlet Reset E Y8E ABP3_INLET_LEACHATE_VALVE ABP3 Inlet Leache Valve

F Y8F ABP3_OUTLET_FAN_RUN_CMD ABP3 Outlet Run

0 7 0 Y90 ABP3_OUTLET_FAN_RESET_CMD ABP3 Outlet Reset

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1 Y91 ABP3_OUTLET_LEACHATE_VALVE ABP3 Outlet Leache Valve

2 Y92 ABP4_INLET_FAN_RUN_CMD ABP4 Inlet Run

3 Y93 ABP4_INLET_FAN_RESET_CMD ABP4 Inlet Reset 4 Y94 ABP4_INLET_LEACHATE_VALVE ABP4 Inlet Leache Valve

5 Y95 ABP4_OUTLET_FAN_RUN_CMD ABP4 Outlet Run 6 Y96 ABP4_OUTLET_FAN_RESET_CMD ABP4 Outlet Reset 7 Y97 ABP4_OUTLET_LEACHATE_VALVE ABP4 Outlet Leache Valve

8 Y98 VENT_LOCAL_REM_LAMP Ventilation local/remote lamp

9 Y99 SCRUBBER_RUN_CMD Scrubber pump Run

A Y9A SCRUBBER_RESET_CMD Scrubber pump Reset

B Y9B

C Y9C D Y9D E Y9E F Y9F

0 8 0 YA0 DAMPER_BIOFILTER1 Bio Filter Damper 1 1 YA1 DAMPER_BIOFILTER2 Bio Filter Damper 2

2 YA2 DAMPER_BIOFILTER3 Bio Filter Damper 3

3 YA3 DAMPER_BIOFILTER4 Bio Filter Damper 4 4 YA4 DAMPER_BIOFILTER5 Bio Filter Damper 5 5 YA5

6 YA6 7 YA7 8 YA8

9 YA9

A YAA

B YAB

C YAC D YAD E YAE F YAF

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PT100 Rack Slot Channel

1 0 1 D800 PT100_1PT1 Bay1 PT100 1 2 D801 PT100_1PT2 Bay1 PT100 2 3 D802 PT100_2PT1 Bay2 PT100 1 4 D803 PT100_2PT2 Bay2 PT100 2 5 D804 PT100_3PT1 Bay3 PT100 1 6 D805 PT100_3PT2 Bay3 PT100 2 7 D806 PT100_4PT1 Bay4 PT100 1 8 D807 PT100_4PT2 Bay4 PT100 2

1 1 1 D808 PT100_5PT1 Bay5 PT100 1 2 D809 PT100_5PT2 Bay5 PT100 2 3 D810 PT100_6PT1 Bay6 PT100 1 4 D811 PT100_6PT2 Bay6 PT100 2 5 D812 PT100_ABP1PT1 ABP1 PT100 1 6 D813 PT100_ABP1PT2 ABP1 PT100 2 7 D814 PT100_ABP1PT3 ABP1 PT100 3 8 D815 PT100_ABP1PT4 ABP1 PT100 4

1 2 1 D816 PT100_ABP1PT5 ABP1 PT100 5 2 D817 PT100_ABP2PT1 ABP2 PT100 1 3 D818 PT100_ABP2PT2 ABP2 PT100 2 4 D819 PT100_ABP2PT3 ABP2 PT100 3 5 D820 PT100_ABP2PT4 ABP2 PT100 4 6 D821 PT100_ABP2PT5 ABP2 PT100 5 7 D822 PT100_ABP3PT1 ABP3 PT100 1 8 D823 PT100_ABP3PT2 ABP3 PT100 2

1 3 1 D824 PT100_ABP3PT3 ABP3 PT100 3 2 D825 PT100_ABP3PT4 ABP3 PT100 4 3 D826 PT100_ABP3PT5 ABP3 PT100 5 4 D827 PT100_ABP4PT1 ABP4 PT100 1 5 D828 PT100_ABP4PT2 ABP4 PT100 2 6 D829 PT100_ABP4PT3 ABP4 PT100 3 7 D830 PT100_ABP4PT4 ABP4 PT100 4 8 D831 PT100_ABP4PT5 ABP4 PT100 5 Analogue Outputs

Rack Slot Channel 0 9 1 D900 DAMPER_BAY1 Outlet Damper Bay 1

2 D901 DAMPER_BAY2 Outlet Damper Bay 2 3 D902 DAMPER_BAY3 Outlet Damper Bay 3 4 D903 DAMPER_BAY4 Outlet Damper Bay 4 5 D904 DAMPER_BAY5 Outlet Damper Bay 5 6 D905 DAMPER_BAY6 Outlet Damper Bay 6 7 D906 DAMPER_VENT1 Ventilation Damper

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1

8 D907 DAMPER_VENT2 Ventilation Damper 2

0 10 1 D908 ABP1_INLET_FAN_SPEED ABP1 Inlet Fan Speed

2 D909 ABP2_INLET_FAN_SPEED ABP2 Inlet Fan Speed 3 D910 ABP3_INLET_FAN_SPEED ABP3 Inlet Fan Speed 4 D911 ABP4_INLET_FAN_SPEED ABP4 Inlet Fan Speed 5 D912 ABP1_OUTLET_FAN_SPEED ABP1 Outlet Fan Speed 6 D913 ABP2_OUTLET_FAN_SPEED ABP2 Outlet Fan Speed 7 D914 ABP3_OUTLET_FAN_SPEED ABP3 Outlet Fan Speed 8 D915 ABP4_OUTLET_FAN_SPEED ABP4 Outlet Fan Speed

0 11 1 D916 DAMPER_BAY7 Inlet Damper Bay 1 2 D917 DAMPER_BAY8 Inlet Damper Bay 2 3 D918 DAMPER_BAY9 Inlet Damper Bay 3 4 D919 DAMPER_BAY10 Inlet Damper Bay 4 5 D920 DAMPER_BAY11 Inlet Damper Bay 5 6 D921 DAMPER_BAY12 Inlet Damper Bay 6 7 D922

8 D923 Analogue Inputs

Rack Slot Channel 1 7 1 D1000 PHM1 PH Meter

2 D1001 3 D1002 4 D1003

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Technical Data

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Performance of Composting System at Waddock Composting, Killamaster, Co. Carlow

Regarding the installation at the Waddock Composting plant at the above address the performance data is outlined below:

Aeration System There are 3 fans fitted for the six aeration tunnels. They are a 15kw 3ph 2 pole motor and each fan aerates 2 bays. All three of these fans are manufactured from 304 2B stainless steel with material thickness ranging from 2.5mm to 5mm. They are of fully welded construction and are a heavy duty type.

These fans are all controlled with VFD’s so that the airflow can be controlled more effectively.

The VFD’s receive a temperature feedback from the probes in the bay and the speed of the blowers are controlled automatically from this feedback. So as the temperature within the bay varies, the speed of the blower varies. The temperature probes are fed back into the PLC control board and read by the PLC. This then sends a signal to the VFD and sets the correct speed. By diverting the signal through the PLC system, it gives a far greater degree of automation to the system.

Extraction System The main extraction fan is a 37kW fan extracting from all six tunnels. This fan is directly driven with a 37kw

3ph 4pole motor. This fan is manufactured from 304 2B stainless steel with material thickness ranging from

2.5mm to 5mm. It is of fully welded construction and a heavy duty type.

From the fan data sheet provided it can be seen that negative pressure will always be maintained within the building even at full capacity.

Ventilation System A single extraction fan is fitted which is directly driven with a 22kw 3ph 4pole motor. This fan is

manufactured from 304 2B stainless steel with material thickness ranging from 2.5mm to 5mm. It is of fully

welded construction and a heavy duty type. This fan is positioned close to the bio-filter.

This fan will be controlled via a VFD which will allow variable speeds to be set. Also included is a small

control panel that can be mounted out in the premises, housing two rotary switches to control this fan as

well. This has the advantage of been able to turn on and off the fan at different speeds without having to go

back to the PC. With the first rotary switch, for instance position 1 = 20% of max. airflow, position 2 =40% of

max etc. The second rotary switch will either open both dampers so that ventilation takes place from the

whole premises, or one damper is open and one damper closed so that ventilation can take place from

either the apex near the new bays or from above the existing bays.

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Bio Filter The bio-filter has been sized based on the maximum airflows from all three areas combined. Using a

retention time of 60seconds and a bio-filter media depth of 3 metres the required area is 300m2. The

drawing shows dimensions of 17.6 metres by 17 metres. Note: that is very unlikely that all systems will be at

full airflow simultaneously. It is also worth noting that if the bio-filter area is increased and the bed depth

reduces but keeping the volume the same, the kw required by the fans decreases.

The preferred filter medium is wood chip with no fines. In Irish weather conditions, we have found that the

introduction of fines tend, over time to compact and cause extra resistance on the fan and decrease the

airflow. Also by grading the wood chip, i.e. large chips at the bottom and smaller towards the top, leads to a

better distribution of air through the filter.

The filter has been designed to be sectioned off into three zones and it operates as follows.

When all three systems are in use, dampers 2 and 4 are closed and dampers 1, 3 and 5 are open. The full

biofilter is being used. As it in intended that the ventilation fan will not be on all the time it is proposed that

when it is off, that damper 3 will close and damper 2 will open, which will increase the biofilter area

available for the main extraction fan (37kw). It would result in a retention time of 100 seconds.

With regard to the centre biofilter section drying out due the air entering it from the ventilation fan, this fan

will usually only be used when steam is seen converging at the apex, which is a sign that the air is wet. More

importantly, bear in mind that this air goes through a scrubber, which it is scoured with water which will

greatly increase the humidity of the air leaving it. Additionally, as mentioned above, when the ventilation fan

is off this section of the bio-filter is automatically changed over to be used for the extraction of the six bays,

which is wet air and will keep the bio-filter moist, as well as increasing the retention time to 100 seconds.

For maintenance and media replacement ensure that the ventilation fan is off at all times. Section 2 can be

worked on.

With dampers 1, 3 and 4 closed and dampers 2 and 5 open, section 1 is diverted into section 2, and the 30kw

can operate up to 70% of airflow before the retention time of 60 seconds is exceeded. Section 2 can be

worked on.

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With dampers 2 and 3 closed, and dampers 1, 4 and 5 open section 3 is diverted into section 2, section 3 can

now be worked on.

In relation to the odour efficiency of the bio-filter, this is hard to quantify. Certainly having a 60 seconds

retention time when fans are operating at full speed is an excellent retention time. Also based on having

scrubbers preceding the bio-filter to remove the ammonia (which can break down the bio-filter and cause it

to stop working) and using our airflows, efficiency levels of 98-99% should be possible. Reported data

suggests efficiencies of greater than 99% are achievable with far less retention time. Basing calculations on

10,000OU/m3 on the air input, then assuming a 99% efficiency, a figure of 100OU/m3 would be the exhaust

air concentration.

Scrubber The scrubber that is installed is a wet scrubber. The main purpose of the scrubber is to reduce the levels of ammonia emissions.

The principles of operation are as follows:

Ammonia laden air enters the scrubber above the water table at the bottom.

Air nozzles spray high pressure water mist down through the scrubber and over two layers of scrubber packing media.

The ammonia impinges on these two layers of packing and the water mist as it passes up through the scrubber.

The water and ammonia fall into the water tank and the ammonia free air leaves through the top.

The sizes are designed to correspond with the associated fan airflow. Using a water medium with no additive

is very typical and will achieve results well in excess of 99%, even at ammonia concentration levels as high as

80ppm. By adding a small quantity of sulphuric acid to maintain a PH of about 8, even higher results are

obtained.

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Overview of the Aeration and Extraction Systems of the Six tunnels.

To achieve the desired results it is imperative that both the aeration system and the extraction system work

in harmony. For negative pressure to be achieved the combined maximum air flow of the three aeration fans

has to be less that the maximum airflow of the extraction fan. We have taken this into consideration in our

design and the fan performance data can be studied on the data sheet provided. It should also be noted that

it would be very rare that all three aeration fans would be operating at full speed (cooling mode) at the same

time.

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Fan Performance Data

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EPA Export 17-02-2015:23:10:40

18.5kw fan

2,700m3/hr @ 100pa. 2,850m3/hr @ 80pa. 2,420m3/hr @ 60pa.

37kw Main Extraction Fan.

22,100m3/hr @ 100pa.

25,500m3/hr @ 80pa. 27,200m3/hr @ 60pa. 28,900m3/hr @ 40pa.

22kw Ventilation Fan.

13,600m3/hr @100pa.

15,300m3/hr @ 80pa. 17,000m3/hr @ 60pa.

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EPA Export 17-02-2015:23:10:40

List of Parts

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EPA Export 17-02-2015:23:10:40

Aeration System

3 off 18.5kW 3ph 2 pole direct driven motors

Extraction System

1 off 37kW 3ph 4 pole direct driven motor

Ventilation System

1 off 22kW 3ph 4 pole motor

Scrubber

Lowara SHE 50-125/40/P Stainless Steel pump 1.5kW

Dampers

Belimo NM24A-SR 24VAC/DC

Probes

4 foot long PT100 3 wire probes, complete with handles

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EPA Export 17-02-2015:23:10:40

Control System

Control system is all Mitsubishi equipment consisting of the following;

1 off PLC Q series CPU module 1024/2048 I/0

Power base unit

Power supply unit

1 off serial input module

1 off serial output module

PT100 input modules

VFD’s input modules

VFD’s output modules

Series CC master link

CC link interface to each VFD

600 point server conn., serial driver

1 off 37kw VFD

1 off 22kw VFD

3 off 18.5kw VFD’s

1 off 24VDC 10A power supply

PLC Software

Mitsubishi GX Works

Citect Scada

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EPA Export 17-02-2015:23:10:40

PLC Card Layout

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Drawings

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EPA Export 17-02-2015:23:10:40

Redwood SystemsParkway Building,Whitestwon Ind Est,Tallaght,Dublin 24.Tel: 01-4596756; Fax: 01-4610452

Proposal For: Waddock Composting

Project: New Composting System

Drawn By: Fergus O'Brien

Date: 13-7-10

Scale: Not to scale

Reference: WC13710

Waddock Composting Civil holes in tunnel wall 11 off pipes per bay (500mm spacing)

hole size to suit 4" wavin

Centre line of bay

5822.5 mm

5522.5 mm

300.0 mm

500.0 mm

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EPA Export 17-02-2015:23:10:40

Redwood SystemsParkway Building,Whitestwon Ind Est,Tallaght,Dublin 24.Tel: 01-4596756; Fax: 01-4610452

Proposal For: Waddock Composting

Project: New Composting System

Drawn By: Fergus O'Brien

Date: 10-5-10

Scale: Not to scale

Reference: WC10510/6m

Waddock Composting Aerationfan for New bays

Flexible Duct Connection

Wavin Bend

Connection Spigot

Control dampers

5.5m bay 5.5m bay

11 off pipes per bay (500mm spacing)

5522.5mm 55225mm

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EPA Export 17-02-2015:23:10:40

BIOFILTER OPERATION & MAINTENANCE GUIDANCE 1

O P E R A T I O N A N D M A I N T E N A N C E G U I D A N C E

BIOFILTER OPERATIONAL GUIDANCE FOR

WADDOCK COMPOSTING

Waddock Composting Ltd.

DESCRIPTION OF THE TECHNOLOGY

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2

Definition of Biofiltration

Biofiltration is the use of microorganisms growing in a media bed to remove and oxidize compounds in a foul airstream. A typical biofilter consists of a media bed containing contaminant degrading microorganisms, a media support structure, a foul air distribution system, and some method of controlling the biofilter moisture content. The media can consist of various materials including soil, woodchip, peat, compost, sand or synthetic material (plastic packing material). Typically, the foul airstream to be treated is distributed over the bottom of the biofilter bed and forced upward through the media. The moist filter media provides physical and chemical conditions appropriate for the transfer of the contaminants from the vapor phase and supports microbial biodegradation of the adsorped and absorbed contaminants. The figure below is a simplified schematic of Waddock Composting Facility’s (WCF) open-vessel biofilter system.

FIGURE 1

Schematic of Biofilter

A foul airstream containing biodegradable organic and inorganic odorous compounds passes through an air-distribution system underneath the filter medium. The air piping

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system is set on cement blocks to raise it off the ground so the air can be evenly distributed under the pipe.

A medium such as chip wood with a particle size up to 100mm is spread loosely and evenly over the air distribution system. We screen the old woodchip along with the new woodchip at a rate of 4:1 through a 12mm trommel and place the >12mm woodchip around the pipes up to a height of 1.5m and then we place the 0 – 100mm to the full height of 3m. By mixing the new with the old woodchip we are reintroducing the bacteria into the new media bed. The media provides an environment for microorganisms that biologically degrade the odorous compounds. The filter media serves four primary purposes. It provides;

A stable matrix through which the airstream flows evenly

A surface area and moist medium for sorption of odorous compounds

Large surface area for microbial attachment and growth

A source of nutrients and water for the microorganisms.

Construction of Biofilter; January of 2011.

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Biofilters have successfully removed a wide range of inorganic and organic compounds in gas streams. Easily biodegradable odorous compounds such as aldehydes and organic acids as well as sulfur dioxide, nitrous oxides, and hydrogen sulfide, can be removed to a level of 99% or better with biofilters. Volatile organic compounds including methane, propane have been removed to 90% or better with biofilters. Ammonia, amines and other nitrogen-based compounds in low concentrations can also be effectively reduced. The removal efficiencies for each system are a function of numerous design and operating criteria, such as media type, temperature, pH, superficial velocity, and moisture content. Three process mechanisims remove odorous compounds in a biofilter; sorption, biological degradation, and chemical oxidation. A portion of the contaminants in the foul airstream are adsorbed on the surface of the biofilter media and the rest of the contaminants are absorbed by the thin film of liquid (biofilm) surrounding each of the media particles.

Microorganisms in the biofilm oxidize the contaminants and use energy released for maintenance of their own cell material and growth. During biological oxidation, various organic and inorganic compounds are degraded. Organic compounds consisting of carbon, hydrogen and oxygen are fully degraded into carbon dioxide and water. Inorganic compounds, including ammonia (NH3) and hydrogen sulfide (H2S), yield compounds, which form acids.

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OPERATION AND DESIGN PARAMETERS

Several parameters need to be considered and properly maintained in order for a biofilter to effectively control odors. These factors all have one main goal: to provide a suitable environment to sustain the microorganisms responsible for the biofiltration process.

Moisture Control

The proper moisture content of the biofilter is essential for the biofilter to perform at its maximum efficiency. Odorous compounds need to be adsorped or absorbed by the moisture-rich biofilm before microorganisms can use these compounds as a food source. If the biofilm is absent or not thick enough, the ultimate density of the microorganisms cannot be reached. Consequently, the biofilter will perform below expected levels.

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The optimum moisture content varies with the particular filter medium and should be determined on a case-by-case basis. A general range of 40% to 70% is considered typical with a target of 60% being ideal. A sprinkler system is used to control (increase) the media’s moisture level.

Temperature

Microbial activity must be maintained in the biofilter to remove the odorous compounds. Biological activity increases by a factor of approximately 2 for each 10o rise. A temperature range between 70oF and 98oF is considered ideal for the biofiltration process. If temperatures are lower the biofilter will continue to work, but at a reduced rate. Extreme cold temperatures can cause the microorganisms to become dormant. Higher temperatures will accelerate the decomposition (service life) of the media.

pH

The pH of the biofilter should be maintained at or near neutral to facilitate maximum microbial activity required for maximum odour control.

Foul Air Residence Time

Absorption, adsorption, and biodegradation rates vary depending on the biofilter media and the foul airstream compounds being treated. The odorous constituents should be identified and quantified prior to the biofilter design and installation. This will ensure that the proper biofilter size and media is selected.

Review of field experience and references indicates a suggested retention time range of 30 to 180 seconds. High rate compost style biofilter systems are typically designed for 30 seconds or less retention time. This type of system may require that the odorous air be preheated in order to maintain a higher rate of degradation. These higher rate systems also require special attention to detail regarding air distribution and moisture control. Lower rate, simpler open vessel compost systems are typically designed for 45 to 60 seconds retention time.

Oxygen Concentration

The oxygen level is important to the biofiltration process since most of the degradations are aerobic. The microorganisms use the dissolved oxygen in the biofilm. In some cases, the controlling factor to biofilter loading may be oxygen to the biofilter system. Typically however, loading rates are sufficient to maintain aerobic conditions.

If anaerobic conditions develop due either to overloading or short circuiting the biofilter may become the source of odors rather than the device for removing them.

Air Flow Distribution

The airflow distribution section of the Biofilter is located above ground in the media bed. The system consists of a pipe cut in half horizontally and placed on 4 inch blocks so that the odorous air can be evenly distributed through the media. In open top biofilters, the system may also remove excess water caused by precipitation.

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Leachate Control

Excess water is collected from the biofilter. The leachate from the biofilter is collected and drained back into the wastewater treatment system.

Microorganisms

Microorganisms are the workhorses of the biofiltration system. All biofilter design criteria are geared to provide optimal conditions for the microorganisms. Bacteria, actinomycetes and fungi are the principal microorganisms involved in the biological oxidation process. These microorganisms will grow on media such as chipwood.

The microorganisms live in the thin biofilm on the surface area of the filter media. As the foul airstream enters the biofilter, the contaminants diffuse and are either adsorped or absorbed into the biofilm. The microorganisms oxidize the contaminants to non-odorous and non-toxic compounds. The species of microorganisms active in a biofilter vary depending upon the compounds present in the foul airstream and have been shown to vary within the depth of the media.

Two groups of aerobic microorganisms are vital to microbial conversion of the foul airstream contaminants in the biofilter media: autolithotrophic and heteroorganotrophic. Both types obtain the required energy for cell function through chemical reactions

Autolithotrophic bacteria use carbon, present in the foul airstream as carbon dioxide to produce new cell material. A limited number of inorganic compounds in nature are suitable for autolithotrophic degradation. Ammonia and hydrogen sulfide are the primary compounds important to biofiltration applications in wastewater treatment.

The second type of bacteria, heteroorganotrophic bacteria, utilize carbon in the gaseous pollutant as sources for cell growth. The majority of the bacteria used for biofiltration are heteroorganotrophic. Most organic compounds present in foul airstreams ( such as Mercaptans) can be utilized by heteroorganotrophes.

MEDIA

Media Design

A good biofilter media should possess the following characteristics:

Supports a large diverse microbial population,

pH buffering capabilities

ability to retain microbes

appropriate density

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physically stable

low pressure drop

production of clear drainage water (leachate)

high bearing strength.

The media design involves a number of elective decisions, including media ingredients, particle sizing, cross-sectional depth, surface loading rate per square foot, porosity, and desired service life. These parameters are dependant on the foul airstream characteristics, including contaminants of concern and loading rate

Media Replacement

Media replacement can be initiated based on a media effective depth, observations of surface irregularities and exhaust odor, PH irregularities, TVC’s or based on back pressure measurements. All of these are reasonable approaches, and they can be used together if necessary.

The operators create a basic decision model for media exchange based on age, surface appearance, effective depth, exhaust quality, and backpressure. This requires a procedure to record performance right from the beginning on a new or replaced biofilter. It will be important that these measurements are used for future decisions. The recommendations below are intended to provide some structure to this approach. For example, if any of the model parameters exceed a selected specification (i.e. depth is less than four feet, surface has dry spots, or the exhaust has odors present) the biofilter media should be replaced. It should be noted that backpressure will be unique to each biofilter but trends over time can indicate problems, such as a gradually rising backpressure that consumes horsepower and reduces airflow. Depth and age are also closely correlated. If the biofilter looses too much effective depth, it generally also has reached an advanced age since the depth decreases over time. The performance of the biofilter will only be as good as the uniformity of the media.

Cautionary advice about premature media failure

If the resulting airflow across the biofilter surface is unbalanced due to variable media porosity or inconsistent composition, the problem will only become worse over time. The result will be a much shorter residence time than intended (meaning incomplete odor removal) as the airflow favors the portion of the filter with the lowest resistance.

For example, part of the filter might have 60 seconds of residence time and other parts might have 180 seconds. Over time these same rates might drift further apart to 40 seconds and 240 seconds respectively as the problem gets worse. Of course, the airflow that only has 40 seconds may still have odors in it.

Uneven airflow will make replacement of the media a necessity well before anticipated, so careful attention and supervision during the mixing and placement procedure is well worth the time.

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Bio Filter Air Balance based on 2000pa.

Side Elevation of Ducting & Damper

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�� CARLOW PRECAST TANKS Manufacturers and Suppliers of Septic and Effluent Tanks for Sewage Treatment Systems, Water Reservoirs,

Pumping Chambers, Culverts and Special Products.

CP8 BP – Bypass Oil Water Separator. Rev. A – 06/03/09

Page 1 of 3

Technical Data Sheet: CP8 BP Bypass Oil Water Separator.

Type:

Class 1 Separator - Discharged effluent to contain < 5 mg/litre when

tested in accordance with IS EN 858.

Max. Treated Flow:

8 l/s

Storm Flow:

80 l/s

Max. Catchment Area:

4,400 m2

Lid:

Conventionally reinforced precast concrete lid.

Separator: Steel fibre reinforced precast concrete tank with integral steel fibre

reinforced concrete internal weir and baffle walls.

Coalescer: ‘Ortner Wassertechnic’ FIC 10 with float type automatic closure

device. (Closure device automatically shuts the outlet from the main

separation chamber if the oil storage capacity is exceeded)

Load Capacity:

The tank and lid are designed for a soil overburden depth of up to 1m and the most critical of a 10

kN/m2 imposed UDL or a 5,850 kg wheel load acting at any point on the lid surface. Heavy duty

lids can be manufactured for more onerous load applications.

Materials:

Concrete:

Strength Grade: C60/75 (75N)

Min. Cement Content: 350 kg/m3

Max. Water / Cement Ratio 0.5

Max. Aggregate Size: 14mm

Max. Slump: Not applicable – Self compacting mix.

Additives: Glenium – Plasticiser / Water reducing agent.

Crushed Limestone Powder – Filler

Reinforcement:

Lid: High yield type two reinforcement to BS 4449

Tank: 40 kg/m3 - 47/1.0 ‘Duoloc’ Steel fibre reinforcement

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Page 2 of 3

Liquid Retention:

The separator is designed to be watertight in accordance with BS 8007 – ‘Code of practice for

design of concrete structures for retaining aqueous liquids’.

Ventilation:

The main separation chamber should be ventilated in accordance with BS 8301 – ‘Code of

practice for building drainage’. A 100mm diameter opening is provided in the lid for this

purpose.

Design Life:

The separator & lid have a design life of 50 years in a ‘severe’ category environment as defined

by BS 8110.

Warranty:

The product warranty covers the first fifteen years from the date of delivery.

Manufacture:

Quality of manufacture, standard of workmanship & dimensional tolerances comply with BS

8110 Pt. 1. The separator is cast in one pour to prevent the formation of a cold joint. All precast

concrete elements are cured for a minimum of 48 hours prior to delivery.

Access Requirements:

The separator and lid are generally delivered on a platform bodied truck with a hydraulic jib. Up

to 6m reach is possible from the back of the truck to the centre point of the placement position. A

minimum of 4m entrance width and clear height are required.

Excavation & Base preparation requirements:

The depth of excavation should exceed the finished base level by a minimum of 150mm. The

excavation should then be brought to level using crushed rock aggregate (40mm max. size),

which must be compacted and levelled. In exceptional circumstances (Particularly heavy surface

loading or unusually soft ground) a reinforced concrete base may be required.

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Page 3 of 3

The sides of the excavation must be suitably battered to avoid risk of collapse. To minimise the

risks associated with deep, open excavations it is recommended that completion should be

coordinated to coincide with the arrival of the separator. During placement it is imperative that

personnel do not stand beneath a suspended load.

The safety of the excavation and the general works remains the responsibility of the purchaser.

Backfilling

The excavation may be backfilled using excavated material provided that topsoil is not used

below a depth of 150mm and the backfill is free of large stones and cobbles (Larger than 75mm

approx.). Where excavated material is unsuitable for backfilling crushed rock fill may be used

(50mm maximum diameter). Backfilling should be completed in horizontal layers not exceeding

500mm depth, lightly compacted on completion of each layer. The lid should be placed in

position before backfilling begins to avoid unnecessary contamination of the separator.

Fitting of Connecting Pipes:

The inlet and outlet openings are fitted with moulded EDPM wall seals permitting a push through

seal of connecting pipes (Up to 300mm diameter). The wall seals have an expected working life

of greater than 50 years and are watertight to 0.5 Bar of external water pressure.

Floatation:

It is important to note that the separator will float if submerged in water when empty. If it is

anticipated that external water levels will rise higher than 550mm above the base of the separator

then a floatation check must be performed. Pending the result of this check appropriate anti

floatation measures may be required. These measures include adding additional soil overburden

or drilling steel dowel bars into the separator at base level and pouring a hoop of insitu ballast

concrete.

Design Compliances:

BS 8007 Code of practice for design of concrete structures for retaining aqueous

liquids.

BS 8110: Pt. 1 The structural use of concrete

Dramix Design Guidelines for Steel Fibre Reinforced Concrete Structures

- BEKAERT.

PPG3 Use & Design of Oil Separators in Surface Water Drainage Systems – EPA

IS EN 858: Pt.1 Separator Systems for light liquids.

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