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Kerry Ingredients (Ireland) Ltd, Charleville
Industrial Emissions Licence Review Application
OES Consulting
Attachment No F.1
Treatment, Abatement and Control
Systems
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Industrial Emissions Licence Review Application
OES Consulting Page 1 of 10
Attachment No. F.1. Treatment, Abatement and Control Systems
The facility has abatement equipment installed on air and surface water
emission points from the site. These include equipment installed on the dryer
exhaust stacks for reduction of particulates, wastewater treatment for
treatment of process effluent.
F.1.1 Emissions to Air
Boiler Emissions
As outlined in Attachment E.1 there are 6 no. ‘Boiler’ emission points on site
(A1-1 to A1-6 corresponding to Dryer 1C burner, Boiler 2, Boiler 4, Boiler 5 and
CHP boiler/CHP bypass stack). The primary potential pollutant associated with
these boiler emissions are Nitrogen oxides (NOx). In order to mitigate the
potential NOx emission these Boiler 2 and Boiler 4 are equipped with low NOx
burners.
Main Emissions – Dryers
There are currently 6 no. Main emission points located at the main dairy
processing facility. These refer to the four dryers onsite namely Niro 1/Dryer 1C,
Niro 2, Niro 3, and Niro 4. At present, only two dryers namely Dryer 1C and Niro
3 are in use. The primary material emitted from the dryers are particulates
arising from the drying process. Process air leaving the drying chamber
contains a small of proportion of particulates. In order to mitigate the level of
particulates emitted from these sources both Dryer 1C and Niro 3 are
equipped with baghouses/bag filters. These bag filter abatement systems are
capable of being cleaned in place by the CIP system. This further enables
recovery of any process/product particulates retained by the filtration system.
Remaining dryers are equipped with Cyclone filtration systems to mitigate the
extent of particulate emissions from these emission sources.
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Figure F.1.1 Typical Bagfilter Abatement System
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OES Consulting Page 3 of 10
Figure F.1.2 Typical Cyclone Air Abatement System
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Industrial Emissions Licence Review Application
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F.1.2 Emissions to Surface Water
At present the Wastewater Treatment Plant (WWTP) comprises Preliminary,
Secondary and Tertiary and Sludge Treatment including the following unit
processes.
• Flow and Strength Balancing
• pH control
• Dissolved Air Flotation (DAF) to remove Oils, Fats and Greases (OFG)
• Anoxic Denitrification
• Carbonaceous Oxidation and Nitrification
• Phosphorous (P) Removal
• Final Clarification
• Tertiary Filtration on Rapid Gravity Filters
• Metering and Proportional Sampling of Influent and Effluent
• Excess Biological Sludge Thickening
• Biological Sludge and OFG Float Dewatering and Lime Stabilisation
• Storage of Liquid Sludge and Sludge Cake
The existing WWTP will form an integral part of the upgraded plant and
Conventional Activated Sludge will continue to be the preferred treatment
process to serve the upgraded WWTP. A process flow diagram illustrating the
current WWTP processes and detailed description of each stage is presented
below.
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Industrial Emissions Licence Review Application
OES Consulting Page 5 of 10
Figure F.1.3. WWTP Process Flow (current)
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Preliminary Stage
The preliminary stage is designed to convey untreated flow from Kerry
Ingredients (Ireland), Charleville processing facility to a concrete balancing
tank, which has the capacity of twelve hours flow at maximum daily flow rate.
A scum removal device is incorporated in this balancing to facilitate periodic
removal of floating solids from the surface of the tank. This balancing is
aerated by means of a floating aerator.
Control of pH is achieved by the means of a dual pH correction system using
acid and caustic from bulk storage tanks. Effluent passes forward from the pH
control to a twin cell Dissolved Air Flotation (DAF) system where the removal
of Oils, Fats and Grease (OFG) takes place. The OFG is then pumped to a
covered holding tank. This tank is fitted with a mixer to provide uniform
conditions prior to draw-off for treatment and disposal. Flow from the DAF
units is directed to the Secondary Treatment Stage.
Secondary Stage:
Secondary Treatment takes place in earthen lagoons with oxygen input
provided by surface aerators. One lagoon acts as an anoxic reactor and the
second as an aerobic reactor.
The Secondary Treatment Stage removes Carbonaceous BOD, Organic
Nitrogen, Ammonia and Phosphate and mineralises the sludge. The aerobic
reactor removes BOD while providing optimum conditions for nitrification. The
nitrate nitrogen so formed is de-nitrified in the anoxic lagoon using raw
wastewater as the carbon donor.
Mixed liquor from the aerobic reactor overflows to the final clarifiers. In-line
addition of inorganic salt (aluminium chloride or ferric sulphate) takes place
to facilitate simultaneous precipitation of the remaining phosphorous with the
bio-solids in the final clarifiers. Sludge from the final clarifiers is either returned
to the secondary stage or wasted to the sludge thickening and dewatering
system
Tertiary Stage
The tertiary stage of treatment involves a rapid gravity filtration system using 4
No. parallel filter units which have fully automatic backwashing system utilising
clean water and an air scour.
At present treated wastewater gravitates to final effluent monitoring and
sampling chamber before being pumped to the storage lagoon. Discharge
from the storage lagoons passes through a flow measurement and sampling
station and flow is regulated against the flow in the Charleville Stream.
Sludge Treatment Stage
Excess Sludge from the biological system is drawn off on a regular basis for
thickening in a concrete picket fence thickener to a dry solids content of
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Industrial Emissions Licence Review Application
OES Consulting Page 7 of 10
1.5%. Thickened sludge is then pumped to the decanting centrifuge where
with polyelectrolyte addition it is thickened to a dry solids content of
approximately 9.5%. This is then pumped to a concrete liquid storage tank
prior to landspreading. OFG float is pumped at regular intervals from the
holding tank for treatment with the biological sludge.
Alternatively, the solids can be taken to 18-20% solids in the decanter and
can then be stabilised by the addition of lime in a ‘ploughshare’ mixer. An
open concrete storage area is available for sludge cake.
At present, out of spec treated effluent is recirculated to Landets 2,4,5,6,7,8
and 9 and emergency overflow from WWTP Balance Tank is diverted to
Landet 10. It is proposed that this operation be continued presently and
following upgrade of the WWTP.
Proposed WWTP
Following Primary Treatment in the existing balance tank, pH correction
system and DAF tanks, the liquor will enter a new splitter tank which will divide
the flows between the existing Secondary Treatment System in the Anoxic &
Aeration lagoons and the new tanks installed as part of the upgrade.
The new circular anoxic tank and two circular aeration tanks will be designed
to operate in parallel with the existing anoxic and aeration lagoons. The liquor
in the two new aeration tanks will be oxygenated via a fine bubble diffused
aeration system located near the floor of the tanks and the air supply will be
controlled by dissolved oxygen monitoring to ensure efficient oxygenation of
the tank liquor. The effluent from the two new aeration tanks will be clarified in
the new circular settlement tank, following which it will discharge to a sump
from where it will either be pumped to the new cooling tower where required
to reduce the temperature of the effluent, or directly to the existing treated
waste water flow measurement/sampling chamber along with the treated
waste water from the existing system.
Sludge collected from the existing DAF plant, and the existing and new
treatment systems will continue to be treated and stored in the existing picket
fence thickening and holding tanks and treated in the existing de-watering
centrifuges.
A process flow diagram illustrating the proposed processes is presented
below.
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Industrial Emissions Licence Review Application
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Figure F.1.4 Proposed WWTP Process Flow
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Industrial Emissions Licence Review Application
OES Consulting Page 9 of 10
Control of Emissions to Water
Under the current IE Licence (Licence Ref No: P0386-03) the
methods/parameters applied in order to appropriately control the emission of
treated process effluent to surface water are as outlined in Schedule C.2.1 of
the licence as presented below.
Figure F.1.5 Current control parameters for effluent treatment
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Industrial Emissions Licence Review Application
OES Consulting Page 10 of 10
In conjunction with the proposed upgrade to the existing WWTP the following
amendments to Schedule C.2.1 are proposed.
Table F.1.1 Proposed Control of Emissions to Water (WWTP)
Control Parameter Frequency Method
Balance/Inflow
Flow
pH
COD (ex DAF unit)
Phosphate
Continuous
Continuous
Continuous
Continuous
Flow meter
pH meter
COD Sensor
Phosphate Analyser
Anoxic/Aeration Tanks
Flow
Dissolved Oxygen
MLSS
SVI
F/M Ratio
Nitrate
Continuous
Continuous
5 days per week
5 days per week
5 days per week
Continuous
Flow meter
Fixed DO Meter
Lab test
Lab test
Lab Test
Nitrate probe
Clarifier
Suspended Solids
5 days per week
Lab test
Final Effluent
Flow
Ammonia
Nitrate
Suspended Solids
Organic Load (COD)
pH
Temperature
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Flow Meter
Ammonia probe
Nitrate probe
Suspended Solids meter
COD Sensor
Ph meter
Temperature probe
Sludge Dewatering
Sludge Condition
Daily Inspection
Daily Visual Inspection
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Industrial Emissions Licence Review Application
OES Consulting
Attachment No F.2
Emissions Monitoring and Sampling
Points
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Industrial Emissions Licence Review Application
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Attachment No. F.2 Emissions Monitoring and Sampling Points
Surface water Monitoring
Under the existing Industrial Emissions Licence (IEL) (Licence Ref No. P0386-03)
KIIL Charleville engages in regular monitoring of discharges to surface water
from both the main processing facility and wastewater treatment plant
(WWTP). It currently monitoring surface discharges at 7 no. surface water
emission monitoring points, namely SWEP1 to SWEP6. These monitoring points
are located on both the Charleville Stream/Glen River (SWEP1) and Mill Race
stream (SWEP2 to SWEP6) which traverses the main processing facility from the
south-west of the.
SWEP1 relates to the effluent discharged to the Charleville Stream post-
treatment at the WWTP located c.2.km north of the main processing facility.
The current monitoring programme for SWEP1 as required under the current
IEL presented in Table F.2.1 below.
Table F.2.1 SWEP1 Emission Monitoring (Current)
Parameter Monitoring
Frequency
Analysis Method/Technique
Flow Continuous On-line flow meter with
recorder
Flow in Charleville
Stream
Continuous On-line flow meter with
recorder
Temperature Daily On-line temperature probe
with recorder
pH Continuous Ph electrode/meter with
recorder
Chemical Oxygen
Demand (COD)
Daily Standard Method
Biochemical Oxygen
Demand (BOD)
Weekly Standard Method
Suspended Solids Daily Standard Method
Ammonia (as N) Daily Standard Method
Total Nitrogen Monthyl Standard Method
Total Phosphorous Weekly Standard Method
Orthophosphate as P Weekly Standard Method
Oils, Fats & Greases Monthly Standard Method
Toxicity As may be
required
To be agreed by the Agency
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Table F.2.2 SW-1 Emission Monitoring (Proposed)
Parameter Monitoring
Frequency
Analysis Method/Technique
Flow Continuous On-line flow meter with
recorder
Temperature Continuous On-line temperature probe
with recorder
pH Continuous Ph electrode/meter with
recorder
Chemical Oxygen
Demand (COD)
Daily Standard Method
Biochemical Oxygen
Demand (BOD)
Weekly Standard Method
Suspended Solids Daily Standard Method
Ammonia (as N) Daily Standard Method
Total Nitrogen Monthly Standard Method
Orthophosphate as P Weekly Standard Method
Oils, Fats & Greases Monthly Standard Method
Toxicity As may be
required
To be agreed by the Agency
The current monitoring programme for SWEP2 to SWEP6 (SW-1 to SW-6) as
required under the current IEL presented in Table F.2.3 below.
Table F.2.3 Storm Water Emissions Monitoring
Parameter Monitoring
Frequency
Analysis Method/Technique
pH Weekly Ph Electrode/meter
Temperature Weekly Temperature probe
Conductivity Weekly Conductivity meter
COD Weekly Standard Method
Ammonia Monthly Standard Method
Orthophosphate Monthly Standard Method
Visual Inspection Daily Sample and examine for
colour and odour
As well as conducting effluent discharge monitoring as outlined above
ambient monitoring of the relevant, potentially affected surface water bodies
i.e. the Charleville Stream/Glen River and Mill Race stream. At present
ambient surface monitoring is conducted at 7 no. monitoring points namely
ASW3, ASW4, ASW5 (Mill Race stream) ASW6 and ASW7 (Charleville
Stream/Glen River – Main Plant and Location 1 and Location 3 (Charleville
Stream - WWTP) as required under the existing IEL.
The current monitoring programme for receiving waters are outlined in Tables
F.2.4 and F.2.5 below.
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Table F.2.4 Ambient Monitoring – Charleville Stream/Glen River & Mill Race (ASW3 –
ASW7)
Parameter Monitoring
Frequency
Analysis Method/Technique
pH Daily Ph Electrode/meter
Temperature Daily Temperature probe
Conductivity Daily Conductivity meter
COD Daily Standard Method
Ammonia Monthly Standard Method
Orthophosphate Monthly Standard Method
Visual Inspection Daily Sample and examine for
colour and odour Table F.2.5 Ambient Monitoring – WWTP (Location 1 and Location 3)
Parameter Monitoring
Frequency
Analysis Method/Technique
Molybdate-reactive
Phosphorous
Monthly Standard Method
Visual Inspection Daily Sample and examine for
colour and odour
Biological Quality (Q)
Rating/ Q Index
Annually (June to
September period)
To be agreed by the Agency
As part of this licence review it is proposed that ambient monitoring of the
Charleville Stream at Location 1 and Location 3 as per Condition C.6 under
the current IEL will be continued and regulated under the IEL up to the point
by which discharge of treated effluent to the Charleville Stream will cease
and discharge of treated effluent to the River Maigue is initiated.
With respect to the discharges to water KIIL (Charleville) has demonstrated
continuing compliance with licence requirements since the current reviewed
IEL has been issued i.e. since 2013.
Air Monitoring
Under their existing licence KIIL Charleville are currently required to conduct
annual monitoring on 4 no. ‘Boiler’ emission points currently referred to as
AEP2, AEP3, AEP4 and AEP54. Additionally, under the current IE licence
monitoring of 6 no. main emissions points currently referred to as AEP10,
AEP11, AEP12, AEP13, AEP14 and AEP15. The required monitoring parameters
and frequency of monitoring are outlined in Table F.5 and Table F.6 below.
Table F.2.6 Emissions to Air Monitoring (‘Boiler’ Emissions)
Parameter Monitoring
Frequency
Analysis Method/Technique
SOx (as SO2) Note 1 Annually Flue gas analyser
NOx (as NO2) Annually Flue gas analyser
CO Annually Flue gas analyser
Particulates Note 1 Annually Isokinetic/Gravimetric Note 1: Monitoring of SO2 and Particulates to be conducted only when fuel oil is used.
At present, only natural gas is used.
Note 2: monitoring frequency for emission point AEP54 is bi-annually.
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Table F.2.7 Emissions to Air Monitoring (‘Main’ Emissions)
Parameter Monitoring
Frequency
Analysis Method/Technique
Particulates Quarterly Isokinetic/Gravimetric
Particulates – PM10 and
PM2.5
Annually Isokinetic/Gravimetric
As with monitoring of emissions to water, ambient air monitoring is conducted
in order to assess the potential dispersion of any pollutants to the receiving
environment/atmosphere as a result of the sites activities and associated air
emissions. As per the existing IEL ambient air quality monitoring is conducted
at 4 no. ambient air monitoring points (AAMP1 to AAMP4). Locations of these
monitoring points is illustrated in Drawing 9. The required monitoring
parameters and frequency are presented in Table F.2.8 below. As part of this
Licence Review Application it is proposed that number of Ambient Air
Monitoring Points (AAMP) be reduced so two points i.e. that only AAMP1 and
AAMP4 are utilised for the purpose of monitoring ambient air quality. Table F.2.8 Ambient Monitoring – Emissions to Air
Parameter Monitoring
Frequency
Analysis Method/Technique
Particulates Continuous EN12341
Nitrogen oxides (AAMP4
only)
Continuous Chemiluminescence (ISO
7996:1985)
Sulphur dioxide (AAMP4
only) Note 1
Continuous UV fluorescence (ISO/FDIS
10498) Note 1: Monitoring required where fuel oil is used.
With respect to emissions to air KIIL Charleville has demonstrated ongoing
compliance with licence conditions regulating the sites atmospheric
emissions.
Groundwater Monitoring
There are no proposed changes with respect to ongoing groundwater
monitoring. Quarterly monitoring will continue to be carried at 3 no.GW
monitoring wells as per Condition C.6 of the current IEL.
Noise Monitoring
An ambient noise monitoring survey is conducted annually at ambient noise
monitoring points located in the vicinity of the main dairy processing,
Kilmallock Road site and at the WWTP. This survey will continue to be
conducted and results report to the Agency on an annual basis as part of the
Annual Environmental Report (AER).
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Lockers 15 x 2
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TOC No1
TOC No2
TOC No3 & 4
NIRO 2
NIRO 3
TOC No5
IMF PLANT
TOC No6
LORRY
WASH
TOC No7
WHEY
TOC No 8 & 9
PROCESS
CHEESE
NIRO 1
PUMP HOUSE
MAIN SEWER
DISCHARGE
CHEESE
STRINGS
AEP2
A1-6
A1-5
A1-6
A1-2
A1-3
A1-4
A2-1
A2-2
A2-3
A2-4
A2-5
A2-6
ASW6
AAMP4
ASW3
AAMP1
ASW7
ASW4
SW-6
SW-5
SW-4
SW-3
SW-2
ASW5
A1-1
KERRY INGREDIENTSCHARLEVILLE
DRAWING 9MONITORING POINTS
(SHEET 1 OF 2)
1195-08-09
MASTER LAYOUT
0
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