molex ireland ltd · 2014. 12. 16. · sulphide 0.009 nd 0.03 100 tin 1.885 1.069 0.975 100 cadmium...

Molex Ireland Limited Annual Environmental Report 2010

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MOLEX IRELAND LTD

IPPC LICENCE NO. P0288-02

1.1 ANNUAL ENVIRONMENTAL REPORT 2010

1 MARCH 2011


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CONTENTS

1 INTRODUCTION 4

1.1 Employment 4

2 ENVIRONMENTAL DATA SUMMARY INFORMATION 6

2.1 Emissions to Surface Water 6

2.2 Emissions to Sewer 9

2.3 Emissions to Atmosphere 11

2.4 Waste Management 13

2.5 Noise 24

2.6 Energy and Water Consumption 25

2.7 Agency Monitoring and Enforcement 26

2.8 Environmental Incidents and Complaints 28

2.9 AER 2010 Returns Excel Worksheets 28

3 ENVIRONMENTAL MANAGEMENT OF THE ACTIVITY 29

3.1 Environmental Management System – ISO 14001 29

3.2 EMP 2007 Report and Schedule of Objectives and Targets 2010 29 3.3 Pollution Emission Register (PER) 32

4 OTHER REPORTS 33

4.1 Bund Integrity Assessment 33

4.2 Firewater Retention Study. 33

4.3 Environmental Liabilities 33

4.4 Intrusive Hydrogeological Investigation. 33

4.5 CCTV Study. 34

5 SOLVENT USAGE 34


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APPENDIX A

Environmental Policy

APPENDIX B

Reports on Emissions to Atmosphere 2010

APPENDIX C

Pollution Emissions Register Report 2010

APPENDIX D

PRTR 2010 Returns Excel Worksheets

APPENDIX E

Bund Integregity Report 2010

APPENDIX F

Executive Summary of Fire Water Retention Study 2010


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1 INTRODUCTION Licensee: Molex Ireland Limited

Location of Activity: Shannon Industrial Estate, Co. Clare

Licence Register Number: P0288-02

Molex Ireland Limited is based in Shannon Industrial Estate at National Grid Reference E 1397 N 1622, near the town of Shannon. Molex manufactures a variety of electrical and electronic interconnecting devices for the Industrial Market. The facility is involved in the stamping, electroplating of metal connectors and moulding of plastic into housings and the assembly of these parts.

Molex Ireland Limited was granted an Integrated Pollution Control Licence (IPC) on 26th February 1998. This licence was subsequently upgraded to an IPPC Licence on 29th April 2006. One of the requirements of this licence is to prepare an Annual Environmental Report for submission to the Environmental Protection Agency (EPA). This report, in compliance with Condition 2.2.1 of the licence, details environmental performance at the site for the period January to December 2010. This report has been prepared in accordance with the EPA Guidance Note for Annual Environmental Reports, 2000.

Condition 2.2 of Molex’s IPPC Licence requires the licensee to establish and maintain an Environmental Management System (EMS). Molex have established the elements of an EMS as relevant to the conditions of the IPPC Licence and the ISO 14001 Environmental Management System Standard and were awarded ISO 14001 Accreditation in September of 2000.

An Environmental Policy has been prepared and is located at the employee entrance within the company. The Environmental Policy is also displayed within the Molex Ireland website. A copy has been included as Appendix A.

In accordance with Condition 6.5 of the IPPC Licence, Molex can confirm that there was no significant change in solvent usage (i.e. no solvents on site) or work practices on site during 2010.

There was one environmental incident during 2010 and this was brought to the attention of the Agency in accordance with licence conditions and is dealt with in the report.

The Shannon Site experienced a significant change in the product portfolio during 2010 which resulted in five plating lines becoming excess to the business needs and these lines were sold to a German Company specialising in plating, which has resulted in a downsizing of plating operations and the elimination of copper and pure tin (Culmo) plating processes.

1.1 Employment There are currently 300 persons employed by Molex Ireland Limited (Shannon). The factory is a significant employer in the Shannon region. Figure 1.2 outlines Molex’s organisation for Environmental Management on-site.


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Figure 1.2: Staff Organizational Chart


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2 ENVIRONMENTAL DATA SUMMARY INFORMATION

2.1 Emissions to Surface Water A surface water run-off sampling system is in place at Molex Ireland Limited. It allows for the collection of surface water runoff which is ultimately discharged to the estuary.

The surface water sampling points are inspected on a daily basis, sampled and analysed for pH and conductivity in accordance with Schedule C.2.3 of the IPPC Licence.

On a quarterly basis the sample is also analysed for COD, tin, cadmium, arsenic, copper, nickel, lead, zinc, cobalt and iron.

2.1.1 Summary Information For the purposes of this section, an average value for the pH and conductivity results obtained over each month during 2010 is provided.

Note: There are two Surface Water Sampling Points; results shown are the averaged for the two sampling points.

Table 2.1: Emissions to Surface Water: pH and Conductivity

Month 2010

SWSP1 SWSP2

pH Conductivity (µµµµS)

pH Conductivity (µµµµS)

January 7.24 242 7.38 371

February 7.25 190 7.25 282

March 7.28 137 7.29 150

April 7.03 130 7.33 219

May 6.79 154 7.16 199

June 6.88 150 7.26 185

July 7.2 148 7.27 252

August 7.07 248 7.27 171

September 7.39 210 7.52 191

October 8.43 955 7.34 310

November 8.42 310 7.72 356

December 7.48 539 8.71 1,690


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Table 2.2.1: Emissions to Surface Water: COD and Heavy Metals at location SWSP1

Parameter

Date

20-Jan-10 07-May-10 20-July -10 13-Oct -10

COD (mg/L) 15 50 13 201

Tin (µg/L) 2.9 6.3 ND 15.6

Cadmium (µg/L)

ND ND ND 0.06

Arsenic (µg/L) 0.3 0.3 0.2 5.3

Copper (µg/L) 19.2 82.5 10.3 219.8

Nickel (µg/L) 36.5 56.6 10.7 87.5

Lead (µg/L) 1.5 2.1 ND 6.4

Zinc (µg/L) 17.3 24.6 6.1 33.2

Cobalt (µg/L) 0.3 0.9 0.2 2

Iron (µg/L) 47.9 135.7 17.1 135.4

Table 2.2.2: Emissions to Surface Water: COD and Heavy Metals at location SWSP2

Parameter

Date

20-Jan-10 07-May-10 20-July -10 13-Oct -10

COD (mg/L) 17 60 13 36

Tin (µg/L) ND ND ND ND

Cadmium (µg/L)

ND ND ND ND

Arsenic (µg/L) 0.3 ND ND 0.3

Copper (µg/L) 7.5 ND 1.4 1.7

Nickel (µg/L) 3.5 0.8 4.1 5.2

Lead (µg/L) 0.3 ND ND 0.3

Zinc (µg/L) 22.4 8.8 22.2 11.1

Cobalt (µg/L) 0.3 0.1 1 1.3

Iron (µg/L) 101.5 328.6 1,431 2,329

2.1.2 Details of Non Compliance There were no non compliances with respect to emissions to surface water from January to December 2010, however high levels of conductivity were measured in SWSP1 during the October to December especially following dry spell periods. The cause of this was the fact that the water chillier units 1 & 2 were emitting a water spray which was high in salt (sodium chloride) which was being used as a water softener. This practice has been discontinued and has now been substituted with reverse osmosis water.


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High levels of conductivity were measured on SWSP2 during December and this was attributable to the gritting of the local roads during the cold winter period.


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2.2 Emissions to Sewer Effluent is discharged from reference point SE1 following treatment in the on-site wastewater treatment plant. Flow, temperature and pH are recorded continuously in accordance with Licence requirements. A daily composite sample is analysed for a variety of parameters. The sample is analysed weekly for sulphates, tin, copper, nickel, iron and total heavy metals. The remaining parameters; COD, BOD, suspended solids, nitrates, sulphide, chlorides, total phosphorus, total nitrogen, detergents, oils/fats/grease, cadmium, arsenic, lead, zinc, cobalt and organohalogens are analysed on a quarterly basis. All parameters are monitored in accordance with the requirements of the IPPC Licence.

On the 10th of October 2006, Molex forwarded a request to the EPA including justifications as to why the monitoring frequency of the following parameters should be reduced:

Parameter IPPC Monitoring Requested Frequency Frequency Change

Sulphates Daily Weekly

Sulphide Monthly Quarterly

Cadmium Monthly Quarterly

Arsenic Monthly Quarterly

Lead Weekly Quarterly

Zinc Weekly Quarterly

Cobalt Monthly Quarterly

The EPA subsequently granted permission to Molex on the 13th of June 2007 (EPA Ref. P0288-02/gc 03ld.doc) to reduce the monitoring frequency in accordance with Molex’s request.


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2.2.1 Summary Information

Table 2.3: Total Emissions to Sewer (Ref. Point SE1) 2008 - 2010

Parameter Mass Emissions (kg)

(01.08 – 12.08)

Mass Emissions (kg)

(01.09 – 12.09)

Mass Emissions (kg)

(01.10 – 12.10)

% COMPLIANCE

Sulphate 10,484 6,978 5,565 100

Sulphide 0.009 ND 0.03 100

Tin 1.885 1.069 0.975 100

Cadmium ND ND ND 100

Arsenic ND ND 0.011 100

Copper 0.639 0.129 0.279 100

Nickel 2.566 1.787 1.710 100

Lead 0.069 ND 0.003 100

Zinc 0.017 ND 0.044 100

Cobalt ND 0.00798 0.024 100

Iron 1.337 0.613 1.575 100

COD 258.1 350.7 279.1 100

BOD 587.3 36.9 240.3 100

Suspended Solids

124.7 53.6 173.3 100

Detergents 0.115 0.50031 1 100

Chloride 3,633 3,007 1,950 100

Fat/Oil/Grease ND 8.631 ND 100

Total Nitrogen 151.8 121 62 100

Nitrates 5 4.9392 2.2 100

Total Phosphorus 7.816 0.9245 0.495 100

Organohalogens ND 0.0214 ND 100

Volatile Organic Compounds

0.048 100

2.2.2 Details of Non Compliance. During the period January-December 2010, there was no exceedance of the discharge limits


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2.3 Emissions to Atmosphere Monitoring and analysis of emissions from Vents A3-3 & A3-4 in the electroplating department was carried out in May and October 2010 as required by Schedule C.1.2 of the IPPC Licence. Schedule C.1.2 requires Molex to analyse for TA Luft Inorganic Particulate Matter Class II & Class III, and TA Luft Inorganics Class II & III twice a year, and for ammonia monthly.

As part of Molex’s effort to introduce cleaner technologies on-site, during February 2006 Molex removed ammonia from the electroplating processes resulting in negligible ammonia emissions to atmosphere. As a result Molex wrote to the EPA in June 2006 requesting that the monitoring frequency for Ammonia as per Schedule C.1.2 be reduced from Monthly to biannually, the EPA subsequently granted this request.

Two atmospheric emission points, A3-3 & A3-4 were sampled, both of which extract from the plating lines. Each vent was assessed for the following substances:

• trace metals

• chloride as HCl

• sulphate as H2SO4

• cyanide as CN-

• ammonia as NH3

Monitoring was carried out whilst all the plating lines were running. Sampling was undertaken over 1 hour sampling intervals. Table 2.4 below summarises the mass emissions to the atmosphere for 2010.

2.3.1 Summary of Results The following tables summarise the results obtained from the monitoring and analysis of emissions from the plating department. Detailed copies of the 2 Atmospheric Emissions Surveys in 2010 are included as Appendix B.

2.3.2 Details of Non Compliances 2009 - 2010. During the September 2009 analysis of the volume flow from Emission Point Ref A3-4 a flow of 10,326 Nm3/hour was recorded. The Agency was made aware of this and Molex fitted an inverter to regulate the fan motor to ensure compliance with the emission volume set in the licence. The installation of this inverter has resulted in a stable compliant volume flow from this emission point during 2010.

During the October 2010 analysis the level of 15.4 mg/Nm3 hydrocyanic acid was detected from Emission Point Ref A3-4, the Agency was informed of this incident.

This level appears to be well out of character with the levels to be expected from the plating process. Molex therefore will investigate this further, which will involve a number of studies to establish what level of hydrocyanic acid is typically generated from the plating process. The published literature does not reference the generation of hydrocyanic acid as part of the electrolytic process. Therefore airing on the side of caution, Molex calculated the total hydrocyanic acid generated from the site, the calculations used in this report are based on the total equivalent hydrocyanic acid purchased during the year.


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Table 2.4: Mass Emissions to Atmosphere 201 0*

Parameter

Mass Emissions (kg/yr) 1

Vent A3-3 Vent A3-4

Cobalt ND ND

Copper ND ND

Nickel ND ND

Lead ND ND

Tin ND ND

HCl 0.8 1.55

Ammonia 1.44 ND

Hydrogen Cyanide

3.33 156.67

2.3.3 Trend Analysis Results for scheduled emission point, Vent A3-3 for 2009 and 2010 are compared in Table 2.5 below.

Table 2.5: Comparison of Mass Emissions to Atmosphere from Vents A3-3 and A3-4: 2009 and 2010

Parameter Mass Emissions (kg/yr) for vent A3-3

Mass Emissions (kg/yr) for vent A3-4

2009 2010 2009 2010

Cyanide 28.49 3.33 51.07 156.67

Cobalt ND ND ND ND

Copper ND ND ND ND

Lead ND ND ND ND

Nickel ND ND ND ND

HCl ND 0.8 ND 1.47

Tin ND ND ND ND

Ammonia ND 1.44 ND ND

. 1 The annualised figures are based on a 80 hour week, 48 weeks year (3,840 hours).

* Results used are averaged between the biannual emissions to air monitoring.


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2.4 Waste Management Tables 2.7 and 2.8 overleaf have been completed for Molex Ireland, in accordance with the Guidance Note for the Annual Environmental Report, for the period January to December 2010.

2.4.1 Waste Analysis Two hydroxide sludge loads were collected and removed off-site during 2010. Table 2.6 below summarises the analytical results obtained from a set of samples taken from each waste load.


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Table 2.6: Hydroxide Sludge Analysis 2010

Parameter

(ppm) or %

18/05/10 16/09/10

Aluminium 4.043 2.03

Antimony 0 0

Arsenic 18 6

Barium 136 129

Beryllium 1 1

Bismuth 0 0

Lead 0.01 0.01%

Cadmium 0 0

Calcium 89,900 107,600

Chloride 0.07% 0.22%

Chromium +6 N.D ND

Chromium 0.01% 0.01%

Cobalt 0.00% 0.00%

Hydrogen Cyanide NP NP

Cyanide CN ND ND

Fluoride 0.13% 0.07%

Iron 12.32% 13.65%

Copper 0.20% 0.08%

Magnesium 3.151 3.226

Manganese 437 430

Nickel 1.02% 0.58%

Mercury 0 0.0

Selenium 0 0.0

Silver 299 2,010.9

Sulfur 1.37% 1.11%

Thallium 31 0

Tin 3.44% 4.25%

Zinc 0.03% 0.04%

Gold 345.1 330.5

Platinum 0.4 0.0

Palladium 137.9 173.8

Solid Content 48.7% 46.0%

Tonnage (T) 10.760T 9.870T


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Table 2.7: Non Hazardous Waste Arising for 2010

Description of Waste

EWC Code

Tonnage Waste Haulier Waste Contractor

Waste / IPC/Permit Licence No.’s

Final destination Contact Person/ Tel no./email

& Recovery / Disposal Code

Waste metal from

machinery

16 01 17 3.025 Hegarty Metal Recycling

Ballysimon, Tipperary Road,

Limerick

Hegarty Metal Recycling

Ballysimon, Tipperary Road,

Limerick

Waste Permit: WP05-04

Recycling of metals R4

Michael Bergin 061 401743

Non ferrous metal filings and turnings




Recycled R4


Metal not otherwise specified




Recycled R4


Copper, bronze, &

brass




Recycled R4


Iron and steel 17 04 05 5.02 Hegarty Metal Recycling


Waste Permit: WPO5-04

Recycled R4


Cardboard and paper

20 01 01 92.812 Veolia/Greenstar Ballykeefe Dock Road,

Limerick

Waste Licence W0082-02

Recycled R3 Trina Buckley 021-4328031

Mixed Packaging

15 01 06 1 Veolia/Greenstar Ballykeefe Dock Road,

Limerick




16

Timber 20 01 38 78.2 Veolia/Greenstar Ballykeefe Dock Road,

Limerick


Production of fuel R1 Trina Buckley 021-4328031

Compost 20 02 01 2.84 Veolia/Greenstar Ballykeefe Dock Road,

Limerick


R3 Organic substance recycling/reclamation

Trina Buckley 021-4328031

Plastic Waste 20 01 39 99.9 Veolia/Greenstar Ballykeefe Dock Road,

Limerick



Mixed Municipal

waste (General Waste)


Limerick


Landfill D1 Trina Buckley 021-4328031

Soil and stones

(Rubble)


Limerick



C & D Waste 17 01 07 7.56 Veolia/Greenstar Ballykeefe Dock Road,

Limerick



Waste canteen oil

20.01.25 1.16 Frylite Frylite, Kilcolgan,

Co. Galway

Waste Permit: WR-77 (Galway)

LN/08/01 (Tyrone)

Oil re-refining or other re-uses of oil

R9

Sally O Kane 028-7138 3133 (ext 236)

Mixed LDPE Film

15.01.02 2.01 Danelle Danelle, Kilnock, Ballon,

Co. Carlow

Waste Permit: WP01/08

R3

Kay Fennelly +35359 9159680

Hard plastic 15.01.02 6.3 Danelle Danelle, Kilnock, Ballon

Co. Carlow


R3



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Clear LDPE Plastic

15.01.02 0.5 Danelle Danelle, Kilnock, Ballon

Co. Carlow


R3


Scrap Assembly

product with precious

metal

20 01 40 44.93

Veolia Mastermelt Refining Services

BL 1312, Recovered R4 Refined

Jeni Alcock +44(0) 1298 766900

Sanitary Waste

180104 0.898 Cannon Hygiene, Unit 2 Richmond Ind. Est., 8 North Richmond St

Dublin 1.

Cannon Hygiene, Unit 2 Richmond Ind. Est., 8 North Richmond St

Dublin 1.

Waste Permit WFP-LKC-09-001-01

D15/D1 Storage/Landfill

Linda Murphy 00353 (0)1 7047700

PU 552 FL/10 Natural resin

160509 0.292 Enva Ireland Ltd.

Enva Ireland Ltd.,

Smithstown Industrial Estate,

Shannon, Co. Clare

Waste License

W0041-01

R1-Lindenschmidt, Germany

Ann Marie O'Connell

061-707400

Total Recycled

421.09

Total Disposed (Landfill)

260.058

Total 681.15


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Table 2.8: Hazardous Waste Arising for 2010

Description of Waste

EWC Code

Tonnage Consignment Note No.

Waste Haulier Waste Contractor Waste / IPC/Permit License No.’s

Final destination & Disposal / Recovery Code

Contact Person/Tel no.

Cleaner Filters

150202* 0.192

B576304

B593113

Enva Ireland Ltd.

Enva Ireland Ltd., Smithstown Industrial Estate, Shannon, Co.

Clare

Waste License W0041-01 Waste Collection Permit: WCP-DC-08-116-

01


Ann Marie O'Connell

061-707400

Copper plating solution

110205* 1.2 B576304

Enva Ireland Ltd.


Clare


01

D9- Enva Shannon Ann Marie O'Connell

061-707400

Gloves/white suits

contaminated with plating

chemicals

150202*

0.463 B576304

B593113

Enva Ireland Ltd.


Clare


01


Ann Marie O'Connell

061-707400

Tin plating solution

(methane sulphonic

acid)

060405* 1

B576304 Enva Ireland Ltd.


Clare


01


061-707400

Tin plating solution

(sulphate & 10%

sulphuric acid)

060405* 1.2

B576304 Enva Ireland Ltd.


Clare


01


061-707400

Anti-tarnish (UN-3244)

110198* 3.446 B593113 Enva Ireland Ltd.


Clare


01


Ann Marie O'Connell

061-707400


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Nickel Filters 150202* 0.078 B593113 Enva Ireland Ltd.


Clare


01


Ann Marie O'Connell

061-707400

Nickel Solution



Clare


01


Ann Marie O'Connell

061-707400

Tin filters 150202* 0.104 B593113 Enva Ireland Ltd.


Clare


01


Ann Marie O'Connell

061-707400

Tin Solution 060204* 1.0 B593113 Enva Ireland Ltd.


Clare


01

D9 Enva Shannon Ann Marie O'Connell

061-707400

Wevo Hardener

300M



Clare


01


Ann Marie O'Connell

061-707400

Aerosols 160504* 0.06 B592099 Enva Ireland Ltd.

Enva Ireland Ltd. Portlaoise Clonminam

Industrial Estate Co. Laois

Waste License W0184-01

Waste Collection Permit: WCP-DC-

08-116-01

R4 SBH Germany Annemarieke Van Der

Voort 057-8678600

Waste Oil

130208* 9.7 N/A Enva Ireland Ltd

Enva Ireland Ltd. Portlaoise Clonminam

Industrial Estate Co. Laois

Waste License W0184-01

Waste Collection Permit: WCP-DC-

08-116-01

R9 Enva Portlaoise Annemarieke Van Der

Voort 057-8678600


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Dry waste

contaminated with

Hydrocarbons

150202*

4.425

B576571

Enva Ireland

Ltd

Enva Ireland Ltd.

Portlaoise Clonminam Industrial Estate Co. Laois

Waste License

W0184-01 Waste Collection Permit: WCP-DC-

08-116-01

D10 KWA Germany

Annemarieke

Van Der Voort

057-8678600

Fluorescent tubes WEEE

200121*

0.145

B575843 Irish Lamp Recycling Ltd

Irish Lamp Recycling Co. Ltd, Kilkenny Road, Athy,

Co. Kildare

WFP-KE-08-348-01

Recycled R4/R5

Jim Cuddy 059-8631377

Hydroxide sludge

from effluent treatment of plating shop

110109*

18.76

B587204 B592018

Veolia World Resources Company GmbH, D-04808

Wurzen, IndustriesstraBe7,

Germany

SL83A0032 Metal Reclamation D15 & R4

Steve Waite +

441926431444

Waste cloths & filters with

Gold potassium cyanide

110198*

0.0905 0.0945

B576098 B592028

Veolia TES Technical Solutions, Ireland Ltd

Mastermelt Refining Services Ltd

BL 1312 Metal reclaim R4

Jeni Alcock +44(0) 1298

766900

Waste Gold Potassium

cyanide

110198* 2.839 0.7065 0.913

B576098 B592007 B592028

Veolia TES Technical Solutions, Ireland Ltd


BL 1312 Metal reclaim R4


766900

Waste Silver Potassium

110198*

0.8995

B592007

Veolia TES Technical


BL 1312

Metal reclaim R4



21

cyanide Solutions, Ireland Ltd

766900

Total Recycled

47.79

Total Disposed

0

Total 47.79


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2.4.2 Waste Minimisation Indices Key annual waste management data for the period January to December 2010 is presented in the table 2.9 below:

Table 2.9: Waste Management Data Required for Calculation of Indices

Period Jan-Dec 2010

Raw Materials Usage (tonnes) 4049.8

Waste Produced (tonnes) 728.94

Waste Recovered (tonnes) 468.88

The following indices have been calculated for the period January to December 2010.

Gross Waste Minimisation Index (Gross WaMI)

Gross WaMI: Waste Produced x 100 Raw Materials

(728.94/4049.8) x 100

18%

Nett of Process Waste Minimisation Index (Nett of P rocess WaMI)

Nett of Process: WaMI Waste Produced – Amount Recovered x 100 Raw Materials

((728.94-468.88) /4049.8)) x 100

6.42%


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2.4.3 National Waste Database Data Report Sheet

Table 2.10: National Waste Database Data Report Sheet

NACE Code

(two letters and max. four numbers)

2561

Reporting Period

January to December 2010

Number of Employees

(for reporting period)

300

Total Tonnage of Waste Pro duced

Hazardous

Non Hazardous

728.94

47.79

681.15

Total Tonnage of Waste Recovered

Hazardous

Non Hazardous

468.88

47.79

421.09


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2.5 Noise

Condition 6.10 of Molex’s IPPC Licence requires that a noise survey of the site operations be carried out every three years and a summary of the results submitted as part of the AER. An external consultant carried out a noise survey of the site during May 2008. The report was submitted to the EPA as part of the 2008 AER.

Schedule B.4 of the IPPC licence sets a daytime noise limit of 55 dB(A) LAeq, and a night-time noise limit of 45 dB(A) LAeq at noise sensitive locations.

The measured underlying noise levels (LA90) at the nearest noise sensitive location, i.e. Tullyglass Hill, were 52 dB(A) and 41dB(A) daytime and night-time respectively. The noise level attributable to Molex at this location is considerably less than this measured level.

There was no clearly audible tonal component or impulsive component in the noise emission from the Molex plant at the noise sensitive location, denoted H1.

It is planned to carry out a noise survey again in 2011 in accordance with IPPC Licence requirements.

.


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2.6 Energy and Water Consumption Energy (electricity and oil) and water usage for the site for the period January to December 2010 are given in the following table.

Table 2.11: Resource Consumption 2010

Oil (m 3) Mains Water (m3)

Electricity (kW)

Daytime

Electricity (kW)

Night time

Gas Usage (m3)

30.01 29,356 7,019,868

4,694,326 2,970

Table 2.12 below compares the resource consumption levels during 2008, 2009 with those from 2010.

Table 2.12: Trend in Resource Consumption

2008 2009 2010

Oil (m 3) 35.0 25.032 30.01

Mains Water (m 3) 11,114 38,741 29,356

Gas (m 3) 6,393 3,951 2,970

Electricity (kW) - Daytime 8,218,057 6,000,707 7,019,868

Electricity (kW) - Night time 5,634,296 3,642,321 4,694,326

No. of Plated Terminals Produced

1,729 x 106 779,000,000 1,003,529,487

Energy Audit

As per Condition 7.1 of the IPPC Licence, Molex engaged a consultancy firm to carry out an Energy Audit in January 2006. This Audit Report was attached as Appendix H in the 2006 AER.


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2.7 Agency Monitoring and Enforcement

2.7.1 Aqueous Emissions Sampling and Analysis The EPA took two samples of sewer emission from the Molex site on 20/04/2010 and 07/10/2010

Table 2.13 provides a comparison of the EPA results with results from Molex’s monitoring programme taken on or close to the date of the EPA monitoring programme.

Table 2.13: Emissions to Sewer – Discharged from Reference Point SE1

Parameter mg/l Emission Limits mg/l

EPA Results Molex Results

(on dates close to EPA monitoring dates)

Date

20/04/10 07/10/10 Q2 composite Q 4 composite

Sample type Composite Composite Composite Composite

Flow / day 150m3 44 49

pH 6-9 7.53 7.71 - -

Temperature 43° C max - -

BOD 300 >7 >24 10 48

COD 600 13 46 11 58

Suspended Solids 300 3 4 3 31

Nitrates 30 0.316 0.189 <0.27 0.35

Chlorides 500 132 614 273 256

Sulphates (as SO 4) 1000 646 514 580 560

Nickel 0.5 0.019 0.023 0.08 0.0096

Cobalt 0.5 0.007 <0.005 0.005 0.0037

Copper 0.5 <0.005 <0.005 0.0006 0.0021

Zinc 0.5 0.007 0.144 0.011 0.0078

Arsenic 0.5 <0.001 0.001 ND 0.0003

Cadmium 0.1 <0.0001 0.0004 ND 0.00005

Lead 0.5 <0.001 0.009 0.0002 0.001

Tin 2.0 0.006 0.033 0.008 0.0029

VOC Screen µg/l - 3.8 8 1.417


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Table 2.14: Surface Water Sampling Point results.

Parameter

Sample taken on 7/10/2010

Units SWSP1 SWSP2

Conductivity @ 25 C uS/cm 4140 289

Chemical Oxygen Demand mg/l O2 145 47

Iron mg/l 0.334 0.482

Manganese mg/l 0.012 0.009

Cadmium mg/l <0.0001 <0.0001

Chromium mg/l 0.005 0.007

Copper mg/l 0.438 0.052

Nickel mg/l 0.127 0.030

Lead mg/l 0.005 0.005

Zinc mg/l 0.044 0.084

Total Heavy Metals mg/l 0.619 0.177

There was no split samples taken when the Agency visited, going forward the process is in place to ensure that split samples are taken. Therefore it is not possible to make a valid comparison between the EPA reported results and Molex’s results.

The Agency recorded a chloride level of 614 mg/l for a daily composite sample while the Molex weekly composite level was 256 mg/l. Without the split samples it was not possible to investigate this in more depth.

High levels of conductivity was detected in Surface Water Sampling Point 1, this is attributed to the fact that the catchment area falls within the range of the chillier farm which uses free water chillier units to control water temperature used in Stamping and Moulding. Sodium chloride was being used to soften the hard water and given that a fine spray being emitted from these units resulted in a high conductivity being recorded in water runoff from this area. Action has been taken and now reverse osmosis (RO) water is now being used in this chillier system.

2.7.2 Atmospheric Emission Sampling and Analysis

No Air Emission sampling was conducted by the Agency during 2010

2.7.3 Site Inspection undertaken by an EPA Inspecto r.

No site Audit or Inspection was conducted by the Agency during 2010


28

2.8 Environmental Incidents and Complaints

Environmental Incidents In the period January to December 2010, Molex reported one incident with respect to the IPPC licence.

Environmental Complaints Molex Ireland Limited received no complaints during the period from January to December 2010.

2.9 AER 2010 Returns Excel Worksheets

Please refer to Appendix D for a copy of the AER 2010 Returns Excel Worksheets.


29

3.0 Environmental Management of the activity

3.1 Environmental Management System – ISO 14001 Condition 2.2 of Molex Ireland’s IPPC Licence requires the licensee to establish and maintain an Environmental Management System (EMS). In January 2000, Molex Ireland began to modify the EMS which was in place as required by the IPPC Licence in order to meet with the requirements set out by the ISO 14001 Environmental Management System Standard.

The company was awarded accreditation to the Standard in September 2000. (Molex received revised 2004 ISO-14001 certification in Sep 2005). Molex Ireland carries out regular internal audits to assess the EMS for continued compliance. An annual audit is scheduled by the ISO 14001 Certification Body to ensure Molex are compliant with ISO 14001 standards.

During the implementation phase of the Environmental Management System, all employees received training on general environmental awareness. In addition, this training programme has been included in the induction programme for new employees. The Environmental Health and Safety Manager delivers this training in conjunction with the Training Manager.

A number of quality auditors have been trained in internal environmental auditing. Physical site audits and audits of the EMS are carried out on a regular basis by them in accordance with the audit schedule.

3.2 EMP 2010 Report and Schedule of Objectives and Targ ets 2011 A revised Schedule of Objectives and Targets for 2010, as per Condition 2.2.2.2 of the IPPC Licence has been incorporated into the Environmental Management System. Table 3.1 outlines Molex’s Objectives and Targets for 2011.

Due to the continuation and crossover of all of the Objectives and Targets from the 2010 Schedule, the following table is both a report on the 2010 Objectives and Targets (EMP Report) and a schedule of Objectives and Targets for 2011 onwards.


30

Table 3.1 Schedule of Objectives and Targets 2011 (includes EMP Report for 2010)

Objectives 2010 Targets Time Frame Respo nsibility

1. Energy & Resource Efficiency Carry out an Energy audit (completed in 2006) review findings and implement its findings over the next 5 years.

Continue to track energy usage in the plant both at local and at departmental level, also purchased energy tracking meters

Institute Energy awareness campaigns

Ongoing

Ongoing

2011

EHS/Facilities and Greenbelt Team

E-Greenbelt team

2. Introduce Cleaner Technology Introduce cleaner technologies as they become commercially available.

Ensure all new projects are RoHS compliant

Uploading Bill of Substances (BoS) for components on SAP system

Lead & ammonia were removed from all plating processes in June 06 & Feb 06 respectively.

Molex will continue to monitor cleaner technologies.

Comply with the Requirements of the REACH Directive.

Ensure that all refrigeration equipment on-site is on the register and the coolant is identified and managed in accordance with Best Practice, per EPA Notifications on 17th July 2009

Create Register of all RAC equipment for site 2010

Ongoing

Ongoing

Ongoing

Complete

Ongoing

Complete

EHS

Facilities

3. Reduction & Minimization of waste

Molex will continue to monitor for further recycling streams. (5 yr plan).

Review monthly waste figures going to landfill and various recycling facilities. Investigate any discrepancies or unaccountable peaks in the waste figures

Remove canteen biodegradable waste from the landfill components

Investigate the possibility of recycling/reuse of plastic resin stream

Ongoing

Ongoing

2010

2011

EHS/Facilities/ Canteen staff

Facilities

4. Develop more stringent control measures/mechanisms in the effluent treatment plant. (Cleaner Technology)

Investigate ways to minimise loading on the effluent treatment plant to ensure compliant discharges to sewer.

Ceased disposal of waste nickel plating solutions in WWTP in 2007. NI based chemistries now sent off site for disposal

Install an online Turbidity Meter Q1 2008

Ongoing

Complete

Complete

Complete

EHS


31

Replace cross flow filtration membranes – Q2 2008, completed.

Use RO water (soft water) in plant water chillers system

2011

Facilities

5. As per condition 3.9 of Licence: “The provision of a catchment system to collect any leaks from flanges and valves of all over ground pipes used to transport material other than water shall be examined.”

To ensure that pipe work and its contents does not pose a threat to the environment via spills and/or leaks. Continuous monitoring and auditing will facilitate the control and reduction in risk of leaks.

Ongoing EHS

6. As per condition 7.3 of Licence: “The licensee shall identify opportunities for reduction in the quantity of water used on site including recycling and reuse initiatives, wherever possible.”

Through continuous monitoring of water usage through bills issued by the local authority and analysis of where on site water is specifically used, Molex will ensure that water usage is kept to the required minimum.

Ongoing EHS

7. Ensure that the volume flow for emission point A3-4 is not exceeded during operations and is compliant with the licence conditions.

Investigate and fit controlling equipment to ensue that the volume flow stays within the limit as specified in the licence.

Installed an inverter to control flow rate 2010

2010

Complete

EHS/Facilities

8. Investigate hydrocyanic acid emissions levels from the site.

Ensure that emissions to atmosphere are in compliance with Licence conditions. 2011 Plating +EH&S


32

3.3 Pollution Emission Register (PER)

In accordance with Condition 6.11.1 of the IPPC Licence and as agreed with the EPA, Molex completed a mass balance for the following substances:

• Nickel

• Tin

A copy of the PER Report for the period January to December 2010 is included in Appendix C.

Molex introduced ammonia free and lead free electroplating chemistries, which eliminated the use of ammonia and lead in the facility, since January & June 2006 respectively.

As a result and as agreed with the EPA, Molex will did not calculate a mass balance for either ammonia or lead in the PER 2007 and will not include these parameters in future PERs.

Molex Ireland as a result of the economic downturn and company restructuring has discontinued Copper plating and pure Tin plating at the end of 2009. Therefore it is not feasible to continue with copper in the per as stocks are now reduced to zero (March 2010)

Molex proposes to include Nickel and tin in PER 2010


4.0 OTHER REPORTS

4.1 Bund Integrity Assessment In accordance with Condition 3.5.5 of IPPC Licence P0288-02, Molex Ireland is required to undertake a Bund Integrity Assessment by external consultants on a three year cycle.

During 2008 the fuel bund was sealed and fitted with a pump for the management of rain water. Also a monitoring program was instituted at the request of the Agency.

An assessment of the bunds on site was undertaken during 2010 and the report is attached in Appendix E.

4.2 Firewater Retention Study. Molex (Ireland) Ltd. contracted external consultants to carry out a fire-water retention study on its electrical components manufacturing facility in accordance with Condition 3.7 of its IPPC Licence P0288-02. The purpose of this study was to determine the requirement or otherwise for the provision of dedicated on-site fire-water retention on the basis of an environmental risk assessment.

The full report was attached as Appendix I in the 2006 AER.

A review of the Firewater Retention Capacity will be undertaken during 2010 and a summary report is attached in Appendix F.

Hard Copies will be forwarded to the Agency in April 2011

4.3 Environmental Liabilities In accordance with Condition 12.3.2 of the IPPC Licence, Molex contracted external consultants to perform an Environmental Liabilities Risk Assessment (ELRA).

In accordance with Condition 12.3.2, the ELRA will be reviewed as necessary to reflect any significant change on site or at a minimum every three years and submitted as part of the AER.

A Residuals Management Plan (RMP) was also completed as per condition 10.2.1 of the IPPC Licence.

In Accordance with Condition 10.2.2, Molex have reviewed the RMP and as there have been no significant changes to the processes on-site during 2008 Molex do not propose to amend the content of the RMP with regards the scope for decommissioning the site, as submitted in the 2006 AER.

These reports were included in Appendix J of the 2006 AER.

Molex will conduct a review of the Environmental Liabilities Risk Assessment (ELRA), in light of the changes that occurred during 2010, this review will be conducted during 2011.

4.4 Intrusive Hydrogeological Investigation. External consultants were commissioned during 2006 by Molex Ireland Ltd. to undertake a hydrogeological investigation at the facility in the Shannon Industrial Estate, in compliance with Condition 6.9.1 of the IPPC Licence.

The entire report was included as Appendix K in the 2006 AER.


4.5 CCTV Survey

A CCTV Survey of underground pipes was carried out by external consultants in November 2009. The full report was attached in the 2009 AER. The next CCTV study will be carried out in 2012.

5 SOLVENT USAGE Molex Ireland Ltd. does not have manufacturing processes that incorporate solvents. However, a small quantity of propan-2-ol is kept on site for miscellaneous cleaning purpose


APPENDIX A

ENVIRONMENTAL POLICY

Molex Ireland Ltd. AEP Division

Number: ENVMAN4.2 Effective Date: June 8th 2009

Revision: 11

Subject: Environmental Policy Page 1 of 1

Uncontrolled document, Valid only on day of printing, Master Copy on Intranet. Printed on 30/03/2011


APPENDIX B

REPORTS ON EMISSIONS TO ATMOSPHERE 2010

Email: [email protected] www.enviro-consult.com Registered Office as above. Registered Number 243 412

Tel: 01 276 1428

Directors: Noel J. McGrath Robert B. Sutcliffe

Environmental Services for Industry Including – ► Air, Noise & Water Monitoring ► Energy & Water use reduction ► Bund Testing ► IPPC/Waste Licence Compliance ► Environmental Management Systems to ISO 14001 ► EIS & Planning Affiliations & Accreditations

► MCERTS Accredited personnel for stack testing ► Member of Source Testing Association ► Member Water Monitoring Association, Membership No WMA 0041

Stack Emission Monitoring Report

Bi-annual 1 of 2010

Molex (Ireland) Ltd.

IPPC Licence No: Licence P0288-02

Environmental Efficiency Document Number 1247-01 v2.01

Environmental Efficiency Consultants Document 1247-01 v2.01

Air Emissions Monitoring Report for B1/2010

Licence No P0288-02 Molex (Ireland) Ltd. Report 1 of 2010

Page 2 of 25

1. Part 1: Executive Summary

1.1 Cover Sheet

Document Title

Air Emissions Monitoring Report – 2010: Bi-annual 1

Licence Register

No.

P0288-02

Licence holder and

Installation name Molex (Ireland) Ltd.

Date(s) of the

monitoring visit 26/05/2010

Name and address

of client

organisation


Shannon Industrial Estate, Shannon, Co. Clare.

Name and address

of monitoring

Organisation

Environmental Efficiency, Parnell House, 19 Quinsboro Road, Bray,

Co. Wicklow

Date of report

24/06/2010

Monitoring team

and qualifications

Richard McElroy, B.Eng (Hons) Environmental Engineering, MCerts

Level 1 (MM08916)

Report Author and

qualifications

Róisín Ní Dhubhda BSc, MSc., AIEMA

Name and function

of person approving

report

Bob Sutcliffe, CEng, MIMechE, CMIWM, Technical Director

Internal document

number

1247-01 v2.01

Report Format LQS SR03 Air Monitoring EPA-AG2 Template v1.7

Environmental Efficiency report status and approvals

Signed for and on behalf of Issue Status Date Author Environmental

Efficiency Client

1.00

2.01 Approved 23/03/2011 RND

Conditions relating to the issue of this report:

1. No alteration to this report by third parties is permitted

2. Where this report is reproduced, it shall only be reproduced in full.

3. Reports remain the property of Environmental & Efficiency Consultants

(Ireland) Limited until paid for in full.




Page 3 of 25

1. PART 1: EXECUTIVE SUMMARY...........................................................................................2

1.1 COVER SHEET.........................................................................................................................2 1.2 MONITORING OBJECTIVES ......................................................................................................4 1.3 MONITORING RESULTS ............................................................................................................4

1.3.1 Emission point A3-3 ..........................................................................................................5 1.3.2 Emission Point A3-4..........................................................................................................7

2. PART 2: SUPPORTING INFORMATION ................................................................................9

2.1 COVER SHEET.........................................................................................................................9 2.2 ANNEX 1...............................................................................................................................10

2.2.1 Names, functions and qualifications of monitoring staff.................................................10 2.2.2 Substances monitored, methods used and operating procedure .....................................10

2.3 UNCERTAINTY CALCULATIONS .............................................................................................11

APPENDIX 1 EMISSION POINT A3-3..........................................................................................................12 APPENDIX 2 EMISSION POINT A3-4..........................................................................................................19




Page 4 of 25

1.2 Monitoring Objectives

The objective of the monitoring is to determine compliance with the Emission Limit

Values stated in the client’s licence. Such monitoring is required for the following

emission points, parameters and at the frequency indicated in the table below.

Emission

Point Parameter

Frequency of

monitoring

Reported in

this report

Comment

A3-3

TA Luft Inorganic

Particulate Matter

Class II

Biannually Yes No comment

A3-3 TA Luft Inorganic

Particulate Matter

Class III

Biannually

Yes No comment

A3-3 TA Luft Inorganics

Class II

Biannually Yes

No comment


Class III

Biannually Yes

No comment


Particulate Matter

Class II



Particulate Matter

Class III



Class II



Class III


1.3 Monitoring results

The results of the monitoring reported in this document are tabulated below. The

methods used are defined by Standard Operating Procedures (SOP), each SOP having

a unique number. The relevant detail regarding each SOP is given in Section 2.

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ng o

f

pla

nt

Norm

al l

oad

Type

of

abat

emen

t S

crubber

1.3

.2.3

C

om

pari

son

of

oper

ato

r C

EM

S d

ata

an

d P

erio

dic

Mon

itori

ng R

esu

lts

Ther

e is

no C

EM

S d

ata

for

this

em

issi

on p

oin

t.

1.3

.2.4

C

om

men

ts

Issu

e 2010:

B1

Monit

ori

ng l

oca

tion

A3-4

(P

lati

ng S

hop R

oof)

Dev

iati

ons

from

SS

P a

nd S

OP

s n/a




Page 9 of 25

2. Part 2: Supporting Information

EPA AG2 states that the supporting information is an option requirement.

2.1 Cover Sheet

Document Title


Licence Register

No.

P0288-02

Licence holder and

Installation name Molex (Ireland) Ltd.

Date(s) of the

monitoring visit 26/05/2010

Name and address

of client

organisation



Name and address

of monitoring

Organisation


Co. Wicklow

Date of report

24/06/2010

Monitoring team

and qualifications

Richard McElroy, B.Eng (Hons) Environmental Engineering, MCerts

Level 1 (MM08916)

Report Author and

qualifications


Name and function

of person approving

report


Internal document

number

1247-01 v2.01





Page 10 of 25

2.2 Annex 1

2.2.1 Names, functions and qualifications of monitoring staff

Name Function MCERTS Level Qualifications

Richard McElroy Lead Monitoring

Technician Level 1 (MM08916) B.Eng (Env Eng)

Ronan Sutcliffe Assistant Monitoring

Technician Trainee Dip. in

Environmental

Protection

2.2.2 Substances monitored, methods used and operating procedure

The methods used are referenced by SOPs (Standard Operating Procedures) in Part 1

of this report. The descriptions of the methods referenced by these SOPs are listed

below.

SOP Parameter Method Standard Analysis by Accreditation

99.80 TA Luft

Inorganic

Particulate

Matter Class II

Isokinetic

sampling.

Analysis by

SOPs specified

below.

ISO 9096 EEC Not accredited

01.08 Particulates Gravimetric Environmental

Efficiency

None

99.81 TA Luft

Inorganic

Particulate

Matter Class III

Isokinetic

sampling.

Analysis by

SOPs specified

below.

ISO 9096 N/A N/A

01.08 Particulates Gravimetric Environmental

Efficiency

Not UKAS

accredited 01.04 Any gas with use

of appropriate

tube selected by

reference to

manufacturer’s

web site

Sorbent tube RPS Laboratories ISO 17025:2005

98.06 Hydrogen

Bromide

IC SAL Laboratory Not UKAS

accredited 99.95 Hydrogen

Fluoride


accredited 98.08 Hydrogen

Sulphide


accredited 98.07 Hydrocyanic

Acid (as CN)

Colorimetry SAL Laboratory Not UKAS

accredited 99.94 Chlorine IC SAL Laboratory Not UKAS

accredited 10.98 Ammonia Colorimetry SAL Laboratory Not UKAS

accredited 01.31 Velocity and

volume flow rate

Determination of

velocity using a

Pitot tube and

manometer

ISO 9096/

ISEN

13284

PART 1

Environmental

Efficiency

None




Page 11 of 25

The following table summarises the equipment used and the QC checks. The SOP

details the equipment used and QC checks.

SOP Equipment QC Check

01.31 Pitot tube Zero check

01.31 Manometer Zero check

01.19 FID Zero check and Span check with calibration

gas at 500 ppm at start and end of use of FID

01.04 Pump (< 3 litres/minute) Flow rate set in lab prior to use on site

01.08 Isokinetic sampling train Leak Test. Swirl Test. Sample blank.

2.3 Uncertainty Calculations

Uncertainties are calculated for 95% confidence based on available data. The

calculations used are described by SOPs and the actual calculation for each

monitoring result is determined by spreadsheet referenced by the same SOP.

Calculations are not included in this report; however, a copy of the spreadsheet is

available on request.

SOP

Method

96.01

UOM FGA and FID (O2, NOx, SOx, CO, Efficiency, TOC, Volume

Flow)

96.02 UOM Isokinetic Monitoring

96.10 UOM Sorbent Tube

96.11

UOM of concentration by extraction onto self indicating colorimetric

tube

96.12 UOM of velocity measurement using Pitot tube

96.14 UOM Impinger and pump




Page 12 of 25

Appendix 1 Emission Point A3-3

A1.1 Diagram of stack

A1.2 Results Calculations

Calculation for flow rate – A3-3

Parameter Value Unit Comment

Velocity 8.07 m/s -

Duct cross section area 0.152 m2 -

Flow rate 4,415.9 m3/hour -

Duct Temperature 22 C -

Ambient pressure 1,022 hPa -

Normalised flow rate 4,122 Nm3/hour +/- 166.2

Sampling plane

Platform

Sampling Plane




Page 13 of 25

A1.3 Analysis details where applicable




Page 14 of 25




Page 15 of 25




Page 16 of 25




Page 17 of 25




Page 18 of 25

A1.4 Derivation of total or class parameters

The general method for determining the results for ‘class parameters’, e.g. TA Luft

Class II is to speciated the sample and for each substance found determine whether it

is a member of the class of interest. The tables below show the substances found that

belong to each class of interest. The concentrations are detailed on the following

Certificate of Analysis.

TA Luft Inorganic Particulates Class II SOP Parameter Mass, µg

99.80 Lead <100

99.80 Cobalt <100 99.80 Nickel <100 99.80 Selenium <100 99.80 Tellurium <100 Total <250

TA Luft Inorganic Particulates Class III SOP Parameter Mass, µg

99.81 Antimony <100 99.81 Chromium <100 99.81 Easily soluble cyanides <100 99.81 Easily soluble fluorides <100 99.81 Copper <100 99.81 Manganese <100 99.81 Vanadium <100 99.81 Tin <100 Total <400

TA Luft Inorganics Class II SOP Parameter Mass, µg

99.80 Hydrogen Bromide <2

99.81 Hydrogen Fluoride <5

99.80 Hydrogen Sulphide <5

99.80 Hydrocyanic Acid (as CN) 2

99.80 Chlorine 1

Total <9

TA Luft Inorganics Class III SOP Parameter Mass, µg

99.81 Ammonia <0.2

Total <0.1




Page 19 of 25

Appendix 2 Emission Point A3-4





Velocity 7.61 m/s -






Sampling plane

Platform

Sampling Plane




Page 20 of 25





Page 21 of 25




Page 22 of 25




Page 23 of 25




Page 24 of 25




Page 25 of 25

A2.4 Derivation of total or class parameters

The general method for determining the results for ‘class parameters’, e.g. TA Luft

Class II is to speciated the sample and for each substance found determine whether it

is a member of the class of interest. The tables below show the substances found that

belong to each class of interest. The concentrations are detailed on the following

Certificate of Analysis.

TA Luft Inorganic Particulates Class II SOP Parameter Mass, µg

99.80 Lead <100

99.80 Cobalt <100 99.80 Nickel <100 99.80 Selenium <100 99.80 Tellurium <100 Total <250

TA Luft Inorganic Particulates Class III SOP Parameter Mass, µg

99.81 Antimony <100 99.81 Chromium <100 99.81 Easily soluble cyanides <100 99.81 Easily soluble fluorides <100 99.81 Copper <100 99.81 Manganese <100 99.81 Vanadium <100 99.81 Tin <100 Total <400

TA Luft Inorganics Class II SOP Parameter Mass, µg

99.80 Hydrogen Bromide <2

99.81 Hydrogen Fluoride <5

99.80 Hydrogen Sulphide <5

99.80 Hydrocyanic Acid (as CN) 13

99.80 Chlorine 1

Total <20

TA Luft Inorganics Class III SOP Parameter Mass, µg

99.81 Ammonia <0.2

Total <0.1

Tel: + 353 (0)1 276 1428 Fax: + 353 (0)1 276 1561 Email:[email protected] www.enviro-consult.com

Registered Office as above. Registered Number 243 412

Directors: Noel J. McGrath, Robert B. Sutcliffe

Stack Emission Monitoring Report

2010: Bi-annual 2


IPPC Licence No: Licence No P0288-02

(Environmental Efficiency Document Number 1247-02 v2.01


Emissions Monitoring Report for B2/2010

IPPC Licence No. P0288-02 Molex (Ireland) Ltd. Report 2 of 2010 Version 2.01

Page 2 of 32

1. Part 1: Executive Summary

1.1 Cover Sheet

Document Title


Licence Register No.

P0288-02

Licence holder and

Installation name


Date(s) of the

monitoring visit

12/10/2010

Name and address of

client organisation



Name and address of

monitoring Organisation


Co. Wicklow

Date of report

23/02/2011

Monitoring team and

qualifications Richard McElroy, B.Eng (Hons) Environmental Engineering, MCerts

Level 1 (MM08916)

Report Author and

qualifications


Name and function of

person approving report


Internal document number 1247-02 v2.01


Environmental Efficiency report status and approvals

Signed for and on behalf of Issue Status Date Author Environmental

Efficiency Client

1.00 Draft RND

2.01 Approved 24/02/2011




3. Reports remain the property of Environmental & Efficiency Consultants

(Ireland) Limited until paid for in full.




Page 3 of 32

1. PART 1: EXECUTIVE SUMMARY...........................................................................................2

1.1 COVER SHEET.........................................................................................................................2 1.2 MONITORING OBJECTIVES ......................................................................................................4 1.3 MONITORING RESULTS ............................................................................................................4

1.3.1 Emission point A3-3 ..........................................................................................................5 1.3.2 Emission point A3-4 ..........................................................................................................9

2. PART 2: SUPPORTING INFORMATION ..............................................................................13

2.1 COVER SHEET.......................................................................................................................13 2.2 ANNEX 1...............................................................................................................................14

2.2.1 Names, functions and qualifications of monitoring staff.................................................14 2.2.2 Substances monitored, methods used and operating procedure .....................................14

2.3 UNCERTAINTY CALCULATIONS .............................................................................................16

APPENDIX 1 EMISSION POINTS A3-3 ........................................................................................................17 APPENDIX 2 EMISSION POINT A3-4 ..........................................................................................................25




Page 4 of 32

1.2 Monitoring Objectives

The objective of the monitoring is to determine compliance with the Emission Limit

Values stated in the client’s licence. Such monitoring is required for the following

emission points, parameters and at the frequency indicated in the table below.

Emission

Point

Parameter Frequency of

monitoring

Reported in

this report

Comment

A3-3

TA Luft

Inorganic

Particulate

Matter Class II

Biannually Yes -

A3-3 TA Luft

Inorganic

Particulate

Matter Class III

Biannually

Yes -

A3-3 TA Luft

Inorganics

Class II

Biannually Yes -

A3-3 TA Luft

Inorganics

Class III

Biannually Yes -

A3-4 TA Luft

Inorganic

Particulate

Matter Class II

Biannually Yes

-

A3-4 TA Luft

Inorganic

Particulate

Matter Class III

Biannually Yes

-

A3-4 TA Luft

Inorganics

Class II

Biannually Yes -

A3-4 TA Luft

Inorganics

Class III

Biannually Yes -

1.3 Monitoring results

The results of the monitoring reported in this document are tabulated below. The

methods used are defined by Standard Operating Procedures (SOP), each SOP having

a unique number. The relevant detail regarding each SOP is given in Section 2.

Envir

onm

enta

l E

ffic

iency

Consu

ltan

ts

Docu

men

t 1247-0

2 v

2.0

1

E

mis

sions

Monit

ori

ng R

eport

for

B2/2

010

IPP

C L

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0288-0

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Mole

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.

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f 2010 V

ersi

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.01

P

age

5 o

f 32

1.3

.1

Em

issi

on

poin

t A

3-3

1.3

.1.1

R

esu

lts

TA

Lu

ft I

norg

an

ics

Part

icu

late

Matt

er

Ref

eren

ce

Co

nd

itio

ns

SO

P

Pa

ram

eter

E

LV

R

esu

lt

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cert

ain

ty

at

95

%

con

fid

ence

Un

its

Da

te

Sta

rt/

En

d

Tim

e

Co

mp

lia

nce

T

P

O2

M

Fu

el

Co

mm

ent

99

.80

TA

Luft

Ino

rgan

ic

Par

ticu

late

Mat

ter

Cla

ss

II

0.5

<

0.0

59

+

/- 0

.4

mg/N

m3

12

/10

/20

10

12

.11

-

12

.41

Yes

Y

Y

N

N

N

/A

-

99

.81

TA

Luft

Ino

rgan

ic

Par

ticu

late

Mat

ter

Cla

ss

III

1.0

<

0.1

07

+

/- 0

.4

mg/N

m3

12

/10

/20

10

12

.11

-

12

.41

Yes

Y

Y

N

N

N

/A

-

Envir

onm

enta

l E

ffic

iency

Consu

ltan

ts

Docu

men

t 1247-0

2 v

2.0

1

E

mis

sions

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ori

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eport

for

B2/2

010

IPP

C L

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0288-0

2

Mole

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rela

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Ltd

.

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2 o

f 2010 V

ersi

on 2

.01

P

age

6 o

f 32

TA

Lu

ft I

norg

an

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Cla

ss I

I R

efer

ence

Co

nd

itio

ns

SO

P

Pa

ram

eter

E

LV

R

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lt

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cert

ain

ty

at

95

%

con

fid

ence

Un

its

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te

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En

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Tim

e

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mp

lia

nce

T

P

O2

M

Fu

el

Co

mm

ent

98

.06

H

yd

rogen

Bro

mid

e

No

t

spec

ifie

d

<0

.06

8

+/-

0.6

67

m

g/N

m3

12

/10

/20

10

11

.15

-

11

.45

Yes

Y

Y

N

N

N

/A

-

99

.95

H

yd

rogen

Flu

ori

de

No

t

spec

ifie

d

<0

.06

8

+/-

0.6

67

m

g/N

m3

12

/10

/20

10

11

.15

-

11

.45

Yes

Y

Y

N

N

N

/A

-

98

.08

H

yd

rogen

Sulp

hid

e

No

t

spec

ifie

d

0.3

23

+

/- 0

.02

7

mg/N

m3

12

/10

/20

10

11

.15

-

11

.45

Yes

Y

Y

N

N

N

/A

-

98

.07

H

yd

rocy

anic

Aci

d (

as C

N)

No

t

spec

ifie

d

<0

.17

1

+/-

0.6

67

m

g/N

m3

12

/10

/20

10

11

.15

-

11

.45

Yes

Y

Y

N

N

N

/A

-

99

.94

C

hlo

rine

No

t

spec

ifie

d

0.0

81

+

/- 0

.16

7

mg/N

m3

12

/10

/20

10

11

.15

-

11

.45

Yes

Y

Y

N

N

N

/A

-

-

TA

Lu

ft

Ino

rga

nic

s

Cla

ss I

I

3.0

<

0.7

11

+

/- 1

.16

7

mg/N

m3

12

/10

/20

10

1

1.1

5

-

11

.45

Yes

Y

Y

N

N

N

/A

To

tal

TA

Lu

ft I

norg

an

ics

Cla

ss I

II

Ref

eren

ce

Co

nd

itio

ns

SO

P

Pa

ram

eter

E

LV

R

esu

lt

Un

cert

ain

ty

at

95

%

con

fid

ence

Un

its

Da

te

Sta

rt/

En

d

Tim

e

Co

mp

lia

nce

T

P

O2

M

Fu

el

Co

mm

ent

10

.98

A

mm

onia

3

0.0

0

.17

5

+/-

0.6

67

m

g/N

m3

12

/10

/20

10

11

.15

-

11

.45

Yes

Y

Y

N

N

N

/A

To

tal

Envir

onm

enta

l E

ffic

iency

Consu

ltan

ts

Docu

men

t 1247-0

2 v

2.0

1

E

mis

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for

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66

.2

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10

11

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11

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Y

Y

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N

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appli

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e fo

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, ox

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and m

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) fo

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in t

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above

table

is

indic

ated

by ‘

Y’

(Yes

) under

the

resp

ecti

ve

read

ing (

T, P

, O

2 o

r M

). If

‘N

’ (N

o)

is i

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, th

en t

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refe

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s not

appli

ed.

Ref

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ions

Tem

per

ature

, K

P

ress

ure

, hP

a O

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, %

M

ois

ture

273.1

5

1,0

13.2

5

N/A

N

/A

1.3

.1.2

M

eth

ods

Sit

e S

pec

ific

Pro

toco

l re

fere

nce

num

ber

for

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S 1

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Envir

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Consu

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1.3

.1.3

O

per

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Pro

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sta

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Ele

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Conti

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or

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If b

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ch s

ample

d

Not

appli

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use

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Norm

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oad

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or

conti

nuous

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f pla

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al l

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of

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t S

crubber

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.1.4

C

om

pari

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of

oper

ato

r C

EM

S d

ata

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d P

erio

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Mon

itori

ng R

esu

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Ther

e is

no C

EM

S d

ata

for

this

em

issi

on p

oin

t

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onm

enta

l E

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Consu

ltan

ts

Docu

men

t 1247-0

2 v

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1

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1.3

.1.5

C

om

men

ts

Issu

e 2010:

B2

Monit

ori

ng l

oca

tion

A3-3

(P

lati

ng S

hop R

oof)

A3-4

(P

lati

ng S

hop R

oof)

Dev

iati

ons

from

SS

P a

nd S

OP

s n/a

Envir

onm

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l E

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Consu

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ts

Docu

men

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1.3

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Em

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on

poin

t A

3-4

1.3

.2.1

R

esu

lts

TA

Lu

ft I

norg

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ic P

art

icu

late

Matt

er

Ref

eren

ce

Co

nd

itio

ns

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P

Pa

ram

eter

E

LV

R

esu

lt

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cert

ain

ty

at

95

%

con

fid

ence

Un

its

Da

te

Sta

rt/

En

d

Tim

e

Co

mp

lia

nce

T

P

O2

M

Fu

el

Co

mm

ent

99

.80

TA

Luft

Ino

rgan

ic

Par

ticu

late

Mat

ter

Cla

ss I

I

0.5

<

0.0

31

+

/- 0

.51

m

g/N

m3

12

/10

/20

10

1

1.3

5

Yes

Y

Y

N

N

N

/A

-

99

.81

TA

Luft

Ino

rgan

ic

Par

ticu

late

Mat

ter

Cla

ss

III

1.0

0

.87

7

+/-

0.5

1

mg/N

m3

12

/10

/20

10

1

1.3

5

Yes

Y

Y

N

N

N

/A

-

Envir

onm

enta

l E

ffic

iency

Consu

ltan

ts

Docu

men

t 1247-0

2 v

2.0

1

E

mis

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ng R

eport

for

B2/2

010

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C L

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f 2010 V

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on 2

.01

P

age

10 o

f 32

TA

Lu

ft I

norg

an

ics

Cla

ss I

I

Ref

eren

ce

Co

nd

itio

ns

SO

P

Pa

ram

eter

E

LV

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lt

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cert

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at

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%

con

fid

ence

Un

its

Da

te

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rt/

En

d

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Co

mp

lia

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P

O2

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ent

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yd

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Bro

mid

e

No

t

spec

ifie

d

<0

.06

1

+/-

0.0

27

m

g/N

m3

12

/10

/20

10

1

2.0

7

Yes

Y

Y

N

N

N

/A

-

99

.95

H

yd

rogen

Flo

uri

de

No

t

spec

ifie

d

<0

.06

1

+/-

0.0

27

m

g/N

m3

12

/10

/20

10

12

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Yes

Y

Y

N

N

N

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-

98

.08

H

yd

rogen

Sulp

hid

e

No

t

spec

ifie

d

<0

.29

3

+/-

0.0

27

m

g/N

m3

12

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10

12

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Y

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-

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yd

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anic

Aci

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as C

N)

No

t

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12

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+

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nic

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Cla

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+

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0.4

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+

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tal

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+

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Y

es

Y

Y

N

N

N/A

-

Envir

onm

enta

l E

ffic

iency

Consu

ltan

ts

Docu

men

t 1247-0

2 v

2.0

1

E

mis

sions

Monit

ori

ng R

eport

for

B2/2

010

IPP

C L

icen

ce N

o. P

0288-0

2

Mole

x (I

rela

nd)

Ltd

.

Rep

ort

2 o

f 2010 V

ersi

on 2

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P

age

11 o

f 32

The

appli

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f ea

ch o

f th

e fo

ur

poss

ible

Ref

eren

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ondit

ions

(tem

per

ature

, pre

ssure

, ox

ygen

and m

ois

ture

) fo

r ea

ch p

aram

eter

in t

he

above

table

is

indic

ated

by ‘

Y’

(Yes

) under

the

resp

ecti

ve

read

ing (

T, P

, O

2 o

r M

). If

‘N

’ (N

o)

is i

ndic

ated

, th

en t

he

refe

rence

condit

ion i

s not

appli

ed.

Ref

eren

ce C

ondit

ions

Tem

per

ature

, K

P

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, hP

a O

xygen

, %

M

ois

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M

eth

ods

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Pro

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fere

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O

per

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Pro

cess

sta

tus

Ele

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-pla

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Conti

nuous

or

bat

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Conti

nuous

If b

atch

, det

ails

of

par

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bat

ch s

ample

d

Not

appli

cable

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use

d

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ctri

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Fee

dst

ock

use

d

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al l

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al l

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, th

roughput

or

conti

nuous

rati

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pla

nt

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Type

of

abat

emen

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crubber

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om

pari

son

of

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ata

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Mon

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e is

no C

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ata

for

this

em

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on p

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C

om

men

ts

Issu

e 2010:

B2

Envir

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enta

l E

ffic

iency

Consu

ltan

ts

Docu

men

t 1247-0

2 v

2.0

1

E

mis

sions

Monit

ori

ng R

eport

for

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010

IPP

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icen

ce N

o. P

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2

Mole

x (I

rela

nd)

Ltd

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f 2010 V

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age

12 o

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Monit

ori

ng l

oca

tion

A3-3

(P

lati

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hop R

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A3-4

(P

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hop R

oof)

Dev

iati

ons

from

SS

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nd S

OP

s n/a




Page 13 of 32

2. Part 2: Supporting Information

2.1 Cover Sheet

Document Title


Licence Register No.

P0288-02

Licence holder and

Installation name


Date(s) of the

monitoring visit

12/10/2010

Name and address of

client organisation



Name and address of

monitoring Organisation


Co. Wicklow

Date of report

23/02/2011

Monitoring team and

qualifications Richard McElroy, B.Eng (Hons) Environmental Engineering, MCerts

Level 1 (MM08916)

Report Author and

qualifications


Name and function of

person approving report


Internal document number 1247-02 v2.00





Page 14 of 32

2.2 Annex 1

2.2.1 Names, functions and qualifications of monitoring staff

Name Function MCERTS Level Qualifications

Richard McElroy Lead Monitoring

Technician Level 1 (MM08916) B.Eng (Env Eng)

Ronan Sutcliffe Assistant Monitoring

Technician Trainee Dip. in Environmental

Protection

2.2.2 Substances monitored, methods used and operating procedure

The methods used are referenced by SOPs (Standard Operating Procedures) in Part 1

of this report. The descriptions of the methods referenced by these SOPs are listed

below.

TA Luft Inorganic Particulate Matter Class II SOP SOP type Parameter Method Standard Analysis by Accreditation

of Analysis

method

99.80 Sample

collection

TA Luft

Inorganic

Particulate

Matter Class

II

Isokinetic

sampling.

Analysis by

SOPs

specified

below.

ISO

9096

N/A N/A

99.29 Analysis Lead dust ICP/OES SAL

Laboratory

UKAS

accredited

98.09 Analysis Cobalt dust ICP/OES SAL

Laboratory

UKAS

accredited 99.28 Analysis Nickel dust ICP/OES SAL

Laboratory

UKAS

accredited 98.02 Analysis Selenium

dust

ICP/OES SAL

Laboratory

UKAS

accredited 98.03 Analysis Tellurium

dust

ICP/OES SAL

Laboratory

Not UKAS

accredited 01.08 Analysis Particulates Gravimetric Environmental

Efficiency

Not UKAS

accredited

TA Luft Inorganic Particulate Matter Class III SOP SOP type Parameter Method Standard Analysis by Accreditation

of Analysis

method

99.81 Sample

collection

TA Luft

Inorganic

Particulate

Matter Class

III

Isokinetic

sampling.

Analysis by

SOPs

specified

below.

ISO

9096

N/A N/A

99.25 Analysis Antimony

Dust

ICP/OES SAL

Laboratory

UKAS

accredited 99.25 Analysis Chromium

dust

ICP/OES SAL

Laboratory

UKAS

accredited




Page 15 of 32

SOP SOP type Parameter Method Standard Analysis by Accreditation

of Analysis

method

98.04 Analysis Easily

Soluble

Cyanides

Colorimetry SAL

Laboratory

Not UKAS

accredited

98.05 Analysis Easily

Soluble

Fluorides

IC SAL

Laboratory

Not UKAS

accredited

99.26 Analysis Copper dust ICP/OES SAL

Laboratory

UKAS

accredited 99.27 Analysis Manganese

dust

ICP/OES SAL

Laboratory

UKAS

accredited 10.56 Analysis Vanadium

dust

ICP/OES SAL

Laboratory

UKAS

accredited 10.54 Analysis Tin dust ICP/OES SAL

Laboratory

UKAS

accredited 01.08 Analysis Particulates Gravimetric Environmental

Efficiency

Not UKAS

accredited

TA Luft Inorganic Class II SOP SOP type Parameter Method Standard Analysis by Accreditation

of Analysis

method

01.04 Sample

collection

Any gas with

use of

appropriate

tube selected

by reference to

manufacturer’s

web site

Sorbent tube N/A N/A

98.06 Analysis Hydrogen

Bromide

IC SAL

Laboratory

Not UKAS

accredited 99.95 Analysis Hydrogen

Fluoride

IC SAL

Laboratory

Not UKAS

accredited 98.08 Analysis Hydrogen

Sulphide

IC SAL

Laboratory

Not UKAS

accredited 98.07 Analysis Hydrocyanic

Acid (as CN)

Colorimetry SAL

Laboratory

Not UKAS

accredited 99.94 Analysis Chlorine IC SAL

Laboratory

Not UKAS

accredited

TA Luft Inorganics Class III SOP SOP type Parameter Method Standard Analysis by Accreditation

of Analysis

method

01.04 Sample

collection

Any gas with

use of

appropriate

tube selected

by reference to

manufacturer’s

web site

Sorbent tube N/A N/A

10.98 Analysis Ammonia Colorimetry SAL

Laboratory

Not UKAS

accredited




Page 16 of 32

Volume flow SOP SOP type Parameter Method Standard Analysis by Accreditation

of Analysis

method

01.31 Sample

collection

Velocity and

volume flow

rate

Determination

of velocity

using a Pitot

tube and

manometer

ISO

9096/

ISEN

13284

PART 1

Environmental

Efficiency

None

The following table summarises the equipment used and the QC checks. The SOP

details the equipment used and QC checks.

SOP Equipment QC Check

01.31 Pitot tube Zero check

01.31 Manometer Zero check

01.19 FID Zero check and Span check with calibration

gas at 500 ppm at start and end of use of FID

01.04 Pump (< 3 litres/minute) Flow rate set in lab prior to use on site

01.08 Isokinetic sampling train Leak Test. Swirl Test. Sample blank.

2.3 Uncertainty Calculations

Uncertainties are calculated for 95% confidence based on available data. The

calculations used are described by SOPs and the actual calculation for each

monitoring result is determined by spreadsheet referenced by the same SOP.

SOP

Method

96.01 UOM FGA and FID

96.02 UOM Isokinetic Monitoring

96.03 UOM of Oxygen determination by FGA

96.04 UOM of NOx determination by FGA

96.05 UOM of SOx determination by FGA

96.06 UOM of CO determination by FGA

96.07 UOM of CO2 determination by FGA

96.08 UOM of temperature determination by FGA

96.09 UOM of Boiler Efficiency determination by FGA

96.10 UOM Sorbent Tube

96.11

UOM of concentration by extraction onto self indicating colorimetric

tube

96.12 UOM of velocity measurement using Pitot tube

96.13 UOM of volume flow rate

96.14 UOM Impinger and pump




Page 17 of 32

Appendix 1 Emission Points A3-3


A1.2 Data re the monitoring conditions are as below

Emission Point A3-3

Parameter Value Units

Date of test 12/10/2010 dd/mm/yyyy

Time of test 11.15 hour

Run time 30 minutes

Stack velocity 8.07 m/s

Stack Temperature 22.0 Celsius

Ambient Pressure 1,022 hPa

Oxygen % 20.9 %

Sampling plane

Platform

Sampling Plane




Page 18 of 32





Page 19 of 32




Page 20 of 32




Page 21 of 32




Page 22 of 32




Page 23 of 32




Page 24 of 32




Velocity 8.07 m/s -









Page 25 of 32

Appendix 2 Emission point A3-4


A1.2 Data re the monitoring conditions are as below

Emission Point A3-4

Parameter Value Units

Date of test 12/10/2010 dd/mm/yyyy

Time of test 11.35 hour

Run time 30 minutes

Duct velocity 7.61 m/s

Duct Temperature 22.0 Celsius

Ambient Pressure 1,022 hPa

Oxygen % 20.9 %

Sampling plane

Platform

Sampling Plane




Page 26 of 32





Page 27 of 32




Page 28 of 32




Page 29 of 32




Page 30 of 32




Page 31 of 32




Page 32 of 32




Velocity 7.61 m/s -







APPENDIX C

POLLUTION EMISSION REGISTER REPORT 2010

Molex Ireland Limited Pollution Emissions Register 2010

POLLUTION EMISSIONS REGISTER - 2010


1

CONTENTS

1. INTRODUCTION 2

2. USES AND METHOD OF MEASUREMENT OF MATERIALS 2

2.1 Nickel 2

2.2 Tin 4

3. PER RESULTS 5

3.1 Nickel 5

3.2 Tin 6

3.4 Pollution Emission Register 2010 7


2

1. INTRODUCTION Condition 6.11 of Molex’s IPPC Licence requires the company to prepare a Pollution Emissions Register (PER) on substances agreed with the EPA and to submit this as part of the company’s Annual Environmental Report (AER).

Molex submitted a proposal to the Agency in June 2002 stating that it would complete a mass balance PER on the following substances:

• Nickel • Copper

• Ammonia • Lead

• Tin

During the year 2006 Molex went lead free and ammonia free and advised the Agency in the 2006 AER of these developments and as such advised the Agency that lead and ammonia will be removed from the 2007 PER and subsequent PERs as there is no grounds to conduct a mass analysis on these agents and this continues to be the case.

During 2009 Molex ceased plating copper in Shannon and advised the Agency in the 2009 AER that copper plating had been discontinued.

Molex proposes to undertake a PER on nickel and tin for year 2011.

2. USES AND METHOD OF MEASUREMENT OF MATERIALS

2.1 Nickel

2.1.1 Uses of Nickel Nickel is used in the nickel plating solution and nickel anodes. The purpose of nickel plating is to prevent the migration of zinc into tin and copper into gold. It is the standard finish in connector manufacture. Also, nickel is used as an alloying element in palladium-nickel, where it possesses properties suitable for electronic applications.

Nickel is also used as a brightening and hardening agent in one gold plating bath.

The primary source of nickel is the metal anode. However a range of support chemistries containing nickel are required to replenish loss due to drag-out and plating inefficiencies.

In the case of palladium-nickel plating the chemistry is added as a soluble salt.

2.1.2 Measurement of Nickel The quantities of both the nickel going either to sewer or to the sludge were determined as follows:

Independently of the above, the nickel content of the sludge was determined by the waste contractors, World Resources.

The emissions to atmosphere from the plating department and the fugitive emissions were determined by external consultants.


3

Supplier records of weight of anode purchased indicated the amount of nickel plated onto parts and coupled with supplier information on nickel chemistries provided sufficient information for a mass balance on nickel.

It was assumed that the concentration of nickel chemistry in each of the plating baths is constant. This was a reasonable assumption since there is SPC control on the density of all plating baths.

As Molex Ireland do not have a direct method of measuring the amount of nickel plated onto the parts, it is reasonable to assume that accounting for the losses from the system via air extraction (measured), drag-out captured in effluent and sludge analysis, all the remaining nickel is plated onto the connectors.

Opening stock of nickel

(stock take)

=

Discharge to sewer

(analysis of discharge)

+ +

Change in inventory of nickel

(Supplier information)

Plating onto parts

(extrapolation)

+

Discharge to sludge

(analysis)

+

Emissions to atmosphere

(analysis)

+

Closing stock of nickel

(stock take)

+

Unaccounted losses


4

2.2 Tin

2.2.1 Uses of Tin Tin is plated on electronic connectors to afford them properties that allow ease of application, be it solderable joint or a friction contact surface.

There is one type of tin plating used in Molex Ireland during 2010.

. Pure tin, based on methyl sulphonic acid, currently there are six baths in operation.

Tin replenishment is both in soluble anode format and also as liquid chemistry.

2.2.2 Measurement of Tin The tin content of the waste sludge was determined by the waste contractors, World Resources. The emissions to atmosphere from the plating department and the fugitive emissions were determined by external consultants.

Supplier records of weight of anode purchased indicated the amount of tin plated onto parts and coupled with supplier information on tin chemistries provided sufficient information for a mass balance on tin.

It was assumed that the concentration of tin chemistry in each of the plating baths is constant. This was a reasonable assumption since there is close control on the exercised on the chemistries

Molex Ireland does not have a direct method of measuring the tin plated onto the parts, it is reasonable to assume that accounting for the losses from the system, via air extraction (measured), drag-out captured in effluent and sludge analysis, all the remaining tin is plated onto the connectors.

Opening stock of tin (stock take)

=

Discharge to sewer (analysis of discharge)

+ +

Change in inventory

(supplier information)

Discharge to sludge (analysis)

+

Emissions to Atmosphere (analysis)

+

Plating onto products

+

Closing stock

(stock take)

+

Unaccounted losses


5

3. PER RESULTS

3.1 Nickel

3.1.1 Mass Balance The mass balance was carried out over the period January to December 2010. The difference between inputs and outputs is known as the unaccounted losses.

The mass balance equation is as follows:

On– Cn + In = Dn + Pn + Dd + Ea + U

Table 3.1: Result of Mass Balance for Nickel

Initial Inputs Ref. Kg Final Outputs Ref. Kg

Opening Stock of Nickel

On 322.55 Discharge to Sewer

Dn 1.710

Change in Inventory of Nickel

In 2062.60 Plating onto Parts

Pn 1946.02

Closing Stock of Nickel Cn 346.6 Discharge to Sludge

Dd 90.82

Emissions to Atmosphere

Ea 0.0

Unaccounted Losses

U 0.0

3.1.2 Gross and Net Eco-Efficiencies

Index of Gross Eco Efficiency (IGEE)

IGEE = (Gross Process Waste / Gross Usage) x 100

= ((Dn + Dd +Ea + U) / (On– Cn + In) x 100

= ((1.71 + 90.82 + 0 + 0)/(322.55– 346.6+ 2062.60)) x 100

= 4.54

Index of Nett Eco-Efficiency (INEE)

INEE = ((Gross Process Waste–Material Recovered) / Gross Usage)) x 100

= (Dn + Dd + Ea – Dd + U) / (On– Cn + In) x 100

= ((1.71+ 90.82+ 0 – 90.82 + 0) / (322.55– 346.6 + 2062.6)) x 100

= 0.084


6

3.2 Tin

3.2.1 Mass Balance The mass balance was carried out over the period January to December 2010. The difference between inputs and outputs is known as the unaccounted losses.

The mass balance equation is as follows:

Ot – Ct + It = Dt + Dd + Ea + Pt + U

Table 3.3: Result of the Mass Balance for Tin

Initial Inputs Ref. Kg Final Outputs Ref. Kg

Opening Stock of Tin

Ot 206.1 Discharge to Sewer Dt 0.975

Closing Stock of Tin Ct 145.05 Discharge to Sludge Dd 513.77

Change in Inventory It 3,249.00 Emissions to Atmosphere

Ea 0.00

Plating onto product Pt 2795.31

Unaccounted Losses

U 0.00

3.2.2 Gross and Nett Eco-Efficiencies

Index of Gross Eco Efficiency (IGEE)

IGEE = (Gross Process Waste / Gross Usage) x 100

= ((Dt+ Dd + Ea + U) / (Ot – Ct + It)) x 100

= ((0.975 + 513.77 + 0 + 0) / (206.1 – 145.05 + 3249)) x 100

= 15.55

Index of Nett Eco-Efficiency (INEE)

INEE = ((Gross Process Waste–Material Recovered) / Gross Usage)) x 100

= (Dt + Dd + Ea – Dd + U) / (Ot– Ct + It ) x 100

= ((0.975 + 513.77 + 0 – 513.77 + 0) / (206.1– 145.05 + 3,249.00)) x 100

= 0.0294


7

3.3 Pollution Emission Register 2010

FACILITY IDENTIFICATION

Facility Name Molex Ireland Limited

Register No. 288-02

National Grid Reference E1397 N1622

Reporting Period

(mm-yy to mm-yy)

January 2010 to December 2010

Production units / amount Connectors plated 1,003,529,487

Employee No. 300

POLLUTANTS SUMMARY

Pollutant Name

CAS No. Input (kg)

Gross Usage

(kg)

Outputs

(kg)

Eco-Productivity

Indices

Air MoM

Liq. Eff. MoM

Waste MoM

Prod MoM Recovery

(kg)

Treated

(kg)

Unaccounted (kg)

IGEE INEE

Nickel 7440-02-0 2,038.55 2,038.55 0 M 1.71 M 90.82 B 1946.02 E 90.82 0 0 4.54 0.084

Tin 7440-31-5 3310.05 3310.05 0 M 0.975 M 513.77 B 2795.31 E 513.77 0 0 15.55 0.0294


APPENDIX D

PRTR 2010 RETURNS EXCEL WORKSHEETS

| PRTR# : P0288 | Facility Name : Molex Ireland Limited | Filename : Heating Oil Consumption .xlsx | Return Year : 2010 | 2390 30/03/2011 09:06

Guidance to completing the PRTR workbook

Version 1.1.11

REFERENCE YEAR 2010

1. FACILITY IDENTIFICATIONParent Company Name Molex Ireland Limited

Facility Name Molex Ireland LimitedPRTR Identification Number P0288

Licence Number P0288-02

Waste or IPPC Classes of ActivityNo. class_name

12.3

The surface treatment of metals and plastic materials using an electrolytic or chemical process where the volume of the treatment vats exceeds 30 m3.

Address 1 Shannon Industrial EstateAddress 2 ShannonAddress 3 Co. ClareAddress 4

Country IrelandCoordinates of Location -8.89104 52.7086

River Basin District IEGBNISHNACE Code 2561

Main Economic Activity Treatment and coating of metalsAER Returns Contact Name Donal Horgan

AER Returns Contact Email Address [email protected] Returns Contact Position Environmental Health and Safety Manager

AER Returns Contact Telephone Number 061-702400AER Returns Contact Mobile Phone Number

AER Returns Workbook

AER Returns Contact Mobile Phone NumberAER Returns Contact Fax Number 061-702700

Production Volume 1003529487.0Production Volume Units pcs

Number of Installations 1Number of Operating Hours in Year 3840

Number of Employees 300User Feedback/Comments

Web Address www//molex.com

2. PRTR CLASS ACTIVITIESActivity Number Activity Name

2(f)Installations for surface treatment of metals and plastic materials using an electrolytic or chemical process

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

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

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

used ?

4.1 RELEASES TO AIR Link to previous years emissions data | PRTR# : P0288 | Facility Name : Molex Ireland Limited | Filename : Heating Oil Consumption .xlsx | Return Year : 2010 | 30/03/2011 09:06

8 10 18 18 26 27 6 7 6 6 6 7 9SECTION A : SECTOR SPECIFIC PRTR POLLUTANTS

Please enter all quantities in this section in KGsQUANTITY

No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 Emission Point 2 T (Total) KG/YearA (Accidental) KG/Year

F (Fugitive) KG/Year

06 Ammonia (NH3) M CRM NIOSH 6015 1.44 0.0 1.44 0.0 0.080 Chlorine and inorganic compounds (as HCl) M CRM NIOSH 6011 0.8 1.55 2.35 0.0 0.085 Hydrogen cyanide (HCN) M CRM NIOSH 6010 3.33 156.67 160.0 0.0 0.0

* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button

SECTION B : REMAINING PRTR POLLUTANTSPlease enter all quantities in this section in KGs

QUANTITY

No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year0.0 0.0 0.0 0.0


SECTION C : REMAINING POLLUTANT EMISSIONS (As required in your Licence)Please enter all quantities in this section in KGs

QUANTITY

Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 Emission Point 2 T (Total) KG/YearA (Accidental) KG/Year

F (Fugitive) KG/Year

228 TA Luft inorganic dust particles class 2 M ALT ISO 9096/ISEN 13284-1 1.8 3.9 5.7 0.0 0.0229 TA Luft inorganic dust particles class 3 M ALT ISO 9096/ISEN 13284-1 2.0 18.6 20.6 0.0 0.0


Additional Data Requested from Landfill operators

Landfill: Molex Ireland LimitedPlease enter summary data on the quantities of methane flared and / or utilised

additional_pollutant_no T (Total) kg/Year M/C/E Method CodeDesignation or

DescriptionFacility Total Capacity m3

per hourTotal estimated methane generation (as per

site model) 0.0 N/AMethane flared 0.0 0.0 (Total Flaring Capacity)

Methane utilised in engine/s 0.0 0.0 (Total Utilising Capacity)Net methane emission (as reported in Section

A above) 0.0 N/A

RELEASES TO AIRPOLLUTANT METHOD

Method Used

POLLUTANT

RELEASES TO AIR

RELEASES TO AIRMETHOD

POLLUTANT METHODMethod Used

For the purposes of the National Inventory on Greenhouse Gases, landfill operators are requested to provide summary data on landfill gas (Methane) flared or utilised on their facilities to accompany the figures for total methane generated. Operators should only report their Net methane (CH4) emission to the environment under T(total) KG/yr for Section A: Sector specific PRTR pollutants above. Please complete the table below:

Method Used

Method Used

Sheet : Releases to Waters AER Returns Workbook 25/3/2011 12:45

4.2 RELEASES TO WATERS Link to previous years emissions data | PRTR# : P0288 | Facility Name : Molex Ireland Limited | Filename : Heating Oil Consumption .xlsx | Return Year : 2010 | 30/03/2011 09:06

8 9 17 17 25 25 6 6 6 6 6 6SECTION A : SECTOR SPECIFIC PRTR POLLUTANTS Data on ambient monitoring of storm/surface water or groundwater, conducted as part of your licence requirements, should NOT be submitted under AER / PRTR Reporting as this only concerns Releases from your facility


No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year0.0 0.0 0.0 0.00.0 0.0 0.0 0.0


SECTION B : REMAINING PRTR POLLUTANTSPlease enter all quantities in this section in KGs

QUANTITY

No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year0.0 0.0 0.0 0.0


SECTION C : REMAINING POLLUTANT EMISSIONS (as required in your Licence)Please enter all quantities in this section in KGs

QUANTITY

Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year0.0 0.0 0.0 0.0


RELEASES TO WATERS

Method Used

RELEASES TO WATERS

RELEASES TO WATERS

Method Used

POLLUTANTMethod Used

POLLUTANT

POLLUTANT

| PRTR# : P0288 | Facility Name : Molex Ireland Limited | Filename : P0288_2010_01 Eddeted.xls | Return Year : 2010 | Page 1 of 2

Sheet : Releases to Wastewater or Sewer AER Returns Workbook 25/3/2011 12:4

4.3 RELEASES TO WASTEWATER OR SEWER Link to previous years emissions data | PRTR# : P0288 | Facility Name : Molex Ireland Limited | Filename : Heating Oil Consumption .xlsx | Return Year : 2010 |30/03/2011 09:06

8 15 23 35 6 6 6 6 35SECTION A : PRTR POLLUTANTS


No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year

79 Chlorides (as Cl) M CRMProcedure based on EPA Standard Method 325.1 1950.0 1950.0 0.0 0.0

20 Copper and compounds (as Cu) M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 210.279 0.279 0.0 0.0

22 Nickel and compounds (as Ni) M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 211.71 1.71 0.0 0.0

12 Total nitrogen M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 2162.0 62.0 0.0 0.0

13 Total phosphorus M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 210.495 0.495 0.0 0.0

24 Zinc and compounds (as Zn) M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 210.044 0.044 0.0 0.0

17 Arsenic and compounds (as As) M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 210.011 0.011 0.0 0.0

23 Lead and compounds (as Pb) M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 210.003 0.003 0.0 0.0* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button

SECTION B : REMAINING POLLUTANT EMISSIONS (as required in your Licence)Please enter all quantities in this section in KGs

QUANTITY

Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year

303 BOD M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 21240.3 240.3 0.0 0.0

356 Cobalt M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 210.024 0.024 0.0 0.0

306 COD M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 21279.1 279.1 0.0 0.0

308 Detergents (as MBAS) M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 1998, 201.0 1.0 0.0 0.0

314 Fats, Oils and Greases M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 210.0 0.0 0.0 0.0

357 Iron M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 211.575 1.575 0.0 0.0

327 Nitrate (as N) M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 212.2 2.2 0.0 0.0

343 Sulphate M CRMProcedure based on EPA Standard Method 375.4 5565.0 5565.0 0.0 0.0

353 Sulphides M CRM Procedure based on Standard Methods for the Examination of Water and Wastewater 1998, 200.03 0.03 0.0 0.0

240 Suspended Solids M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 21173.3 173.3 0.0 0.0

358 Tin M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 210.975 0.975 0.0 0.0331 Organohalogens M CRM Procedure based on EPA Method 8260B 0.0 0.0 0.0 0.0237 Volatile organic compounds (as TOC) M CRM Procedure based on EPA Method 8260B 0.048 0.048 0.0 0.0


OFFSITE TRANSFER OF POLLUTANTS DESTINED FOR WASTE-WATER TREATMENT OR SEWER

OFFSITE TRANSFER OF POLLUTANTS DESTINED FOR WASTE-WATER TREATMENT OR SEWER

Method Used

Method Used

POLLUTANT METHOD

POLLUTANT METHOD

Link to previous years emissions data Page 1 of 1

Sheet : Releases to Land AER Returns Workbook 25/3/2011 12:47

4.4 RELEASES TO LAND Link to previous years emissions data | PRTR# : P0288 | Facility Name : Molex Ireland Limited | Filename : Heating Oil Consumption .xlsx | Return Year : 2010 | 30/03/2011 09:06

8 8 16 16 6 6 6 6SECTION A : PRTR POLLUTANTS


No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year0.0 0.0 0.0


SECTION B : REMAINING POLLUTANT EMISSIONS (as required in your Licence)Please enter all quantities in this section in KGs

QUANTITY

Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year0.0 0.0 0.0



RELEASES TO LAND

RELEASES TO LAND



5. ONSITE TREATMENT & OFFSITE TRANSFERS OF WASTE | PRTR# : P0288 | Facility Name : Molex Ireland Limited | Filename : Heating Oil Consumption .xlsx | Return Year : 2010 | 30/03/2011 09:06

5 36 Please enter all quantities on this sheet in Tonnes 23

Quantity (Tonnes per

Year)

Haz Waste : Name and Licence/Permit No of Next

Destination Facility Non Haz Waste: Name and Licence/Permit No of

Recover/Disposer

Haz Waste : Address of Next Destination Facility

Non Haz Waste: Address of Recover/Disposer

Name and License / Permit No. and Address of Final Recoverer /

Disposer (HAZARDOUS WASTE ONLY)

Actual Address of Final Destination i.e. Final Recovery / Disposal Site (HAZARDOUS WASTE ONLY)

Transfer DestinationEuropean Waste

Code Hazardous Quantity T/Year Description of Waste

Waste Treatment Operation M/C/E Method Used

Location of Treatment Name and Licence / Permit No. of Recoverer / Disposer / Broker Address of Recoverer / Disposer / Broker Name and Address of Final Destination i.e. Final Recovery / Disposal Site (HAZARDOUS WASTE ONLY) Licence / Permit No. of Final Destination i.e. Final Recovery / Disposal Site (HAZARDOUS WASTE ONLY)

Within the Country 16 01 17 No 3.025 ferrous metal R4 M Weighed Offsite in Ireland Hegarty Metals,WP05-04

Ballysimon ,Tipperary Road,Limerick,Co. Limerick,Ireland

Within the Country 12 01 03 No 0.484 non-ferrous metal filings and turnings R4 M Weighed Offsite in Ireland Hegarty Metals,WP05-04


Within the Country 12 01 99 No 22.908 wastes not otherwise specified R4 M Weighed Offsite in Ireland Hegarty Metals,WP05-04


Within the Country 17 04 01 No 31.611 copper, bronze, brass R4 M Weighed Offsite in Ireland Hegarty Metals,WP05-04


Within the Country 17 04 05 No 5.02 iron and steel R4 M Weighed Offsite in Ireland Hegarty Metals,WP05-04


Within the Country 20 01 01 No 92.812 paper and cardboard R3 M Weighed Offsite in Ireland Greenstar/Veolia,W0082-02

Ballykeefe,Dock Road,Limerick,Co. Limerick,Ireland

Within the Country 15 01 06 No 1.0 mixed packaging R3 M Weighed Offsite in Ireland Greenstar/Veolia,W0082-02


Within the Country 20 01 38 No 78.2 wood other than that mentioned in 20 01 37 R1 M Weighed Offsite in Ireland Greenstar/Veolia,W0082-02


Within the Country 20 02 01 No 2.84 biodegradable waste R3 M Weighed Offsite in Ireland Greenstar/Veolia,W0082-02


Within the Country 20 01 39 No 99.9 plastics R3 M Weighed Offsite in Ireland Greenstar/Veolia,W0082-02

Ballykeefe,Dock Road,Limerick,Co. Limerick,IrelandBallykeefe,Dock

Method Used

Within the Country 20 03 01 No 259.16 mixed municipal waste D1 M Weighed Offsite in Ireland Greenstar/Veolia,W0082-02


Within the Country 20 02 02 No 20.54 soil and stones R5 M Weighed Offsite in Ireland Greenstar/Veolia,W0082-02


Within the Country 17 01 07 No 7.56

mixture of concrete, bricks, tiles and ceramics other than those mentioned in 17 01 06 R5 M Weighed Offsite in Ireland Greenstar/Veolia,W0082-02


Within the Country 20 01 25 No 1.16 edible oil and fat R9 M Weighed Offsite in Ireland Frylite,WR-77Kilcolgan, , ,Co. Galway,Ireland

To Other Countries 20 01 40 No 44.93 metals R4 M Weighed AbroadMastermelt Refining Services Ltd,BL 1312

Staden Lane Industrial Estate,Ashbourne Road,Buxton Derbyshire.,SK17 9RZ,United Kingdom

Within the Country 18 01 04 No 0.898

wastes whose collection and disposal is not subject to special requirements in order to prevent infection (for example dressings, plaster casts, linen, disposable clothing, diapers) D1 M Weighed Offsite in Ireland

Cannon (OCS),WFP-LKC-09-001-01

North Richmond St.,Unit 2,Dublin 1,.,Ireland

To Other Countries 16 05 09 No 0.292discarded chemicals other than those mentioned in 16 05 06, 16 05 07 or 16 05 08 R1 M Weighed Abroad ENVA Ireland,WOO41-01

Smithstown Industrial Estate,.,Shannon.,Co. Clare.,Ireland

To Other Countries 15 02 02 Yes 0.759

absorbents, filter materials (including oil filters not otherwise specified), wiping cloths, protective clothing contaminated by dangerous substances R1 M Weighed Abroad ENVA Ireland,W0041/01


Lindenschmidt KG,47148089,Krombacher Str. 42-46,Kreuztal,Krombach ,Westfalen,Germany

Krombacher Str. 42-46,Kreuztal,Krombach ,Westfalen,Germany

Within the Country 11 02 05 Yes 1.2wastes from copper hydrometallurgical processes containing dangerous substances D9 M Weighed Offsite in Ireland ENVA Ireland,WOO41-01


Enva Ireland Ltd,W0041-01,Smithstown Industrial Estate,Smithstown ,Shannon,Co. Clare,Ireland

Smithstown Industrial Estate,Smithstown,Shannon,Co. Clare,Ireland

Within the Country 06 04 05 Yes 2.2 wastes containing other heavy metals D9 M Weighed Offsite in Ireland ENVA Ireland,W0041/01




To Other Countries 11 01 98 Yes 3.446other wastes containing dangerous substances R1 M Weighed Abroad ENVA Ireland,W0041/01



Krombacher Str. 42-46,Kreuztal,Krombach ,Westfalen,GermanyTo Other Countries 11 01 98 Yes 3.446 substances R1 M Weighed Abroad ENVA Ireland,W0041/01 Clare.,Ireland ,Westfalen,Germany ,Westfalen,Germany

To Other Countries 06 04 05 Yes 0.412 wastes containing other heavy metals R4 M Weighed Abroad ENVA Ireland,W0041/01


Linderschmidt KG,47148089,Krombacher Str. 42-46,Kreuztal,Krombach ,Westfalen,Germany


To Other Countries 16 05 08 Yes 0.069discarded organic chemicals consisting of or containing dangerous substances R1 M Weighed Abroad ENVA Ireland,W0041/01




Within the Country 20 01 21 Yes 0.145fluorescent tubes and other mercury-containing waste R4 M Weighed Offsite in Ireland

Irish Lamp Recycling Co.,WFP-KE-08-348-01

Kilkenny Road,Athy,Co. Kildare,.,Ireland

Irish Lamp Recycling Co.,WFP-KE-08-348-01,Kilkenny Road,.,Athy,Co. Kildare,Ireland

Kilkenny Road,.,Athy,Co. Kildare,Ireland

To Other Countries 11 01 09 Yes 18.76sludges and filter cakes containing dangerous substances R4 M Weighed Abroad

Veolia Environmental Services Technical Solutions Ltd,W0050-02

Corrin,.,Fermoy,Co. Cork,Ireland

World Resources Comany GmbH,SL83A0032,IndustriesstraBe7,D-04808,Wurzen,.,Germany

IndustriesstraBe7,D-04808,Wurzen,.,Germany

To Other Countries 11 01 98 Yes 5.543other wastes containing dangerous substances R4 M Weighed Abroad

Veolia ES Techanical Solutions,W0054-02

Allied Industrial Estate,Unit 1,Kylemore Road,Dublin 10,Ireland

Mastermelt Refining Services Ltd,BL 1312,Staden Lane Industrial Estate,Ashbourne Road,Buxton,Derbyshire SK17 9RZ,United Kingdom

Staden Lane Industrial Estate,Ashbourne Road,Buxton,Derbyshire SK17 9RZ,United Kingdom

To Other Countries 16 05 04 Yes 0.06gases in pressure containers (including halons) containing dangerous substances R4 M Weighed Abroad Enva Ireland Ltd,W0184-01

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

SBH,121296753,Austrabe5,D74238,Krautheim,.,Germany

Austrabe5,D74238,Krautheim,.,Germany

Within the Country 13 02 08 Yes 9.7 other engine, gear and lubricating oils R9 M Weighed Onsite in Ireland Enva Ireland Ltd,W0184-01


Enva Ireland,W0194-01,Clonminam Industrial Estate,.,Portlaoise,Co. Laoise,Ireland

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


absorbents, filter materials (including oil filters not otherwise specified), wiping cloths, protective clothing contaminated by dangerous substances D10 M Weighed Abroad Enva Ireland Ltd,W0184-01


KWA,E17012100,Graftstr,25,47475 Kamp-Lintfort ,.,Germany

Graftstr,25,47475 Kamp-Lintfort ,.,Germany

Within the Country 15 01 02 No 8.81 plastic packaging R3 M Weighed Offsite in Ireland Danelle,WP01/08Kilnock,".",Ballon,Co. Carlow,Ireland

absorbents, filter materials (including oil Lindenschmidt KG,47148089,Krombacher


absorbents, filter materials (including oil filters not otherwise specified), wiping cloths, protective clothing contaminated by dangerous substances R4 M Weighed Abroad ENVA Ireland,W0041/01


KG,47148089,Krombacher Str. 42-46,Kreuztal,Krombach ,Westfalen,Germany


Within the Country 06 02 04 Yes 1.0 sodium and potassium hydroxide D9 M Weighed Offsite in Ireland ENVA Ireland,WOO41-01




* Select a row by double-clicking the Description of Waste then click the delete button

Link to previous years waste dataLink to previous years waste summary data & percentage change

Sheet : Releases to Waters AER Returns Workbook 25/3/2011 12:45

Data on ambient monitoring of storm/surface water or groundwater, conducted as part of your licence requirements, should NOT be submitted under AER / PRTR Reporting as this only concerns Releases from your facility



APPENDIX E

BUND INTEGRITY REPORT 2010

Tel: + 353 (0)1 276 1428 Fax: + 353 (0)1 276 1561 Email: [email protected] www.enviro-consult.com

Registered Office as above. Registered Number 243 412

Directors: Noel J. McGrath, Robert B. Sutcliffe

Bund Integrity Test Report

for

Molex Ireland Ltd

IPPC Licence P0288-02

EEC Document No.1247-03

Molex Ireland Limited Bund Assessment Report

Environmental Efficiency Document No1247-03 v1.0; Page 2 of 13

QF 1. Document Lead Sheet Document Title Bund Integrity Test Report Project No. 1247 Document No. 1247-03 Client Molex Ireland Limited EPA Licence Number P0288-02

Issue Status Date Author Signed for and on behalf of

Environmental Efficiency

Client

1 Approved 19/07/2010 RBS

Where it is a requirement that this report be issued to a regulatory or other authority, then the client should sign the appropriate place in the above table and, unless specifically agreed in writing to the contrary, forward copies to the appropriate authority (e.g. EPA).

EEC Project Manager: Bob Sutcliffe, CEng, MIMechE

EEC Document Author: Bob Sutcliffe, CEng, MIMechE




3. Reports remain the property of Environmental & Efficiency Consultants (Ireland) Limited until paid for in full.



1. Introduction Molex Ireland Ltd has an IPPC licence. This licence requires that the water tightness of all bunding structures and their resistance to penetration by water or other materials stored therein to be assessed. This report documents the assessment of the bunds on site against this requirement

2. Summary The bunds shown in the table below were assessed. The table describes the assessment method and the results.

Table 1 Tested bunds

Bund No. Bund description Bund Type

Sufficient Capacity?

Assessment Method

Pass/Fail Assessment

01 Plating Area Sump Local Yes VI Pass 02 Chemical Store Bund Local Yes VI Pass 03 Oil Storage Area Local Yes VI Pass 04 Oil storage Bund Local Yes VI Pass 05 Effluent Treatment Area Sump Local Yes VI Pass

Notes

1. The Bund Type is Local, Remote or Combined as per EPA Guidance Note on Storage and Transfer of Materials for Scheduled Activities. The bund types ‘Sump Pallet’ and ‘Double Skinned’ are variants of Local

2. Sufficient Capacity? Sufficient capacity refers to whether the bund meets the EPA 110%/25% capacity rule. Individual bunds should be sized so that their capacity is the greater of 110% of the largest tank within the bund or 25% of the total capacity of tanks and drums in the bund. Where this is not the case, it is commented on in the discussion section. Note that as Sump Pallets do not have a defined primary containment associated with them, the sufficient capacity criterion is not applicable.

3. Assessment Method. a. WRT. The preferred assessment method is a water retention test. The test is

normally to a height that tests the required capacity of the bund. Unless otherwise stated the test protocol is CIRIA 163.

b. VI. Sometimes this is not possible to undertake a water retention test due to low lying electrical equipment or other reason; where this is the case a visual inspection is carried out by a Chartered Engineer.

c. WRT + VI. Where a visual inspection is required, it is sometimes necessary to supplement the visual inspection by a water retention test of the test the bund floor or floor/wall joints.

4. Pass/Fail Integrity Test. If the bund fails the water retention test or visual inspection, then this is denoted as a fail and is commented upon elsewhere in the report.



3. Assessment methods One or more of the following assessment methods were used.

3.1 Water retention test CIRIA 163 is published by Construction Industry Research and Information Association, 6 Storey’s Gate, Westminster, London, SW10 3AU, www.ciria.org.uk. The CIRIA protocol is specifically designed for the testing of bunds located in sites defined as being highly sensitive. This is a six-hour test over which there should be no loss of water after adjustments for rainfall. Environmental Efficiency now uses the CIRIA 163 protocol in preference to the protocol defined in BS8007. This is because BS8007 is primarily concerned with the design of concrete structures for retaining aqueous liquids, e.g. water tanks and reservoirs. BS8007 is not concerned with the secondary containment of hazardous liquids. In addition, the BS8007 test period is for seven days. This means that there is no bund protection for the test period.

3.2 Visual inspection In certain cases a water retention test is not possible. Potential reasons include • The water retention test would require an excessive amount of water • The test water would be contaminated • There is a danger of tank floatation where tanks are not full • Electrical equipment (such as pumps or trace heating) or insulation would be

damaged by flooding the bund • A water retention test would impede the normal operations of the plant

Where a water retention test is not possible then the assessment of water integrity is by means of a visual inspection by a Chartered Engineer. The visual inspection is to ensure that in the opinion of the engineer that the bund is capable of retaining the tanks contents in the event of tank failure. Where the tank is a self bunded tank, also known as a double skinned tank, then the visual inspection is to determine whether the inner skin is liquid tight and also whether the outer skin has any damage. This inspection is as follows

• To determine whether the inner skin is liquid tight a flexible tape is passed between the inner and outer skin to check for the presence of the tank contents (e.g. oil). If there is no trace of the tank contents, then this indicates that the tank is liquid tight. If there are traces of the tank contents, then the self bunded tank has failed the inspection.

• To determine whether the outer skin is liquid tight, the outer skin is examined for cracks, holes or other damage. Any damage will result in a fail.

Where a plastic self bunded tank has no protection from vehicle collision, then this will not result in a fail but remedial action to protect the tank will be recommended.

3.3 Water Retention Test plus Visual Inspection Where a Water Retention Test to the full capacity of the bund is not practical but the inspecting engineer is of the opinion that a Visual Inspection will not give the



necessary degree of assurance as to integrity, a water retention test to a low level (e.g. to below the plinth of a motor) plus a visual inspection is carried out. Such a combination of assessment is applied where there is doubt as to the integrity of the bund floor or floor/wall joint.



4. Bund assessments

4.1 Bund 01 Plating Area Sump

4.1.1 Capacity Contents Rinse water Bund Type Local Largest tank Approximately 1,000 litre Total tank capacity Approximately 4,030 litre Required bund capacity 1 m3

Bund floor area 4 m x 1.45 m = 5.8 m2

Bund wall height 2.2 m Actual bund capacity 12.76 m3

Status Pass

4.1.2 Construction Construction Sump in ground. Concrete walls lined with ceramic tiles. Status Pass

4.1.3 Defects There are no defects

4.1.4 Test A water retention test to full capacity is not possible as there is a danger of tank floatation. A visual inspection was therefore carried out by a Chartered Engineer. The walls and floor appear to be in good condition and assessed as being water tight and therefore the bund passed the visual inspection It is noted that the sump is below ground and that it is well documented that the water table is very high in the area. Any lack of integrity would result in ingress of water. There was no evidence of any water ingress. A channel directs spills in to the bund from the shop floor. This was also visually inspected and was found to be satisfactory.

4.1.5 Recommended remedial action There is no recommended remedial action.



4.1.6 Photographs

Figure 1 View into Bund 01

4.2 Bund 02 Chemical Store bund

4.2.1 Capacity Contents Various drums of acids, plating solutions and other

chemicals. Bund Type Local Largest tank 2,000 litre Total tank capacity 5,440 litre Required bund capacity 2.2 m3

Bund floor area Area 1: 9.00 m x 8.55 m Area 2: 8.40 m x 8.55 m x 0.50 m


Status Pass

4.2.2 Construction Construction Reinforced mass concrete with ceramic tiled walls. Status Pass




4.2.4 Test A water retention test to full capacity is not possible as there is a danger of drum floatation. A visual inspection was therefore carried out by a Chartered Engineer. The walls and floor appear to be in good condition and assessed as being water tight and therefore the bund passed the visual inspection.


4.2.6 Photographs

Figure 2 Bund 02, typical condition of walls and floor



4.3 Bund 03 Oil storage area

4.3.1 Capacity Contents Various oils including waste oil Bund Type Local Largest tank 2,500 litre Total tank capacity 8,100 litre Required bund capacity 2.75 m3

Bund floor area 10.0 m x 2.2 m = 22.2 m2


Status Pass

4.3.2 Construction Construction Mass concrete with rendered walls. Status Pass


4.3.4 Test A water retention test is not possible as there is a test water would be contaminated (there are some oil spills on the floor of the bund). A visual inspection was therefore carried out by a Chartered Engineer. The walls and floor appear to be in good condition and assessed as being water tight and therefore the bund passed the visual inspection.




4.3.6 Photographs

Figure 3 Bund 03, general view

4.4 Bund 04 Oil Storage Bund

4.4.1 Capacity Contents Gas oil Bund Type Local Largest tank 36,230 litre Total tank capacity 36,230 litre Required bund capacity 39.25 m3



Status Pass

4.4.2 Construction Construction Reinforced mass concrete with rendered walls. A sump is

present. Status Pass




4.4.4 Test A water retention test to full capacity is not possible as an excessive amount of test water would be required. A visual inspection was therefore carried out by a Chartered Engineer. The walls and floor appear to be in good condition and assessed as being water tight and therefore the bund passed the visual inspection

4.4.5 Recommended remedial action There is no recommended remedial action. It is however noted that the oil tank is showing signs of age (see photograph below). It is understood that the tank will be replaced at some time in the future.

4.4.6 Photographs

Figure 4 Bund 04, general view



4.5 Bund 05 Effluent Treatment area sump

4.5.1 Capacity Contents Rinse water Bund Type Local Largest tank 5,666 litre Total tank capacity 17,000 litre Required bund capacity 6.23 m3



Status Pass

4.5.2 Construction Construction Reinforced mass concrete Status Pass


4.5.4 Test A water retention test to full capacity is not possible as there is low lying electrical equipment and a danger of tank floatation. A visual inspection was therefore carried out by a Chartered Engineer. The bund is below ground and inspection from ground level is not practical. The bund was therefore entered (the inspecting engineer possessed a Confined Space Certificate). The walls and floor appear to be in good condition and assessed as being water tight and therefore the bund passed the visual inspection.




4.5.6 Photographs

Figure 5 Bund 5, general view interior


APPENDIX F

EXECUTIVE SUMMARY OF FIRE WATER RETENTION STUDY 2010

Executive Summary

Molex (Ireland) Ltd. has contracted Project Management Group Ltd. (PM) to carry out a

fire-water retention study on its electrical components manufacturing facility in the

Shannon Industrial Estate, in accordance with Condition 3.7 of its IPPC Licence, register

number P0288-02. The purpose of this study is to determine the requirement or otherwise

for the provision of dedicated on-site fire-water retention on the basis of an environmental

risk assessment. This document updates the previous Firewater Study and its

recommendations as reported in PM document reference 101155-22-RP-0001 of April 2006

which concluded that a 500m3 firewater retention facility be established.

Since 2006, the net number of electroplating lines on site has reduced by six, returning the

capacity to 1998 levels. Removal of plating lines has resulted in the removal of copper plating

and pure tin plating processes from the site. This has resulted in a reduction of the inventory

of polluting substances and a corresponding reduction in the risk of water pollution in the

case of fire.

An assessment of the overall changes in the risk to the environment from potentially

contaminated fire-water arising on the site has been performed in order to update the

findings of the previous firewater study in lines with the EPA’s “Draft Guidance Note on

Fire-water Retention Facilities”.

This study concludes that:

1. Having reviewed the inventory for the production area in light of the recent reduction of

plating lines, the volumes of materials are such that they are now below the threshold for

the requirement for a firewater retention facility. Every effort should be made to minimise

the inventory of the more hazardous substances used in plating.

2. The maximum quantities of potentially polluting materials stored and used within the

other areas of the facility are small in the context of national and European guidelines for

fire-water run-off environmental risk assessment, and the potential contamination level of

any fire-water release from these areas is low.

CONCLUSION Having reviewed the inventory for the production area in light of the recent reduction of

plating lines, the volumes of materials are such that they are now below the threshold for

the requirement for a firewater retention facility. Every effort should be made to minimise

the inventory of the more hazardous substances used in plating.

The principal potential pollutants on site which could contaminate fire water are the plating

solutions used in the plating shop as described in Scenario (ii) in Section 6. The total WGK 1

equivalent quantity for the four areas in Production is less than the 100 tonne guideline for

WGK 1 equivalent material requiring firewater retention capacity.

The maximum quantities of potentially polluting materials stored and used within the other

areas of the facility are small in the context of national and European guidelines for fire-

water run-off environmental risk assessment, and the potential contamination level of any

fire-water release from these areas is low.

molex ireland ltd · 2014. 12. 16. · sulphide 0.009 nd 0.03 100 tin 1.885 1.069 0.975 100 cadmium...

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