Arch Chemical BV

150 Pages·2010·4.15 MB·English

Arch Chemical BV
Annual Environmental Report 2009

CONTENTS
Section Page No

1. INTRODUCTION..............................................................................................................1

1.1 Foreword..........................................................................................................................1

1.2 IPPC License Details.......................................................................................................1

1.3 Site Description................................................................................................................1

1.4 Environmental Health and Safety Policy..........................................................................2

2. MANAGEMENT OF THE FACILITY................................................................................4

2.1 Environmental Management System...............................................................................4

2.2 Arch Chemicals Management Structure..........................................................................4

2.3 Environmental Management Programme and Schedule of Environmental

Objectives and Targets....................................................................................................6

2.4 Environmental Management Programme Report............................................................6

2.5 Environmental Management Programme Proposal 2010..............................................12

3. SUMMARY INFORMATION ON ENVIRONMENTAL PERFORMANCE......................14

3.1 General...........................................................................................................................14

3.2 Self-Monitoring Data......................................................................................................14

3.3 Emission to Sewer..........................................................................................................14

3.4 Toxicity Testing..............................................................................................................18

3.5 Surface Water Emissions...............................................................................................18

3.6 Groundwater Monitoring Data........................................................................................18

3.7 Emissions to Atmosphere..............................................................................................19

3.8 Waste Management.......................................................................................................20

3.9 Noise..............................................................................................................................23

3.10 Energy and Water Consumption....................................................................................24

3.11 CCTV Inspection............................................................................................................24

3.12 Bund Inspection & Integrity............................................................................................24

3.13 Environmental Incidents and Complaints.......................................................................24

3.14 Spending on Environmental Protection..........................................................................25

3.15 Pollution Emissions Register..........................................................................................25

APPENDIX A - SITE LAYOUT

APPENDIX B - COMPLETED PRTR WORKSHEETS

APPENDIX C - GROUNDWATER MONITORING REPORTS

APPENDIX D - AIR MONITORING REPORT

APPENDIX E - NOISE SURVEY REPORT

APPENDIX F - BUND INTEGRITY TEST REPORT

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Glossary of Terms
WWTP Waste water treatment plant
PER Pollution emission register
PRTR Pollutant Release and Transfer Record
EMP Environmental Management Programme
EMS Environmental Management System
FCC Fingal County Council
AER Annual Environmental Report
HS and E Health, Safety and Environment
SPC Spill prevention and control
BAT Best Available Technology
IPPC Integrated Pollution Prevention and Control
IPPCL Integrated Pollution Prevention and Control License

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1. INTRODUCTION
1.1 Foreword
This document represents the thirteenth edition of the Arch Chemicals BV Annual
Environmental Report (AER).
This Report covers the period 1st January 2009 through to the 31st of December 2009 and
has been prepared in accordance with the EPA ‘Guidance Note for Annual Environmental
Report (October 2000) and other relevant updated guidance notes as provided by the
EPA on the Agency Website (www.epa.ie).
1.2 IPPC License Details
IPPC License Number: P0060-01
Class of Activity: 5.3.0 Chemicals
The manufacture by way of chemical reaction processes of
organic or organo-metallic chemical products other than
those specified in 5.2.
License Issue Date: 30th August 1996
Licensee Address: Watery Lane, Swords, Co. Dublin.
Grid Reference: 718052 747098 (Co Ordinates taken from OSI Website)
1.3 Site Description
Arch Chemicals B.V. manufactures various biocidal salts of Pyridine Thione at Swords,
Co. Dublin. The Arch site is located to the North of Swords Town centre, adjacent to the
plant operated by Bristol Myers Squibb / Swords Laboratories Ltd. Arch Chemicals B.V. is
a wholly owned subsidiary of Arch Chemicals Inc. based in Norwalk, Connecticut, U.S.A.
Arch’s site comprises a production building and warehouse, offices and personnel
facilities, boiler house, maintenance workshop, effluent treatment facility, laboratories,
various storage facilities and cooling water ponds. A site Layout is provided in Appendix
A of this Report.
Production equipment includes glass lined and stainless steel reactors, condensers,
scrubbers, pumps, heat exchangers, holding and storage vessels, filters, homogenizers,
vacuum pumps, sterilising vessels, mixing vessels, and compressors. Unit operations
involved are detailed in Attachment 9 of Arch’s IPPC Licence Application, submitted in
October 1995.
Arch Chemicals B.V., Swords main products are:
• Zinc Omadine (In aqueous dispersion and filter cake form)
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• Copper Omadine (As a filter cake and as a resin/xylene based paste)
• Sodium Omadine 40% Solution
Arch Chemicals B.V. operate a 3 shift cycle, 24 hours per day, on a 5 day week. The
company currently directly employs ~42 personnel. In addition a number of contract
personnel are employed, mainly in support services to the plant.
The sites IPPC licence was granted on 31st August, 1996 and was subsequently
amended on the 21st. October 2005 and 2nd April 2009. Environmental Management of
the site is carried out in accordance with the conditions of the IPPC License as amended.
1.4 Environmental Health and Safety Policy
Responsible Care and Quality Policy Statement
Arch Chemicals, B.V. (ACBV) is a Responsible Care Company and, as such, has publicly
committed itself to managing its activities to provide a high level of protection for the
health and safety of employees, contractors, customers, the public, other stakeholders
and the environment.
Health and Safety
Employees at ACBV believe all accidents are preventable and direct their efforts
accordingly. In fulfilling this commitment, all employees undertake to comply fully with all
relevant legislation and regulations and to ensure full compliance with the requirements of
OHSAS 18001:2007S.R.
Appropriate means and structure are in place to provide a high level of protection for man
and the environment. A comprehensive Occupational Health and Safety Programme is in
place to facilitate continual improvement.
Quality
All employees at ACBV are committed to satisfying customer requirements by supplying
product of the highest possible quality to agreed specifications, on time and at a
competitive price.
The operating philosophy at ACBV is one of continuous improvement and employees will
direct their efforts towards ensuring the Quality Management System operates at all times
in full compliance with requirement of I.S.E.N ISO 9001: 2008.
Environmental
All employees at ACBV are committed to minimising the environmental impacts of its
operation through the systematic minimisation of waste materials and air, water and land
contaminants.
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In this regard, the organisation undertakes to comply fully with the EPA IPPC Licence and
all relevant legislation and regulations and to ensure full compliance with the
requirements of I.S EN ISO 14001: 2004
An extensive environmental programme is in place to monitor inventory and types of
waste and pollutants generated and to assess their environmental impact.
Relevant information is made available to the local community and other interested
parties.
Security/Product Stewardship
In addition all employees at ACBV are committed to meeting or exceeding the
requirements of applicable legal regulatory and Responsible Care® related requirements
in the areas of security and product stewardship with the ultimate goal of achieving the
“GOAL IS ZERO”.
Policies are communicated to all new employees as part of their orientation and are
reviewed as part of the management review to determine their continuing suitability.
To support achievement, objectives and targets that are based on identifying operations,
processes, or products with significant impact on the environmental, health, safety,
distribution, security and product stewardship aspects of our business are agreed on an
annual basis by senior management as part of the Continuous Improvement Plan. These
are communicated to all employees and progress is monitored, measured and reviewed
at the management review meetings.

________________ ___________________ ___________________
Plant Manager H&S Manager Quality/Env Manager
Last Updated: 10th November 2009
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2. MANAGEMENT OF THE FACILITY
2.1 Environmental Management System
An Environmental Management System (EMS) is in place at the site which facilitates in
the management of the environmental performance of the site. The EMS currently
includes the following elements:
• The Environmental Policy;
• A Schedule of Objectives and Targets;
• The Environmental Management Programme;
• The Pollution Emission Register; and
• Programmes relevant to documentation, corrective action, awareness and training,
responsibilities and communications.
The Environmental Quality Policy is the fundamental building block for the EMS. It serves
as the foundation for the rest of the system. This policy sets out the principles, which
govern Arch Chemicals approach to environmental management.
Arch Chemicals BV site in Swords has been certified by the NSAI to the environmental
management system ISO 14001:2004, since February 1998. Arch Chemicals B.V. also
operate a documented Quality Management system to ISO. 9001:2008. The occupational
health and safety management system is certified to OHSAS18001:2007. Arch
Chemicals compliance with these standards is audited twice per year by the NSAI.
Environmental Management on-site is co-ordinated by the Quality and Environmental
Manager, Larry Hanlon, with specific responsibilities assigned to Departmental Managers
and Shift Supervisors.
Arch has established procedures to ensure awareness at all levels, of the importance of
compliance with environmental policy, potential environmental effects of work activities,
and individual roles and responsibilities. These are continuously reviewed for adequacy
and effectiveness and are communicated to all levels of the organization through
established channels.
The Environmental Management Programme Objectives and Targets Report for 2009
and schedule for 2010 are detailed in Section 2.4 and 2.5 of this AER.
2.2 Arch Chemicals Management Structure
The management structure at the Arch Chemicals facility is detailed in Figure 2.1
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Figure 2.1: Arch Chemicals Organisational Chart

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2.3 Environmental Management Programme and Schedule of
Environmental Objectives and Targets
As part of the Environmental Management of activities at the site, Arch Chemicals have
developed Environmental Management Programme (EMP). The EMP programme
promotes the assessment of operations on-site and the continual review of all practicable
options for the use of cleaner technology, cleaner production and the reduction and
minimisation of waste.
Arch Chemicals have established a Schedule of Objectives and Targets to support the
EMP. The Schedule of Objectives and Targets for 2009 was submitted as part of the
2008 AER and these are presented as Table 2.1 below. Table 2.1 combined with the
discussion on individual projects in Section 2.4 below forms the Environmental
Management Programme Report for the calendar year 2009. The status column in Table
2.1 has been updated to reflect project progress in 2009.

2.4 Environmental Management Programme Report
2.4.1 Introduction
Arch Chemicals are required in accordance with Condition 2.3 of the Sites IPPC licence,
to submit an Environmental Management Programme Report (EMP), as part of the AER
for the reporting period January 2009 to December 2009.
Refer to Table 2.1 during the following discussion. Key projects are described in the
following subsections of this AER.

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Table 2.1: Schedule of Objectives for Calendar Year 2009
No. Environmental Overall Objective Planned Responsibility
Aspect Completion
Date
OB1 Records and Verify the quality of all self monitoring compliance data to Dec 2009 Quality and Environmental Manager
Reporting ensure that all data is compliance with the conditions of the assisted by Process Development
Sites IPPC License Manager and Laboratory Staff.
OB2 Protection of To improve the groundwater remediation rate at the site. Dec 2009 Quality and Environmental Manager
Groundwater assisted by Maintenance Manager
OB3 Review of IPPC Complete a review of IPPC License prior to the development Dec 2009 Quality and Environmental Manager
License of any new processes on-site.
OB4 Protection of Upgrade the surfacewater monitoring instrumentation and August 2009 Quality and Environmental Manager
Surface Water associated controls to minimise the potential for release of assisted by Maintenance Manager
contaminated water to the Ward River.
OB5 Sustainability of Implement sustainability measures as a core value in all December Senior Site Management
Operations operations at the facility. 2009

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