Ms. Ann Kehoe, Administration Officer, Office of Licence & guidance, Environmental Protection ...

135 Pages·2006·7.19 MB·English

Ms. Ann Kehoe,
Administration Officer,
Office of Licence & guidance,
Environmental Protection Agency,
PO Box 3000,
JohnstykCastle Estate,
County,. %exford.
December IOth 2006.
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BATNEEC ectionw npeurr rpeBeqxeuicrset sasvivaiel acbolset st echnology not entailing
BBOADT For inysripght o BBieoslto agvicaailla Oblxey Tgeecnh Dnieqmuea nd
CCCTOOPD o n s e n t of cop CCCahlereabmnoiincn agMl IoOnn xPoylxagicedene Demand
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dB Decibel
EIS Environment Impact Statement
EIA Environmental Impact Assessment
EMS Environmental Management System
EPA Environmental Protection Agency
IBC Intermediate Bulk Container
Oxides of Nitrogen / Nitrogen dioxide
PLC Programmable Logic Controller
PRV Pressure Relief Valve
sox/ so1 Oxides of Sulphur / Sulphur Dioxide
TEDL Trade Effluent Discharge Licence
WWTP Waste Water Treatment Plant
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2. Resubmit and claria all the information on emissions to surface waters and
emissions to sewer, as SW3 is indicated on the Environmental Emissions Points
map as a surface water discharge and it is indicated in Table E.2(i) as a discharge
from the waste water treatment plant.
Table E.2 (i) is resubmitted as Attachment E and suitable scaled drawings are also
submitted.
3. Complete the section ‘available waste assimilative capacity’ in Tables E.2(i)
Emissions to Surface Waters
Table E 2 (i). is completed and see Attachment 1.2.1 for explanatory notes on
assimilative capacity in the River Gresse.
4. Complete tables G. I (ii) indicating if each material /substance is List I or List I1
under the Dangerous Substances Directive (76/464L?EC)
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Table G. 1 (ii) is complete as attachment G
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5. Complete Tables H. I(i) and H. I( io.
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Tables H. l(i) and H. l(ii) are complete as attachmenth eHr
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6. Provide a copy of all relevant waste permosiets seo fdn lofy.orr a wny aste contractors used on site.
Ain ccloupdye do.f all relevant waste permeicttiso fnw onpeurrr rpweqauisrte contractors used on site is also
7. Submit appropriately scaledF Oor irnysdripnghta once Survey maps showing the location of the off
sAit esc sallueddg oer sdtnoarnacgee suu n r iv to e sn sy a e nm tn odfa pcloa pins ds usbpmreiattdeidn gsh aorweainsg ( et.hge. aIr:e 1a0s 0o0f 0la anndd s Ip:r e5a0d0i0n0g) a. nd
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off site sludge storage.
8. Complete Table 1.4(i) Groundwater Quality and provide details on groundwater
quality, impacts of activity on groundwater quality and mitigation measures to
protect groundwater. Provide detaiIs of the impact of historic incidents on soil and
groundwater quality, including results of intrusive investigations carried out.
The sites operations / activities do not discharge emissions to ground water.
The storage of all chemicals is in appropriately sized storage areas. The working
stock of chemicals is stored on various mobile bunds through out the plant, and these
locations may vary dependent on the activity of the operation. Hydrocarbons used for
maintenance on plant and equipment are typically sourced in 251t containers which
are stored in mobile bunds prior to use and after use. As part of the EMS on site
regular checks are in place to monitor all of the bunds.
In quarter one of 2006 a new diesel interceptor (class one) was installed as part of the
EMS. The main surface water drains from the entrance, car park and truck refuelling
area all flow through this diesel interceptor. Daily inspections are carried out and
recorded to monitor the discharge.
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As part of the process for securing planning permission for altering the site to
facilitate increases in production capacity the site completed an EM. This was
completed in 2003. Analysis of the ground waters was completed by an external
professional body, Minerex Environmental Ltd. There was some evidence of
hydrocarbon located as indicated in the attached report; however the findings of the
report clearly stated that these levels did not merit any further investigation or
remediation work. The likely source of the material was thought to be the washing of
vehicles. This activity no longer takes place is this area.
A copy of the report is also included in Attachment 1.2.1
9. Provide details of measures used on site to mitigate against noise. Also submit a
copy of the recent noise survey conducted in February 2006.
The noise audit carried out in February 23rd/24*2 006 is submitted.
Electrical power supply units for the operation of refrigeration units on delivery
vehicles and trailers have been installed. The noise generated by refrigeration systems
on the delivery fleet operated with electricity as the power source is lower than the
same equipment operated with diesel as the power source. This measure has reduced
the noise generated by this activity.
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Extract fans which for operational reasons may not bheer switched off have been fitted
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Aan dF ufrotlhloerw ninogis teh .es uoruvtecyo wmiell obfe t hcaatre rcstiiueonrdw vnp eouerr urypet qa ubipryp rqouparritaetre t pwroo g2r0a0m7m toe sm woinlli tboer ndoeviseel olepveedl s
should they be required. For inysripght o
10. Sthueb ampipt laic Watiaosnte. Dis p o so na s l e np t r ofo ccoepduref or Glanbia Dairies, Ballitore as referenced in
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The procedure for waste disposal is submitted in attachment H.
“Q 11. Submit a revised site layout plan indicating the locations of the waste management
and storage areas referred to in the application (Attachment m.
A revised site layout plan is submitted indicating areas of waste management and
storage of waste prior to collection is attached with this response.
12. Indicate the source of water used on site. If the source of water is groundwater well
supply details of the abstraction capacity.
The source of water used by the activities on the sites is from groundwater well and
from municipal authorities (Kildare county council). Water sourced from the
municipal authority is primarily used for the amenity block and canteen. However it
may also be used in the processing of milk in the event of disruption to normal
supply. Groundwater well is the principal source of water used on site. Currently
there are two boreholes on site, with BH - 01 located at E279720 / N196094 and BH-
02 located at E279720 / N196094.
The pumping capacity of BH - 01 is at a rate that varies between 325 and 432m3/d.
The pumping capacity of BH - 02 is at a constant rate of 345.6m3/d.F rom pumping
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tests it is concluded that at present a combined sustainable yield of approximately
670m3/day is obtainable from both wells.
13. Submit a copy of Attachment 1.2.1 referred to in section 1.2 of Attachment I but not
submitted as part of the application
Attachment 1.2.1 is attached
14. With regard to nutrient management submit details of fertiliser Nitrogen and
Phosphorous requirement for each land parcel. Indicate the contribution of the
slurry and sludge to thisf arm. Confirm that the land used is appropriately sized to
deal with the land spreading of all sludge’s from the activity.
The nitrogen requirement for each land parcel is set at 170 kg / ha as part of the
regulation (Good Agricultural practices for the Protection of Waters) SI 378 of 2006.
The phosphorous requirement for each land parcel has been determined by soil
analysis carried out by Teagasc during July and September of 2006. The Teagasc soil
analysis report for each land parcel is included in the original IPPC application. The
values and amounts of phosphorous are given under the heading of “Nutrient
required” kg / ha and the appropriate amount of fertiliser as determined by Teagasc.
The amount of farm slurry returned to the land is deriveusde. from the guidelines issued
by the Department of Agriculture and Food in their pheur blication issued in 2006. It
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oacnc tehpet cthaelc quulaatniotintise sin o tfa sbllued Ig.4e(’isi )f reioctt imiosnw npbtehurer replei qeauvicrteidv itthieast tohfe t hlaen adp pisl iacpapnrto. priately sized to
15. Resubmit Table I.4(iQ and cFoor minyspriplgeht toe columns ‘Volumes of on farm slurry returned
c(aidlc u/hlaat)i’o nasnf do r‘ Ethseti J m i g a o u tn ser ee d n ts P o fs cihnoop wonn f. aIrnm a dslduirtrioy n( ckogm Pphleat)e ’. TParbolvei Id.e4 (siaom foprle N itrogen.
I Table 1.4 (ii) is submitCted in attachment 1.2.1
16. Provide details of measures to be taken to ensure compliance with the requirements
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of the European Communities (Good Agricultural Practice for Protection of
Waters) regulations 2006 (S.1 3 78 of 2006).
Dairy Sludge’s are spread in according to the requirements of (Good Agricultural
Practicef or Protection of Waters) regulations 2006 (S.I. 378 of 2006). The
guidance for the spreading of the dairy sludge’s has been taken from the explanatory
handbook issued by the Department of Agriculture & Food issued in November 2006.
The guidance book details appropriate measures to be taken when spreading on pages
13 and 14. These measures included the following:
Spreading of sludge’s must be completed evenly and as accurately as one
can.
One must not spread use an up ward facing plate or sludge irrigator on a
tanker or umbilical system for spreading organic fertiliser or soiled water.
One must not spread organic fertiliser or soiled water from a road or passage,
even if the passage or road is on ones holding.
One must not spread chemical fertiliser, livestock manure, soiled water or
other organic fertilisers when:
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The land is water logged
The land is flooded or likely to flood
The land is frozen, or covered with snow.
Heavy rain is forecast within 48 hours (one must check with Met Eireann).
One must not spread chemical fertilisers, livestock manure, soiled water or
other organic fertiliser if the ground has steep slope and if there is a
significant risk of causing pollution. When one is deciding whether there is a
risk, one must take into account how close one is to waters, what condition
the soil is in, the ground cover and how much rainfall there is or how much
rainfall is expected.
One must not spread chemical fertiliser on land within 1.4 metres of a surface
watercourse.
Buffer Zones for spreadinv organic fertilisers
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An updated non technical summary is also included as Attachment A.
Kind Regards,
Yours sincerely,
Quality & Environme/tal Manager
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Glanbia Foods Society Ltd Ballitore Dec 2006
IPPC Documentation Attachment A- 1 Non Technical Summarv
Attachment A:
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Glanbia Foods Society Ltd. Ballitore
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Glanbia Foods Society Ltd Ballitore Dee 2006
IPPC Documentation Attachment A- 1N on Technical Summary
Non technical Summary of IPPC Licence Application
A non technical summary of the application is to be included here. The summary
should identify all the environmental impacts of significance associated with the
carrying on of the sites activities and the mitigation measures proposed or
existing to address these impacts. This description should also indicate the
normal operating and days per week of the activity.
The installation and its activities,
The applicant Glanbia Foods Society-Ltd here after maybe referred to (Glanbia
Consumer Foods Ballitore) is located in Ballitore county Kildare. The plant is located
on the eastern outskirts of the village At the Ballitore plant Glanbia Foods Society
operates a liquid milk processing and packing facility. The site serves as part of two
separate stand alone business entities. The other business entity is the grain trading
operation and agribusiness sales and retail outlet. This licence application relates to
the processing of milk (clause 7.2.1 of the standard).
The applicant wishes to draw the agency’s attention to the planning permission
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pertaining to the site. us
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t“hAe sf aspceilciitfyi epdla innn tihneg o preigrminiasls iaopnp lwicaast isoonu tghhet aagnedn coyb tsaohsieons ueeodnld ldf yf.o rrn aoonmyt e Kthialdt adruee c toou an ptyl acnonuendc iel xipna Jnasniouna royf
2dW0ish0c4ihl sa(trr tgehfee # tso i0 tte3hs /e c 4Ra8pi0vae)c.r i tTyG hareen pedls aepn ltanoni n6t g0h0 pames r3nm ooitfs yseieefoctftn ilbou ngew enperneunarr trpn eautqnepuidrd g arIla5ldo0ew mds 3ftho oer f p asl aupnrrofnajiecncegt ewpdea rtiemnrc irsresuianos neo foisf f preeeflrfel uvdaeannyt.t
and has not expired”. For inysripght o
iTnh oer r gaewn emraatteedri ablys tahned i nasu t x a C i lo l ln i sa a e t nr t i yo of ncmo paterials, other substances and the enerw used
Raw Materials
The primary raw material used on site is milk for processing. Additional raw materials
used on site include fuel for the boilers, waste water treatment chemicals, packaging
and cleaning chemicals etc.
Energy Usage
The energy usage at the plant is approximately 6,000,000 Kwh of electricity to power
the plant on annual basis. The duty boiler is fired on marked gas oil (may use
alternatives fuels based on economic reasons) and uses an estimated 41 6,000 1o f oil
per annum. There is approximately 130,000 m3 of water consumed at the plant per
year for the purposes of washing. All energy usage is monitored electronically.
The sources of emissions from the installation
Emissions to the atmosphere
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Glanbia Foods Society Ltd Ballitore Dec 2006
PPC Documentation Attachment A- 1 Non Technical Summarv
There are two boilers on site and these boilers are used for steam generation. Boiler
Al-1 is the duty boiler and boiler A1-2 is the stand by unit. Each boiler has its own
stack and as such there are boiler emission points. ‘
Emissions to surface waters
Uncontaminated storm water is diverted to surface waters via surface water drains.
The receiving surface water is the River Greese labelled SWl , SW2, & SW3. Waste
water produced from the plant operations is diverted to the on site waste water
treatment plant. The waste water is treated prior to discharge to the River Greese
labelled SW 4. This is a licensed activity carried out in agreement with Kildare County
Council.
Emissions to Sewer
Emissions from domestic toilet usage on site flow directly into the locd authority
sewage network labelled SEI. Domestic sewage is generated from a site population of
approximately one hundred and fifty people.
Emissions to Ground
Dairy effluent sludge is produced as a by product of the treatment of waste water on
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site. The waste water is recovered to agricultural land by luasnd spreading. The sludge is
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spread on a suitable land bank in Kildare and surroundoitnhg counties. This is carried out
in agreement with Kildare County council. oses eodn lfy.or any
The conditions of the site of the instaecltiloanw tnpieuorr rpneq.u ir
dTehvee tlootpaeld a.r ea of the site is 5.98 heFocr itanysrripeghst oof which 2.64 hectares are currently
The nature and quantiti e s oo n f s e f n to orf ecospeeable emissions from the installation into each
medium as well as identificC ation of significant effects of the emissions into the
environment
The main atmospheric emissions from the plant arise from the boilers. Boiler Al-1
has a steam output of 2800 kg / hr and boiler A1-2 has a steam output of 2400 kg / hr.
Both stacks produce inter alia sulphur dioxide, oxides of nitrogen, particulate matter
and carbon monoxide. The BAT guidance notes do not specify specific emission
limits for combustion gases for boilers. However analysis carried out conclude that
the emissions conform to the TA Luft Standard.
Emissions to Surface Waters
A maximum of 70m3 of storm water is discharged on a daily basis, however this is
weather dependent. The water is uncontaminated and as such there are no significant
effects of the emission on the environment.
Waste water is produced from the various activities on site and a potential volume of
440 m3 is discharged on a daily basis. The waste water from the operation is treated
separately to comply with the existing emission limit values as specified in the Trade
Effluent discharge licence.
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Glanbia Foods Society Ltd Ballitore Dee 2006
IPPC Documentation Attachment A- 1 Non Technical Summary
Emissions to Ground
1400 m3 approximately of dairy sludge is generated at Glanbia Foods Society Ltd
Ballitore and land spread in 2005. The sludge is a by product of the waste water
treatment process on site. The sludge is processed in accordance with a nutrient
management plan, the code of practice of Good Agricultural Practice and other
relevant legislation and guide lines. Compliance with these guidelines and legislation
and the use of a nutrient management plan ensures there are no significant effects of
the emission on the environment.
The proposed technolow and other techniques for preventing or where this is
not possible emissions from the installation.
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Waste water treatment plant
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The waste water treatment plant ensures compliance with the existing Trade effluent
Discharge licence. The flow is balanced in the balance tank and the removal of oils
fats & greases is effected by the dissolved air floatation unit. The plant incorporates
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the use of a two stage activated sludge process to reduce BuOs D levels, dosing of
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alumimum sulphate to reduce phosphorous levels and aotnh anoxic tank to reduce nitrate
levels and a de watering press to increase the odsers yeo dn mlfy.ora atntye r content of the sludge.
tBChooamti ltebhrues setimonis seifofinc ioefn fclyu ete gsatisnegs coaf utFhsoree i nnybsriopoge hcitts iloeoignwr npsneu rr iirpfseiq ccuiaronntd eufcfteecdt oonn tah ree egnuvlairro bnamsiesn tto. ensure
bWv htehree i nnestcaelslsaatrioyn, m easur e s o fn so e nr t otf hcoep prevention and recovery of waste venerated
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Both hazardous and non hazardous waste streams are produced at the site. Hazardous
waste includes waste oils, light bulbs, inks, chemicals and batteries. Waste oils, light
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bulbs & inks are recycled and waste chemicals are disposed of in a responsible
manner by a licensed operator. Non hazardous waste includes paper, cardboard,
wooden pallets and general refuse.
To minimise waste re use loops of cardboard are used where possible with suppliers,
plastic and cardboard is baled on site recycled on site by a licensed operator. General
refuse is collected by a licensed operator and disposed to landfill. Waste water sludge
is dewatered and recovered by agricultural land spreading by an appropriated licensed
third party operator.
Waste by products (internal product loss / product returns) are used for hrther
processing at other milk processing facilities.
Further measures planned to complv with the veneral principles of the basic
obligations of the operator
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Glanbia Foods Society Ltd Ballitore Dec 2006
IPPC Documentation Attachment A- 1 Non Technical Summw
i. All the appropriate preventative measures are taken against pollution, in
particular through application of the best available techniques.
The BAT guidance notes on the Best Available Techniques for the Food Sector (EPA
draft June 2006) were reviewed to ensure that the appropriate preventative measures
were taken against pollution. Water and energy consumption are monitored to ensure
efficiency. Emissions to atmosphere and to water are minimised and the protection of
ground water and surface is achieved through the best available techniques.
Consideration is given to BAT at all stages of the activity at the site, in relation to
specific unit operations, cleaning, treatment abatement and disposal, emission limit
values and compliance monitoring
ii. No significant pollution is caused
No significant pollution is caused by the activities conducted on site.
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Q iii. waste production is avoided in accordance Council Directive 75/442/EEC
of July 15 1975 on waste; where waste is produced, it is recovered or,
where that is technically and economically impossible, it is disposed of
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while avoiding or reducing any impact on the enusvironment;
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iv. energy is used efficiently ectionw npeurr rpequir
Glanbia Foods Society Ltd BallitoFroer i onysrippgeht roates a benchmarking exercise in relation to a
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v. The necessary measures are taken to prevent accidents and limit their
consequences;
A preventative maintenance programme operated on site; it outlines the essential
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maintenance required on the site. The planned is reviewed regularly by the site
management team. Standard Operating Procedures are also in place for the various
activities onsite. The use of a preventative maintenenance programme and standard
operating procedures minimises the possibility of accidents and limits their
consequences. In the case of an emergency, Glanbia Foods Society Ltd Ballitore has
produced an emergency Preparedness Plan. The plan details the types of potential
emergencies, the organisational structures, roles and responsibilities of the relevant
parties, communications emergency response process, emergency response plans and
emergency shut down of the plan.
vi. The necessary measures taken upon definitive cessation of activities to
avoid any pollution risk and return the site of operation to a satisfactory
state. r
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