PPI Adhesive Products Ltd.

123 Pages·2012·3.91 MB·English

PPI Adhesive Products Ltd.
Annual Environmental Report 2011

Contents
Table of Contents
PPI Adhesive Products Ltd. ....................................................................................................... 1
Annual Environmental Report 2011 Contents ........................................................................... 1
Contents ...................................................................................................................................... 2
Table of Contents ................................................................................................................... 2
1 Introduction ............................................................................................................................. 3
1.1 Licensee Details ............................................................................................................... 3
1.2 Company and Site description .......................................................................................... 3
1.3 Site Activities ................................................................................................................... 3
1.4 Environmental Management Organisation 2011 .............................................................. 4
2 Summary information ............................................................................................................. 5
2.1 Emissions to Surface Water ............................................................................................. 5
2.2 Emissions to Sewer .......................................................................................................... 5
2.3 Emissions to Atmosphere ................................................................................................. 5
2.4 Energy Consumption ........................................................................................................ 7
2.4 Environmental Liability Cover ......................................................................................... 8
2.5 Waste Arisings ................................................................................................................. 8
2.6 Environmental Incidents and Complaints ...................................................................... 10
3 Management of the Activity .................................................................................................. 11
3.1 Environmental Management Programme Report 2011 .................................................. 11
3.2 Environmental Management Programme Proposal 2012 ............................................... 11
3.4 Pollution Emission Register/Pollutant Release and Transfer Register .......................... 11
3.5 Details of Environmental Expenditure ........................................................................... 11
4 Licence Specific Reports ....................................................................................................... 12
4.1 Noise Monitoring ........................................................................................................... 12
4.2 Groundwater/Surface Water Analysis ............................................................................ 12
4.3 Solvent Management Plan .............................................................................................. 12
4.3.1 Solvent Risk Phrases ............................................................................................... 12
4.3.2 Fugitive Emissions .................................................................................................. 12
4.3.3 Solvent Usage .......................................................................................................... 12
4.3.4 Toluene Usage ......................................................................................................... 14
Appendices ............................................................................................................................... 14
Appendix I – Surface Water Monitoring .............................................................................. 15
Appendix II Environmental Management Program 2011 Progress Report ......................... 17
Appendix III Environmental Management Program Proposal 2012 .................................... 21
Appendix IV Waste Management ........................................................................................ 22
Appendix V Solvent Management Plan/PER....................................................................... 25
Appendix VI Solvents and Solvent Containing Raw Materials and associated R-Phrases . 32
Appendix VII PRTR Returns ............................................................................................... 33
Appendix VIII Noise Survey ................................................................................................ 34
Appendix IX Environmental Policy ..................................................................................... 49
Appendix X Grounwater Survey .......................................................................................... 50
1 Introduction

1.1 Licensee Details
License Number: P0093-01

Licensee’s Name: PPI Adhesive Products Ltd.
Address: Units 5/6, IDA Industrial Estate, Cork Road,
Waterford.
National Grid Reference: 1106N, 2582E

1.2 Company and Site description

PPI Adhesive Products Ltd. is located on the IDA Industrial Estate on the Cork Road in
Waterford City. There are two units involved in the manufacture of adhesive tapes. One of
these units is IPPC licensed (Units 5/6) and has been operating since 1970 producing a wide
variety of adhesive tapes for various industrial applications in the domestic and export
markets.

The IPPC licensed unit is located close to the Waterford-Cork road across from a housing
estate. There is a stream located approximately 600 m North East of the site.

The overburden beneath the site consists of clayey sands and gravel and is in the region of 6.5
m thick. Bedrock beneath the plant consists of weathered shale (about 3.5 m thick) overlaying
shale bedrock typical of the Duncannon Group shales indicating that it is the Ross Member of
the Campile Formation. The groundwater is in the region of 10.5 m below the surface.

This Annual Environmental Report, which details the environmental performance at the site
for the period January to December 2011, is compiled in accordance with the Environmental
Policy for the site and EPA reporting guidelines.

1.3 Site Activities

PPI Adhesive Products Ltd. operation manufactures a wide variety of self-adhesive tapes;
laminates and die cut pieces for a wide variety of industrial applications:
Electrical adhesive tapes;
Industrial tapes;
Release films;
Medical & pharmaceutical tapes;
Audio / video splicing tapes;
Electronic tapes;
High temperature labelstock;
Aerospace tapes
The process begins with the delivery of raw materials (films, adhesives, resins, fillers etc.).
These are sourced from a variety of suppliers. Returnable packaging is employed wherever
possible.

The production activity involves blending of adhesive components (resins, pigments, fillers,
etc.) with organic solvents which are then cast onto a substrate (film). This moves on a
conveyor through a coating oven where the adhesive is baked onto the substrate. This is then
rewound onto a master roll. The master rolls are then sent off site for cutting into the final
finished product.

Natural gas is used as a fuel for the thermal oxidiser, coating ovens and for space heating of
the facility. Electricity is used to power the air compressors and other equipment.

There are currently 25 persons employed by PPI Adhesive Products Ltd., the normal hours of
operation are Monday to Thursday 08:00 to 17:00 hrs and Friday 08:00 to 13:00 hrs. Saturday
overtime is also carried out (normally 08:00 to 16:00 hrs, though times can vary).

1.4 Environmental Management Organisation 2011

A copy of our Environmental Policy is included as Appendix X.

Management structure of the facility for the reporting period.

Dermot O’Callaghan
Managing Director
Ellie Hauck Marc Zimmermann Jimmy Savage Billy Walsh
QC Manager Production Director EHS Manager R & D Co-ordinator
Paddy Gallagher
QC Technicians Supervisors R & D Technicians
Production Manager
Maintenance Operatives
Supervisors
Operatives

Environmental Management Organisation
2 Summary information
2.1 Emissions to Surface Water

Emissions to surface water from PPI Adhesive Products Ltd. are mainly due to storm water
runoff from roofs and hard standing areas. There is a small non-contact quantity used as a
coolant for a milling machine that enters a surface water drain, (Ref.: MH 4).

There are four surface water drains located in the yard are at the rear of the facility. These are
sampled according the conditions of the IPPC licence. These samples are analysed for COD
pH value and suspended solids with the results reported as part of the quarterly monitoring
report.

Surface water monitoring carried out in 2011 is included as Appendix I.

2.2 Emissions to Sewer

There are no process emissions to sewer from PPI. Emissions to sewer are from sanitary
sources such as toilets, sinks and the canteen area.
2.3 Emissions to Atmosphere
The main environmental impact from Units 5/6 is due to the use of organic solvents to cast
the adhesives onto the various substrates. Vapours resulting from the process are transported
via the vent header system to a regenerative thermal oxidiser (RTO) for destruction.
Year Average Number Number of Maximum Carbon Maximum %
Emission of hours flow rate emitted in Allowed Carbon Compliance
(mgC/m3) Working worked through form of emitted in form
Days oxidiser hydrocarbons of hydrocarbons
(Nm3/hr)
2011 16.02 232 1806 45,000 1.30t 12.5t 88.6 (Daily)
93.4 (Hourly)
2010 29.3 236 1888 45,000 2.48 t 12.7 t 70.7 (Daily)
72.7 (Hourly)
2009 12.0 166 1256 45,000 0.62 t 8.9 t 96.6 (Daily)
98.6 (Hourly)

2008 22.8 247 2038 45,000 2.09 t 13.3 t 89 (Daily)
94 (Hourly)
Emissions Data
2.4 Energy Consumption

As previously mentioned the sources of energy usage onsite are electricity and natural gas.

Source 2005 2006 2007 2008 2009 2010 2011
Electricity (MWh) 700 691 641 614 375 502 486.6
Annual Electricity Usage

Electricity consumption has continued its decline mainly due to PPI’s policy of ensuring that
equipment not in use is switched off.

Source 2005 2006 2007 2008 2009 2010 2011
Natural Gas (m3) 365,738 328,338 299,462 292,143 188,678 375,910 297,937
Annual Gas Usage

Natural Gas Consumption:

Gas usage decreased in 2011 due to turning off gas burners when not required, manually
switching off oxidiser when coating was finished earlier than expected.
2.4 Environmental Liability Cover

Cover agreed and policy (limit €2,000,000) put in place in 4th July 2011. Based on the ELRA
completed in 2008 this cover is deemed to be adequate. The ELRA was reviewed in 2011.

2.5 Waste Arising’s

A summary of the waste management records for the reporting period is included in the
appendices. As can be seen from the following figures the amount of waste produced varies
year-on-year.

Waste for 2005 2006 2007 2008 2009 2010 2011
Landfill
Tonnes 31.6 59.74 35.9 33.42 18.96 17.48 15.28
Annual Waste to Landfill

Hazardous 2005 2006 2007 2008 2009 2010 2011
Waste
Tonnes 50.095 40.101 52.641 41.064 35.777 29.90 107.47
Annual Hazardous waste generated

As can be seen from the figures above the hazardous waste figures have increased
substantially, this is due to the introduction of a thermal oxidiser cleaning schedule which
accounts for approx. 63 Tonne of the overall hazardous waste figures. In addition to this we
also undertook an ‘old stock removal’ of rubbers and silicones to reduce the risk of drum
leakage associated with older drums, this removal accounted for approx. 7 Tonne, additional
contaminated soils associated with well installation was also removed from site accounting
for 800kg of the overall hazardous waste figures waste

In PPI Adhesive Products Ltd. there are considered 5 main sources of hazardous waste:
Contaminated drums from incoming raw materials, contaminated rags/buckets etc., waste
adhesive, waste silicone primer/adhesive and oxidiser cleaning wastes inclusive of dust and
aqueous waste.

Measuring each of these waste streams separately provides the company with a system that
can provide a method of reducing the waste streams generated thereby reducing costs
associated with hazardous wastes.
Hazardous 2005 2006 2007 2008 2009 2010 2011
Waste
(Drums)
Tonnes 17.770 15.056 16.088 13.968 9.936 15.800 20.560
Annual Hazardous Waste (Contaminated Drums) Generated

Hazardous 2005 2006 2007 2008 2009 2010 2011
Waste
(Silicones
and gels)
Tonnes 3.024 4.870 2.308 2.149 1.718 1.700 10.40
Annual Hazardous Waste (Silicone) Generated

Hazardous 2005 2006 2007 2008 2009 2010 2011
Waste
(Adhesive)
Tonnes 0.800 0.170 1.429 7.847 5.382 1.090 3.000
Annual Hazardous Waste (Adhesive.) Generated

Hazardous 2005 2006 2007 2008 2009 2010 2011
Waste
(Rags)
Tonnes 25.265 20.058 32.816 17.100 18.741 9.8 12.320
Annual Hazardous Waste (Rags) Generated

Hazardous 2005 2006 2007 2008 2009 2010 2011
Waste
(Oxidiser
Washings)
Tonnes N/A N/A N/A N/A N/A N/A 62.36
Annual Hazardous Waste (Rags) Generated

Total Waste 2005 2006 2007 2008 2009 2010
Tonnes 81.695 99.841 88.541 74.484 54.737 127.0 130.414
Total Annual Waste Arising’s (hazardous and non-hazardous)
2.6 Environmental Incidents and Complaints
We received no complaints at the site during 2011
We did not have any incidents at the site of environmental significance in 2011.