Treatment, Abatement & Control Systems Attachment F.1 includes details on treatment, abatement ...

188 Pages·2011·5.47 MB·English

Abbott Cootehill - EPA IPPC Licence Review Application AWN Consulting Limited

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Attachment F.1 – Treatment, Abatement & Control Systems

Attachment F.1 includes details on treatment, abatement and control systems for air and
effluent emissions from the facility. Drawing 008 – Ref: 21029/CD/008 shows the
locations of the various existing and proposed abatement systems for the facility
operations.

Emissions to Atmosphere – Treatment, Abatement & Control Systems

Boilers
There are currently 3 boiler emission points on site – A1-1 (Boiler No.1), A1-2 (Boiler
No.2) and A1-3 (Boiler No.3). These emission points are part of the current IPPC Licence
and are monitored (See Section F.1 of this Licence Review application for more detail).

Steam is generated by 3 gas oil burning boilers enclosed in a boiler room on site.
During normal operating conditions the steam requirement of the plant is supplied by two
of the boilers running at equal load, with the third boiler on standby.
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No specific abatement technologies are employed for the ebr oiler emissions.
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Dryer Towers oses eodn lfy.or any ot
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The dryer exhaust filtration technology that was installed reduces particulate emissions
from the exhaust stream from Dryers to below 20mg/m3 as required in the terms and
conditions of the current IPPC Licence for the facility. The bag filter is not CIP’d
(cleaning in place) and is located downstream of the cyclones (non-product contact).
Waste powder from the filter is down-graded for off-site waste disposal.

The equipment associated with the dryer towers is maintained and calibrated as required
by the EPA under the current IPPC Licence (see Table F.1(i) of the main application
document). Monitoring equipment calibration and maintenance is annual (or as
required).

Odour Abatement System
An odour abatement system was installed when the existing wastewater treatment plant
was installed at the facility. This was detailed as part of the original IPPC Licence
application.

Foul air from the following is collected and treated to remove odour:
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 2 No. Balance Tanks
 Sludge Thickener
 Sludge Holding Tank
 Sludge Dewatering Building

The type of biofilters that were installed was developed by Bord Na Mona, consisting of
shells coated with a specific blend of selected micro-organisms. Shells contain a high
level of calcium carbonate (CaCO ) which neutralises acid as it is produced by the action
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of bacteria. The bacteria are selected for their ability to degrade high levels of hydrogen
sulphide (H S) and show optimum performance at pH 7.
2

The shells act as an active support media associated with a unique system of microbial
inoculation. This system allows extreme diurnal variation treatment during periods of
nutrient starvation. The system is particularly suitable for the treatment of high and
fluctuating levels of H S.
2

Odourous gas is extracted by pump and ducted to the flanged inlet on the filter. As the
odourous gases pass through the filter media, micro-organisms immobilised on the
media oxidise and remove the odourous components of the gas. The unit is rated for
3,100 m3/hr. e.
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Minor Emissions
In addition, there are 12 minor emission points from the site that are not monitored. No
specific abatement is in place for these minor emission points. Controls include the
SOPs that are part of the Environmental Management System for the facility (See
Section C of this application).

Noise Emissions – Abatement & Control Systems

Noise Attenuators
Noise attenuators were fitted to both dryers at the facility.

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A noise attenuator was installed in Dryer 2 in Summer 2006 and a second attenuator
was installed in Dryer 1 during Summer 2007. The sound attenuation units are designed
and built by GEA Niro A/S, the specific model used is SOUNDCIP, Sanitary Sound
Attenuator, Size 1000.

The construction details of the units are outlined in the table below.
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T ypical sound attenuation from the unitse ctiiso nw onpeuurr rtpleiqnuierd below.
For inysripght o
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Each unit consists of a rectangular housing with process gas inlet at the bottom and
outlet on the upper opposite side of the housing. The baffles and carriers are installed
inside the housing. The baffles are made of a sound absorbing material wrapped and
sealed in PFTE foil, which is welded. The baffles act to attenuate the noise from the
source as it passes through the unit.

Emissions to Surface Water – Effluent Treatment, Abatement & Control Systems

Wastewater Treatment Plant
The process flow diagram for the effluent plant can be seen on AIC-00-106.

Raw Influent Inlet Works
All the waste produced in the manufacturing facilities on site, both production and
domestic wastes, combine in an existing collection manhole located beside the raw
influent pumping station. The existing inlet works consists of a fat trap followed by a
macerator prior to discharging into the raw influent pump sump. Also included in the inlet
works is an overflow facility to a production dump tank.

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The new works includes the provision of an automatic fine screen to remove any
screenings greater than 6 mm from the incoming flow. The new screen will be a channel
mounted screen and will be installed in the existing inlet channel upstream of the fat
trap. An auto bagging unit and collection bin will also be provided that will collect and
contain any screenings produced in an enclosed area thus eliminating any risk of foul
odours.

The existing channel from the fat trap to the raw influent sump currently represents a
hydraulic restriction to the incoming flows, therefore to cater for the increased hydraulic
requirements a new channel will be constructed downstream of the new screen to the
influent sump. The existing macerator and fat trap will be removed from the system as it
will be redundant due to the new screening facility.

For any flow in excess of the expected 210 m3/hr arriving at the inlet works, the excess
flows will overflow to the existing production dump tank as currently happens. Any
overflows will be kept aerated using the existing air blowers and returned to the influent
sump via the existing pumps when peak flows have moderated.

Raw Influent Pumping Facility
All flows from the inlet works gravitate to the influent pumpe. sump from where all flows
are pumped to the wastewater treatment facility. The existeri nusg pumping facility consists of
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two no. self priming end suction pumps capable of puotmping a maximum flow of 160
m 3/hr when operated in a duty/standby configuorsaes tieoodn lfny.or. a ny
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mreidnuimciins gin ogp tehrea tiennge crogsyt sr.e q u i r o e n sd e n t t oof coppump to the wastewater treatment plant and thus
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Production Dump Facility
Currently there is an existing COD (Chemical Oxygen Demand) monitor in the existing
influent pump sump. When the COD reading for the incoming influent reaches a preset
value a control valve diverts the pumped raw influent to an existing production dump
tank. The existing production dump tank currently has aeration facilities to prevent the
contents going septic. Duty/Standby progressive cavity pumps return the production
dump to the influent sump at a low rate when the COD of the incoming influent has
receded. This production dump facility will continue to be operated under the current
control philosophy as part of the upgraded works.

Raw Influent Balancing Facility
Currently there are two raw influent buffer tanks on site. Buffer tank no. 1 has a capacity
of 800m3 and buffer tank no. 2 has a capacity of 1000 m3 giving a total combined
capacity of 1800 m3. As part of the upgrade an additional balance tank (buffer tank 3)
with a capacity of 1400 m3 will be provided. This combined with the volumes of the
existing balance tanks equates to a total volume of one days production at the new
design flow rate.

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There is an additional existing 700 m3 oxidation “ditch” and it is planned to use this as an
emergency storage and processing area for influent. This oxidation ditch has aeration
facilities to prevent the contents going septic. Buffer tank No. 1 will overflow to this
oxidation ditch during emergencies.

Buffer tank 3 consists of a glass lined steel tank with a GRP cover. The tank will be
provided with two submersible mixers installed in a duty/standby configuration each with
the capacity to keep the contents of the tank mixed. The tank will be connected to the
existing odour control system with the air flow from each balance tank balanced via
dampers in the ductwork from each tank. The tank will be provided with an aeration
facility to ensure that the contents of the tank are maintained fresh and do not go septic.
The air supply for this aeration system will be taken from existing air blowers dedicated
to the existing outlet buffer tank.

Raw influent will be pumped into buffer tank no. 1, from where it will be pumped to the
new buffer tank (tank no. 3), the flow will then gravitate to the existing buffer tank no.2,
from where it will be pumped to the biological reactors.

The new buffer tank no. 3 will be maintained full at all times and will act as a dedicated
biological load balancing facility. Hydraulic buffering capaciet.y will be provided in buffer
tank no. 1 and buffer tank no. 2. These tanks will be operear utsed at reduced levels to allow
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the required hydraulic buffering. All process returns andot domestic waste will be pumped
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final stage of influent buffering will minimise any wastage of chemicals that would
otherwise occur due to spikes in pH. Two chemicals are provide for pH correction,
Sodium Hydroxide will be dosed in the event that the pH in the buffer tank is too low and
needs to be increased and Sulphuric Acid will be dosed in the event that the pH in the
buffer tank is too high and needs to be reduced.

Biological Treatment Feed Pumps
The existing SBR feed pumps will be reused to transfer the influent from influent buffer
tank no. 2 to the biological reactor. The forward flow rate to the biological reactors will be
circa 145 m3/hr consisting of the design plant flow and return supernatant from the
sludge process.

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Process Treatment Train:

The Process train is as follows:

Biological Treatment → Secondary Clarification → Actiflo → Hydrotech

Biological Treatment
One of the existing SBR tanks will be converted into an anoxic biological reactor (reactor
1) and the other SBR tank will be converted into an aerobic reactor (reactor 2). The
reactors will operate at an MLSS of approximately 3,500 mg/l, providing a sludge age of
5 days in each reactor. Reactor 1 will operate in simultaneous denitrification mode with
the anoxic duration in the reactor being controlled using the existing Nitrate monitor in
the reactor. Reactor 2 will operate as an aerobic reactor however the existing Nitrate
monitor in this reactor will be used to monitor the nitrate level in the reactor. If the Nitrate
level goes above a preset value then the reactor will change to simultaneous de-
nitrification mode until the Nitrate level reduces and the reactor reverts to aerobic mode.

From the existing WWTP, the aeration system, the 2 no. aeration diffusers and the air
blowers, will be reused. Even under peak conditions the exise.ting air blowers will provide
50% standby capacity. The operation of the air bloweresr uswill be controlled using the
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existing DO and Nitrate instruments in the aeration tanotk with the existing submersible
mkeixpet rins skueseppeinngs itohne utsainnkg cthoen teexnitsst ining ssuusbpmenesrsioiobsnels.e eo Tdnm lfhy.orie xa ency rosn. tents of the anoxic tank will be
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bif ya dsdmitiaolnl aml noidtriaficteasti oanres ptroe stehnet ina eFthorra einty siriiopngnhft l uoceonnt,t raodl diinti onthael aaneorxoicb ivco lruemacet ocra. n Ibf ea pdrdoivtiiodneadl
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configuration of the biological reactor is simply reversed by altering the position of
manual valves and changing the duty aeration tank on the control system.

The equipment necessary for the operation of the biological reactors in their current form
as SBR reactors will be maintained as this will allow the biological reactors to be
converted back to SBR reactors during periods of low flow or to allow maintenance to be
completed on the secondary clarifier. When the biological reactors are converted back to
SBR reactors the decant effluent will gravitate to the existing final effluent sump and will
be pumped through the existing tertiary sand filters as is currently the modus operandi.
In this “SBR” mode sludge will be wasted from the biological reactors to the existing
Picket Fence Thickener, with the sludge being pumped to the Thickened Sludge Storage
Tank, from where it will be pumped onto the Decanter Centrifuge for dewatering. This
interchanging ability and flexibility gives the greatest security and confidence that the
plant will operate under all foreseeable conditions. In addition the new plant can be
commissioned off-line and can be operated after commissioning in SBR mode until such
time as it is appropriate to convert SBR’s to dedicated anoxic and aerobic reactors.

As the incoming influent may be deficient in ammonia an external source of ammonia is
required and urea dosing will be provided on the inlet feed line to the anoxic tank. To
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control the ammonia dose an ammonia monitor will be installed in the anoxic tank, this
instrument will be used to ensure that the ammonia in the final effluent is within the
specification required. Controlling the urea dose on this basis is the most efficient and
economical method as it minimizes the chemical consumption and any aeration
requirements associated with nitrification of excess ammonia.

In the event that phosphorous is deficient in the influent a Phosphoric Acid dosing
system is provided for that will dose into the inlet feed line to the anoxic tank. It may be
necessary to dose a source of carbon i.e. Molasses and other nutrients i.e. Ammonia
(Urea) and Phosphorus (Phosphoric Acid). During shut down periods Waste Milk
Powder Tailings may also be added to each of the Biological Reactors through an
eductor system as an external carbon source for the biomass.

Secondary Clarification
Following the biological treatment of the influent, secondary clarification is necessary to
separate the sludge produced in the biological treatment process from the continuation
flow. A new secondary clarifier will be provided which is rated at 0.85 m3/hr, with a side
wall liquid depth of 3.5 meters to allow efficient separation of the biomass from the
continuation flow. The clarifier will be provided with all the necessary accessories such
as the scraper bridge, outlet launder and scum board. e.
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In the event that the settleability of the sludge producoted is poor, provision has been
ibnec lnuedceeds fsoarr yth oen alyd dinit ivoenr yo fe pxocleypmtieorn aplr icoirr ctou mthsoestea s cneoldnca lfye.rori sfai.ne y Tr hinele nt.e Hwo cwlaervifeier,r iwt iilsl beex ppercotveidd etdo
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cg oranvtritoyl lbeedl tv tiah icak deendeirc watiethd tfh l o e w o p nm su e me n t t opef cero.d pT fhloew W cAonSt rpoullmedp vwiail la h daevdei cthaete fda cfliolitwym toe tpeur.m p to the
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To maximise the reduction in the level of MRP in the final effluent, the soluble
phosphorus in the wastewater must be precipitated into a solid form. It is not sufficient to
coagulate the soluble phosphorus in one location of the process only and several
locations have been included for coagulant dosing. Coagulant dosing is applied at the
inlet to the aeration tank and also at the inlet to the secondary clarifier.

Actiflo
The Actiflo process is used to further reduce MRP and to precipitate the soluble
phosphorous out of solution. The Actiflo has an excellent track record worldwide and is a
fit for purpose technology with several references available where Actiflo Technology
has been specifically and successfully used as tertiary treatment to reduce the levels of
phosphorous in final effluent.

The Actiflo comprises a Coagulation Tank, Flocculation Tank fitted with a Turbomix unit,
a Clarification zone fitted with a Sludge hopper, Inclined Plates, a Hydrocyclone Feed
Pump, a Static Hydrocyclone, Polymer dosing and a Sludge Recirculation / Thickening
System. The unit contains Microsand which is kept in suspension by the Turbomix unit
prior to entering the Clarification zone.

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The Actiflo process operates as follows:
Coagulant is injected into the coagulation tank where there is sufficient time for the
influent to coagulate and flocculate. Polymer which is injected into both the
Hydrocyclone and Turbomix chamber coating the Microsand which in turn causes the
floc generated during the Coagulation/Flocculation stage to adhere to it. On entering the
Clarification zone, the Microsand settles (referred to as Ballasted Clarification) and is
withdrawn by means of a Recirculation Pump and is pumped to a Static Hydrocyclone
where a separation of Sludge and Microsand takes place. The design of the
Hydrocyclone is such, that what is known as “the cut”, is selected as being 80:20 i.e.
80% of the feed is sludge (overflow) and the 20% is returned back to the system. The
latter contains Microsand. With the Sludge Recirculation / Thickening System, a
percentage of the overflow is re-circulated to the recirculation pump which allows
concentration of the waste sludge. The percentage of the overflow re-circulated is
controlled by monitoring the suspended solids of the clarified effluent. The fluid mass in
the Clarifier rises through inclined plates and clarified water emerges.

Online phosphorous monitoring will be provided on the influent to the secondary Clarifier
which will allow the calculation of the required coagulant dose for phosphorous
precipitation.
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A Hydrotech tertiary filter is used to further remove theot MRP and soluble phosphorous
fprroiomr tsoo tluhteio Hny. dTrhoete cclha rtiefiretida rwy afitleter rf.r om the Actoisfelso eo dn plfy.orro acnye ss is coagulated and flocculated
TThhee Hwyadteror tfelocwhs T beyrt igarrayv Fityilt einrt oo ptheera cteesn tareescti ofonow fnpl elutror hrpweeq usidr; rum and into the filter segments. Solids
asereg mseepnatsra. tTehde f rboumil dth uep w oaf tecra pbtyu rtheFedor imsnysroipigclihtrd ooss cinrcereena scelost ht hme ohuenatedd l oosns tawcor ossidse tsh eo fD thisec fdilitsecr
painnaitdtiha ataesnd da w arhet iscthuhel tr sethasemu litens l teiinmt weD a ic s t l ec e for a in l slnt eee ni tvnr oegfr loc torthpaisetei ofsinl.t eApr tr eealse epmnreetidnnegtst e cwrlemitahinn he fidgilt hele-rpv ereelle sams uberanect swk wainta estroh j etchtysec. lfTeloh iwes
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backwash water is collected in a trough within the centre of the Discfilter and flows away
by gravity. After backwash cycle, the rotation of the drum and the backwash pump is
stopped. Filtration is, of course, continuous even during the backwash cycle and the
effluent water quality is also the same throughout the backwash cycle. Backwash water
is transferred back to the influent balancing tank no. 1.

The existing online Phosphorous monitor will be reused to monitor the phosphorous on
the Hydrotech filtered water.

Existing Sand Filters:
The existing sand filters will be kept in their current configuration and will be available for
use at their current capacity as an emergency back up with the activated sludge process
in conventional mode or in SBR mode.

Sludge Thickening & Dewatering:
Sludge generated by the Actiflo process will be continuously pumped to the existing
Picket Fence Thickening Tank, where it will be thickened and discharged to the existing
Thickened Sludge Storage Tank (TSST). Supernatant from this thickening process will
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gravitate to the existing supernatant sump, from where it will be pumped back to buffer
tank 1.

Waste Activated Sludge is pumped directly from the secondary clarifier to a new Gravity
Belt Thickener (GBT) unit, located on the first floor of the existing Sludge Dewatering
building. Thickened sludge from the GBT is pumped to the existing TSST, where it is
blended with thickened sludge from the Actiflo process. Polymer solution is prepared in a
new polymer preparation unit and dosed to the feed sludge upstream of the GBT
flocculation tank. Filtrate from the GBT gravitates to the existing filtrate sump, from
where it is pumped back to balancing tank 1.

The new polymer preparation unit will supply polymer to the Actiflo process, hydrotech
tertiary filter (and secondary clarifier if necessary). The polymer will be a low to medium
molecular weight cationic polymer; actual polymer type will be confirmed during site trials
and commissioning.

A new high-efficiency Decanter Centrifuge will be installed within the existing Sludge
Dewatering building. Sludge is pumped to the Centrifuge from the TSST via new duty /
standby progressive cavity pumps. Dewatered sludge cake will be transferred to a
sealed sludge skip located on the ground floor of the ee.xisting Sludge Dewatering
building by means of a progressive cavity sludge cake per uums p. Polymer solution will be
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supplied by the existing Filter Press automatic polymoter preparation unit, with new
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Mitigation Measures for Surface Water Runoff & Similac Condensate

Similac Condensate
Mitigation measures to protect against potential contamination arising from releases to
surface waters are in place at the facility.

Historically, the condensate from the Similac manufacturing process was released into
the Dromore River mixed with the surface water runoff. In recent months, the
condensate has been diverted to the WWTP, due to occurrences of TOC spikes
recorded in the condensate stream (E1). The high TOC peaks are due to Gain and
Similac Advance condensate.

The specification for the TOC monitor that is to be put in place at the facility is included
as Attachment F.1.2. The analyzer is a BioTector product, which is designed for on-line
continuous monitoring. It is designed for outdoor locations, has a self-cleaning capacity
and has a high level of reliability (99%+). The analysis process is a Two Stage Oxidation
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process, with aggressive oxidation of the samples and therefore accurate detection of
TOC spikes. Further details are provided as Attachment F.1.1.

A trial of the TOC analyser was carried out to ensure it was suitable for the site and its
purpose.

The trial took place between 28th October and 15th November 2010 on Evaporator 1.
The analyser continuously monitored Total Organic Carbon (TOC) from the Similac
condensate, Gain condensate and Cleaning In Place (CIP) flow in Evaporator 1 during
this period, and included in this measurement process is the removal of the Total
Inorganic Carbon component from the calculation, outputting the TOC component only.
The Total Nitrogen was also monitored and high peaks highlighted in red in the graph
below are due to CIP Evaporator and/or Dryer CIP. See Graph 1 below.

It has to be mentioned that the Graph below is not a profile of Similac condensate, it also
includes analysis of Gain condensate and CIPs. When the analyser is in place it will be
set up to divert to the Waste Water Treatment Plant when the flow reaches a set TOC
limit which will ensure that high TOC loadings of Gain, CIP and Similac Advance will by
default be sent to the Waste Water Treatment Plant.
e.
The correlation of TOC results to COD results was feor uusnd to be very stable at a
h
correlation factor of 3.0, which is the typical TOC/COotD correlation factor found over
m any years in the dairy industry (see supportinogse s deodno lfyc.oru amny entation in Attachment F.1.1).
DmCuIgPr/il.n. gPT oeth aeka svtr oioaidbl sthederisv acevhdea wrrageginreeg TdpOuoeCt e trone tsiGaulalltyi ne wc tpicaooonsw nlpn leu5urrd rp4teeinq nmuigrs gac/tleo w,n hSdieicmnhsi liaastc ee Aqiudt ivviaasn lecpnert o Ctpooo ans edCdeO nstDoa toedf i1ave6nr0dt
cthoen dWeansstaet eW waitthe ra T TreOaCtm oef n2t7 p mlagn/tl ,Fo owrn ih nyssriipcigthhet o.i sT ehqisu iivsa ale lnimt tiot vaa CluOe Dth oaft 8w0a sm gag/l,r eoer dh iwghithe r,t hteo
A gency in 2010. o n s e n t of cop
C

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