INFRASTRUCTURE & OPERATION

rnent Ltd. IPPC Licence Application

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:04

Attachment N* D.1

INFRASTRUCTURE & OPERATION

Table of Contents

Section

1-0

2.0 Development and Operational History

Introduction and Scope ............................................................................................ 1

3.0 Existing Aetivitks ..................................................................................................... 5 ........................................................................ b

3.1 Sltebyout ........................................................................................................... 5

3.2 Process Description ................................................................................................ 6

3.2.1 3.2.2 3.2.3 3.2.4

3.2.5

3.2.6 3.2.7 3.2.8 3.2.9 3.2.10

3.2.11

Introduction to the cement manufacturing process ........................................... 6

Raw materials preparation .............................................................................. 7

Raw mix milling and mixing .......................................................................... 12

Raw Meal Kilning .......................................................................................... 14

Raw Material analysis and blending ............................................................... 10

Clinker cooling and handling ......................................................................... 16

Clinker grinding ............................................................................................ 18

Coal preparation .......................................................................................... 21

Storage and handling of cement .................................................................... 1,

Use of Alternative Raw Materials ................................................................... 23

Existing Alternative Fuels .............................................................................. 26

3.3 Labotabry Testing ............................................................................................... 31 4.0 Quarrying Activities ................................................................................................ 32

4.1 Project Descript~m ............................................................................................... 32

Proposed Operational Plan ................................................................................ 33 5.0 R e p o w Incidents ................................................................................................. 43

4.1.2

Appendix D . I

Appendix D . I1 Process Flow Schematics

tagan Cement Ltd . Annual Environmental Report 2011

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:04

1.0 Introduction and Scope

This IPPC Ucem Review applbtbn is primarily king s u b m W in order to repeal the Air

Overpressure limits at the nmrest sensitive katims which were r e d u d by the EPA in the most

recent IPPC Ucence for the sfte - po487-06 from 125dB(lin) max. pBak to 12WB(lin) Max. peak.

In addition, the licensee a h seeks the following amendments-

1. Iwrease the emission limit value for Total Organic Carbon from 10 m g p - rn wmgJNm3 for

emtssion point A241 for the m-indnwatlon of waste In order to ammodate varlfng

organic fractions within the raw materials and to bring the licenoe into line with TOC limits

recently granted to another Republk of I&nd k d m e n t producer.

2. Amend the stwage V d u m permitted for Liquid Recwered Fuel (LRF) in Condition 8.9(b) of po487-06 from 20,000 litres tu 150m3, The prmmed use of LRF In PO48746 is 20,OOO

tonnes per annum. This e q m to a use of approximately 60 tonnes per day. Tkefore, the

permitbed storage of 20 brines Is Inadequate.

The prwlous IPPC Revlew req- an i n m s e the exbent of the existing quanying operations at

the Lagan Cement manufacturing facility In KlllasMllen, Co. Meath, the plannlng appllcatlon for whkh required the prepamth of an Environmental Impact Statement (EIS), The prwlous IPPC Review also

bmadened the range af attemtive fuels used as part of lagan CemeWs sustainable fuel programme,

including up to 20,000 Mnes of UquM Fuels (LRF). The purpose of the suskainable fuel

pmgramme is to fuW redm Lagan ~~~s dependence on Imported M I fuels, lagan Cement

is currently lioensed to use 95,000 tonnes of abmative fuels pw annum and the most I P K

Umce rwiew did not alter the volume of atternathe fuels used on a, fhe m p M e llst of European Waste catabgue code permitbed for use on sibe o n be Seen In detal1 in Attachment H.

0

Lagan Cement U has been granted planning permission (TA 900603 - 4'" December, 2009) b

increase the surface area of the existing llmwtane quarry over lands within the townlands of Killaskllh, Coppaboggan, and Tore, Co. Meath. The extension will increase the surface area of the

quarry from the 24.8 hectares previously permittd to a final ovedt extraded a m of 77.25 -res,

appmxlrnately .

Lagan Cement Ltd has undergone an extensive IPPC Licence rwiew to permit the use of alternative

fuds at their facilitv in Kinnaad and are currently Dermlttd to bum the fdlowins fuels:

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:04

0 In September 2010, planning permission was grantEd (Meath County Council Planning Reg.

Ref. No. TA100444) for no increase in the quantum of alternative fuels used In the oement

manufacturing p m of 95,000 bonnes per annum but to include the burning of 20,000

tonnes of Muid Remwed Fuels (LRF).

In May 2008, planning permission was granted (Meath County Council Plannlng Reg. Ref. No.

TA800654) for an increase in the quantum and range of a l k r a t i e fuels used In the emt

manufacturing praass to 95,000 tonnes per annum and to indude the burning of Solid

Recovered Fuel (SRF) and was& shredded tyre chippings.

In February 2007, planning permlsslon (Meath County Council Planning Reg. Ref. No.

TA60580) was granted to utilise a range of arbon neutral bbfuels in the cement prdudbn

pmcess induding woad chips, recyded wood lncludlng construction and demdition (C & D)

timber, sawdust, and residues derived from the sawmill and forestry Industrj; agrkuttural

products and residues such as energy crops, cemls and grains; bio-sludge from the water treatment industry; and b i o d i l and bloethanol, and their derivatives.

I n 2005, plannlng permission (Meath County Council Plannlng Reg. Ref. No. TA50145) was

granted to bum Meat and Bone Meal (MBM) at the cement pbnt ta help Lagan Cement

d u c e its dependence on imported fossil fuels and improve its sustainabillty In terms of reducing CQ emissions. MBM is cladd as a carbon-neutral renewable energy source

0

The m n t manufacturlng facility has been 100% m p l b n t with the requirements of the Waste

Incineration Directire as managed through their IPPC Lkenoe sin= they commend burning

alternative fuels (MBM) in 2006. The Waste Incineratlon Dlrecthre sets out the legal operational and

environmental standards which the faality must comply with when burning any form of akrnathre

fuel material. The use of 95,000 bnnes of alternative fuels per annum, indusk of 20,000 tonnes of Uquld Recwmd Fuels (LRF), falls under the scope of the Annex II ELVs as the muking heat telease

will oome fmm the co-fuelling with less than of 4Q% of hazardous wask (Artlcle 7(2)). All altenrathre

fuels used onsite will contain less than 1% of halogenated organic substanoes (expressed as

chlorine).

The use of up to 20,000 tonnes of LRF of the 95,000 tonnes of alkmthre fuels used on s i k has

further i~reased the swtalnablltty of the cement manufacturing fadlity and represenb further

progress by the m p a n y in delivering a sustainable future for the m p a n y in kms of energy

demands and usage. Lagan Cement Ltd manage a highly energy intenshe operation, tk manufacturing of mnent, wm a safe and secure supply of energy In a sustainable and

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:04

environmentally friendly manner while still achlevlng emmic o o m ~ n e s s , Sustainable

management of the energy requirements at Lagan Cement LM. Is intended to:

0 Reduce C Q emissions from the fadllty

0 Wte and stabilk energy supply for the h g brm

Redm dim on expenshe fossil fuel imporb and

Imrest and assist in Irelands indigenous renewable energy prolects which are often in rural and less M o p e d ateas.

Lagan Cement Ltd ts \~ery mscious of the fact that using rnm more effidendy is an essential

s k p toward mating a more sustainable wdety. I n effectttrts’eco-efficiencf means producing m product, with IES energy, waste and pollution, and the use ob fewer ~ e s o u r ~ ~ ~ This Secbfon of the I P K L h m applkatkn m b e s the hktory of the site and givw detailed tnfomration on the operatianal s y d m s and prcxedum for both the &sting and proposed xthitie.

The use of up to 20,000 tames of LRF of the 95,OOO tonnes a# altwnative fuels U& at the Lagan

facllky is a mapr optton for Ireland SabMylng the National Hmardous Waste Management Plan 2008-

2012. This Ptan sets out the priority actio= that should be taken within the pried ofthe Plan (2008-

2012) in &lion to: the m n t l o n of hazardous warn; improved oollection rates for =&in

categories of hazardous waste; the sbeps that are required tn improve Ireland‘s sdf5ufficiency in

hazardous was& management; and the management of certain legacy hazardous was& such as

For in

spec

tion p

urpo

ses o

nly.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:04

2.0 Devetopment and Operational History

Lagan Cement LM Ls part of the Lagan Group. Headquartered in Belfast, the Lagan name has k e n

synonymous with the quamng and constmctbn industrles for over 30 years in NorthePn Ireland. In addition to the Klllasklllen Cement Plant, the Lagan Graup's other holdings In the Republk indude an inkgrated quarrying, asphalt and bitumen emulsion plant at Ballycmlin, Blanchardstmn, Co. DublIn;Healy Brothers Llme, blmk and con- in Cork; and Fleming's Firedays In Athy, Co. Klldare.

I n addltlon, the Lagan Group also has a number of asphalt plants bmkd thmughout the muntry

Including a pbnt at Klnnegad, Go. Meath (fmmedlatdy adjacent to the eastern boundary of this sib).

On 1#' April 1999, Lagan Cement Ltd. sought planning permission, which was granted in June 2MK1,

to erect and opetak a new oement works and to quarry limestone and shak at Killaskillen, Kin-,

Co. Meath. Following a 2-year construcblon programme, the fadlity commenced production in 2002.

Lagan Asphalt Ud, a slster #Impany of Lagan Cement Ltd, were granbed permksion for the development of an asphalt plant In 2001. The exlstlng limestone quarry and cement works were

granbed planning permissiMl by Mmth Cwnty Coundl in April 1999 (Meath Cwnb Cwndl Planning

Reg. Ref, No. 98/2026). Thls permission was the subject of an appal to An Bord Pleanib, who subsequently upheld the decision of the Pbnning Authority and granted pennissbn for the development on 26* Apd 2000 (An Bord Pleanhla Ref. No. PL 17,1f1198).

This is laeated to the west of the oement plant but is a septate fadlw and a fully independent

operation. The faality does use common entrance roadways to the Lagan Cement W Milty in the

interest of ophrnislng the use of roadways In the a m .

In 2002, b g a n Cement Lkl applied for and received planning permission for an extension t~ the rate

and extent of extmtbn of raw makerials from the shale qua- at the site. This permission was scnrght in anticipation of a need to fulfil contractual requirements in respect of the M6 motorway project whkh runs past the site. Although planning pennksin was grankd, the development was not

progressed since the company did not win the Mobmay contract and hence the materials were not

neKled at that time.

In July of 2004 Lagan Cement Ltd were granted planning pmission for an i m In pducbion in order to mwimlse the efkiency of the plant. The rate of productkn of oement was increased from 4S0,OOO tonnes per annum ID 600,000 tonnes per annum. Retention pemission was ako granted for

the following:

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:04

A redibution of buildings and material handling area,

within the p m n g a m and a reofganlzed

An of the swth eastem fwe of the quarry,

2 no. settlement lagoons as mnstmded,

A rwlsed layout for the site amss.

In Ocbober 2009, Lagan Cement LId w r e granted plannlng pmission to inc- the s u m area of the existing 1i-m quarry from the 24.8 hectares pmiously permitted to a final overall e x t m

area of 77.25 hectam, approximately.

3.0 Existing Activities

3.1 sitebyout

The M n g site on which the plant is I mkd co\rers wet 200 hectarw and contains a sha e qww a limesbone quarry, both of which supply raw materials for the cement rnanufacturlng p-, and bnds In agrkultural use. It l i 2.5 and 4.5 km southwest of Kinwgd and 1.2 to 3.5 km

north of Ballinabmkey in County Meath. It Is approximately 6Okm by road from Dublin and Athlone,

and Mullingar is located appximabely 1 7 h to the north- The Site Locatbn Map and the layout

of the s i k is detailed in Attachment B.2. The m e n t IIVOTJCE is located on the western side of the site

towards the southern boundary, the limestone quarry l ie south east of the WDTkS area and the shale

quarry is located in the North West part of the site.

I t is the intenth of Lagan Cement Ltd to continue tn exbad from the exwing quarry s& until its

end of l fe and progressively -re the site during this p m , as illustrated In the L a m p and

RestamUon Plans submitted as part of the relevant Planning Appliation Documtation and previous

IPPC A p p b t h s . See Attachment K.

The proposed quarry extenskn area oontains limestone m k and the proposed quarry extension will

provide for an estimated exbaahe life of about 15 - 20 p r s , depndlng on the output rate whkh is

Influenced by ecmanlc conditions. The resou- estimate for the proposed quarry exhsion is 13.6

million tonnes. In these phase, it is propwed to extrack limestone rock t~ a depth of 70 metrw above Ordnance Datum (AOD).

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:04

1 The opatbnal plan for the Quarry extension has been upgraded in light c

development. Each of the three phases of the proposed operatkn are summarised b e b . Phase 1: kvelopment of Northem Exhension to a Depth of 70 rn&m AOD Phase 2: Development of South-Eastern and South-WesWn Extensions to a Depth of 70

metres AOD

Phase 3: Removal of Asphalt Plant and Subsequent Development of the Q u a ~ in a SoutherlY

Direction to a Depth of 70 metres AOD.

0

3.2 ProoesgDegaiption

3.2.1 Inwuction b the cement manufacturing prooess

There will be no change to the process operations in the quarry &ension and there wlll be no new

quarry fnfrastrudture. Lagan Cement Ltd manufactures grey Portland cement. There are two tvpes of cement produoed at the facility, namely CEM I and CEM 11. Cwnent is produced In a kiln at very high

temperatures from a mixture of raw materials. Limestone is the prlmary raw material required for the

production of cement. Shale is an impoatant additive for the manufacture of cement. All of the l i m e required is excavated on site from the limestone quarry. The shale quarry pmides the

mmssary shale for the plant and has an estimated life of up to 30 years, afber which time an alternative sou= will be located and the shale will then IE imported onto the s i k Other raw

materials ate currendy imported to the site. There are elght stages In the cement manufacturing

process: L W material pwparam i2

w material analysls and blending

w meal mllllng and mixing

Rawmeal kilning

1 alnker mllng and handling Qinkergrlndlng

4 Storage and handtlng of cement

Coalprepratlon

Each of these in

the manufacturing process, a dexrlptbn of the proaess Is provided togdwr with details d material

throughput, process mtrol systems and s o u m and tmtment of emissions genmted as a mutt of e h actthrlty, A tepresentation of the overall aement production prooess is presentd in

Figure 1 in w n d i x I of this document.

Is -bed in detail in the following d o n s . For each of the main

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:04

3.2.2 Raw mtb&ils preparation

3.2.2.1 prwesd Dscription

The limestone is quarried at the on-& limestone quarry and transprtd from t h m to the Raw

Materlab handllng area and from here into the crusher bulldlng wkm the primary and semndary

crushing takes plae. Crushed material is conveyed under cover to the Blending Bed.

Two qualities of shale are quarrkd and these materiats are fed to the shale crusher whkh is housed

in a separate building In the Raw Materlak handling am. A third quality of shale Is bwgM in and

added to the mix. The three qua lm of shale are pmportioned In attain a correct balance of the

chemical cornpaition In the Blending House.

3.2.2.2 Pracw6-1

Samples ate taken for laboratory anam from the boreholes drilled for blasting. L a m mults

influence the face exploitation qwntitathrely. As amvation advanm the quantities from the different

quarry M are adjjusbed for an optrmised proporblon to attaln the required mlxes and simultaneously

& a m in such a way that all the available materia! mn be used.

3.2.2.3 Emisslons

Air Emissions $L Abatement measures

The main emissiams assoclabed with the raw matedals remvery and preparation are parl icuk

emissions. The main sourcs of dust from the existing quawimg operation are associated with the

raw material &ractin, transport of raw makrial In the ausher and the crusher M, The crushing

and mMal conveying operations are ewlosed, and 1-1 extraction systems vent to Bag Filtes

which control dust emissions from thwe source. I m m materials are shred under w r further

minimising dust missions.

The raw material emissions at the sfte and the following mittgating m e a s u ~ are married out:

* and stodrpiling operatians am the most significant source of dust

Effect& design and management of the Masts to prwent fly rock and significant parbiculatR

emksions

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:04

0 Fixed and mobile water sprays are used to mtrd dust emlssbns frwn InbwMI haul rods, material sbdcpilw and storage and plant yard surfaoes. Loose loads of materials enterlng the site are -red and a ded- wheel wash Is I&

at the entram to the shale quarry.

Afullvehide wash spray and wheel wash is sited near the cement works entram.

Noise Emidonr and sbsbsmaiIt w r n

Noise fnwn the Raw Materials preparatlon stage ofthe p m e s k a m l a k d wlth the excznratiopl, recwwy, transpMtatbn and uushlng of nw material. Noise from the quarry workings is minimised

by ensuring that all plant and equipment meets stringent spedfications for noise missions.

Acoustic xreening bunds are provided betwen the nearest noise senszthre temptor and the quarry

and plant operations resulting In a barrier atknuatbn of at least 15 dB(A).

The most signifimnt potential knm a m with the quanyhg operation k the ptential mise and vibration impacts a-ted with blasting for the purpose of cecovery of raw materials. Blasting

is not generally requlred for ground preparatlon In the shale quarry although one or two blasts per

par may be required to r e m Reef Um&nne; some ripplng of shaky limestone at depth may also

be required. The blasts in the limestone quarry occur once every 1 - 2 ~lleeks on avenge.

careful ckign of the blasts following trial Masts to establish the local site chara&ristics, It Is with the blast do not ex& the llmits imposed at possible In ensun that the vlbrabion

nearby sensitive receptm.

The existing quarry exmations &end to a maximum depth of a b u t 70m below groundwater level

in the limestone area and approximately SOm below groundwater level in the shale area.

Consequently, pumping of In-flowlng groundwater is required to fadlitate qwnying operabions. Both

the existing shale and limestone quarries are worked by dewakrlng uslng sump pumping

arrangements.

R u n d from the d s near the quarries are drained in to the quarries, SurFace water r u n 4 frwn

the undisturbed land-@ m n i n g banks Is also drained thmugh the nea- quarry.

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:04

Water run off and ground water pumped out dms not contain harmful s u k b m . m r s i m

m e soil and fine matter may be in suspension Settlement Lagoons will allow this to be settled

before dlxharge In the Klnnegad Rhrer.

The drainage arrangements for the site ensure that no uncontrolled discharge of drainage fKrm the

slte a n m r at any Urn. Wabr pumped from the quarrles is directed to the Wement LagbMls

w h a midenae time of 28 hours ensures adequate settling capcity. Most d the pumped water Is groundwakr which is free from any mbmlnatlon.

No prooess waste is generated at this stage ofthe m, Some waste oils and lubricating and degreaslng fluids =kited wtth mainbewince and opratbn of the plant, machinery and Imnsp~t

v l e h i may be generated.

3.22.5 Malhunetlon

There am no m c malfuncXkns whlch muld wit in addental or unplanned emWons or dlxharges. In the unlikely event of a pawer failure, the Eag F iks wwld mase to fu-n

temporarily but so would the cnrshing machinw, so the emlsslons potential k ellminaW. Details of montrol m m for m n t i n g unplanned dixha- to the Kinnegad FUrer are outlined In

Atkhment F. a

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:04

3.2.3 Raw Materla1 analysls and blending

3.2.3.1 M p t i o n

A schematic representation of the p m s s invohed in raw material analysis and blending is

presented in Fgum 2 of Appendix I of this Attachment.

The conveyor the raw materials handling area and the Blending House Is fully endosed and

transports crushed Ilrnestmw from the crushed material sine or the ausber b the Bkndimg House. The conveyor is fitted with neutron type analysers for cmUnuous measurement of caldum, silica, Iron and alumina in the taw feed. W i n is ako SbOW sepamtely in the Blending HOE and will be

blended as rquired wfh the sther raw materials when whik mnent is king manufactured.

The mix of s h a k and Ilmestone is Mended in the Blending House reducing fluctuatkns by layhg a

large number of byws on a m i l e . Is redaimed off the plle at appmxjmately the mte at whkh the raw mill (see kkw) needs the blended taw matetbl mixture for the final cunpwltson of the raw meal i.e. an average of abut 37flh.

The oonveyor Is fmed with state of the art a-line analysers for continwus measumnt of ddurn,

silica, iron and alumina In the raw feed, and this albws effective mntd over the at whlch raw

materials am mnveyed to the Blending Bed. Weighing equipment operablng wlth a dwed loop

feedkk, antrots the proporblons of the thme qual- of shale fed into the p r e - W i n g stockpile.

The quantity of each shale quality is tracked and totals must be in predefined propartidns. Thus a

hmp of shale has a consistent compwMon for an optimum sillca to alumina ratio in the raw mk,

3.2.3.3 Ernisdams

Air amlmdaw and abatement measum

All of the conveying and blending operations are endosed so thew is mlnimal potential for emissions

to atmosphere assodakd with this operation. The crushing operabion Is enclosed and so tm Is the crushed mw material s t ~ e so that emissions are contained at source and are also treakd in a Bag

Filter. The conveyor of blended material from the Bknding House Is vented to a 6ag Filter - any dwt

O O l W is fed badc in to the process. There are no other significant sources of emkions to atmosphere - * with this activity,

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:04

Nolse smldons and abatement measures

Thee is rn significant process-related nok sou- assodated with this prooess. The fans colleebing

dust for the bag fitters are all fitM with appropriate silencers.

Water and a-ment measuw

There am no water discharges generated as a result of thls p m .

3.23.4 Was& 0

There k CIO waste generated as a result of this p m s . Any mabrk,; not c99e~ in the initial

flow through are fed back Into the p m at a later stage. Some wask oils and lubricating and

deg-ng fluids a- with maintenam and o m t i o n of the plant, machlnew and tramport vehldesmaybegenerabed.

3.2.3.5 Malfunction

In the event of power loss, actMties In this area would ease temporarily until m r is restwed fbn

the auxiliary diesel genemtor or from the plant mains electrkity supply. There are no spcific

malfunctions which mould lead to unplanned release bo the environment awdaml with thls

operation.

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:04

3.2.4 Raw mix milling and mixing

3.2.4.1 Dederlptlon

A schematic representation of this stage of the manufacturing p m is presented In figure 3 of

Appendix I of this Attachment. The Raw Mill crushes the sub1Mlmm blended Raw Mi to a fine

powder and also dries it.

A belt mnveyor, onto which limetone and imn oxide are also dosed, feeds material redaimed from

the Blending Bed by the d i m e r to a raw mix feed Mn. From the feed bin the material is fed to a

Raw Mlll for grtndlng to a fine dust called raw meal.

Makrlal fed b the raw mill Is propMtioned and controlled. A feed bin on bad d s feeds the mill and as a buffer. The k l of the &r&t in thls bln wntmls the m t ~ at which the bbl mix Is

prepared. Three components, limestone, shale m k and iron sinkrs am welghed and fed in the c o d pmporblon o m the M mveyor feeding the bins. Controlling the raw mix is Important for

the quality of the d l n k produced and for malntahlng the in a more W y operating

mondibkn. S@tdy and constant OondlUom in the kiln very signifmntly help maintain gmd canbustion contrd and reduce emissions of CO and NO*.

The raw mill being a roller mill is fed with the raw mix. The rate of feed is controlled by the pressure

drop of the gases flowing through. Gas temperature is contrdled by air-cooling or by spmying water

either in the conditioning tower or d imly into the material being milled. The fineness of the material

is controlled by adjuments to both the mlll -If and the separator.

The mpit lon d the raw meal is checked during transport to the homogenisation slb. If necessary,

adfusting -1s are added In the feed to the raw mill.

3.2.4.3 Emloslams

Air emissions and abatement nma8um

E m i s s i to atmosphere associated with this proaess arise from the handllng and conveying of raw

E T materbis and the milling opefition. Dust emissions are veW to bag fitters for abatement,

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:04

Mise s m i d m and abatement measures

The operation of the Raw Mill and the fans on the bag filters may mult in noise emissions. The design of the buildings is chosen tn ensure attenuation of noise frwn withln the buildings and all fans

are M with s l l em.

Whation and abatement measurn

Vibrations may m a r as a malt of the operabkn of the Raw Mill. The design of the Mill bultdings has

taken this into aooount and suibble monstrucbion techniques have been employed to ens& that the impacts at nearby receptws are just at or kymd the level of human peroeptlon.

There are no water didarges generated as a mult of this p m . The d i n g water used in the pmess Is recl~ulakd and tx) water dtxharge occurs ES a mult of the p m .

3.24.4 Waste

There k no wask genwabed as a result of thls p-. Any dust coliecM In the embkns -1 spkm and offspc product is fed back in to the mw mill for E--. Some wasbe oils and luhimting

and degmslng flulds a- with maintenance and operation of the plant, m a c h l q and

transport vehicle may be generated.

3.2.4.5 Matfundon I

In the event of pornrer b, acbMties in this area would -temporarily until power k estored fmm the auxitiary d i d generzttnr or from the plant mains eledmity supply. There are no s p c i f ~ ~

maihnctlons whkh muld lead to unplanned release to the environment amdated wlth thts

operation. If the Bag filters were shut down for maintenam or due to pawer Iws, the prooess wwld also be stopped.

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:04

3.2.5 Raw Meat Kilning

3.2.5.1 Deswlptlon

A schematic repentation of this most important proceSs,ig stage in the cement manufaduring

process is presented in Figure 4 in Appendk I of this Attachment. The installabion msists of three

major sections, the preheakr, the kiln and the clinker cooler - the latter operation k dlscwsed in the

following s&tan. A variety of qulpment sem this unit at start-up, shut down and during normal

optation.

Raw material is drawn from the raw meal feed silos through dlsdlarge h o w tu a welghlmg Mn and Is i M U c e d &e b the top of the mlumn in the kiln preheater. As it is guided down through the

cydones in the syskrn, it pi& up the heat ofthe gases from the klln. Milled coal or oll is added to the hot meal and the temperature rlses, drMng off carbon dioxide in the caldning process. At the bottom of the pve-heakr the hot material is intraduoed inb the kiln where its kmperature is

gradually brought up to 142OOC utilizing flame temperatures of up tn 2000%. As the kiln rotats the

material Inside krmbk fdlowlng a spiral path on the inside of the kiln shell, finally readMg the outlet where it drops into the cmler. H m the intermediate product, dlnkev, Is abruptly 0ooM bo 6oooc and

then down to IWC at a s h r pace. The heat of the material is -red heating the air needed

for mbustbn.

3.2.5.2 ProeeoscOntrd

Raw meal fed to the kiln is weighed and dosed predsely to maintain constant conditions. It Is equally

Important that the chemid and physid qualltk of the raw mal are wnsbnt and accurate (this

having been assured in the preceding step, i.e. preblerpding, dwlng, grinding and hamagenislng.

Assuring constant conditions makes mombustion control of the kiln and the mldner much k t k r and Is Imwrtant for both energy savings and cleaner mmbustin gases. CombwtSon gasw frun the kiln

are m n M . There is a gas anal- for O2 and CO m@nt at the klln o m which i n d i m the qualityofofmbustloninthe kiln.Attheexitofthe~aldnwthe4andCOcontentofthegasesis

also measured. G a s enkring the kiln ESP are also sampled and CO is measured. Gas d u m thmugh the whde kiln systm are mtrolkd and kept at the minimum requlred level far energy

efficiency. Maintaining d u m low helps redm emissions. Thwe measurements are mded by

the Central Control system and the values are used b control mbusbion and to pmtect the Installation. If safety limlts are exceeded alarm are triggered and the ESP high voltage is amtrolled

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:04

or even shut down. In the event of an ESP trip, all fuel and raw material supply to the Mn are shut

off ammatically.

3.2.5.3 Emlaslons

Air emissions and ababment rneaam

The maln emlsskns wsoclakd with thls process am mbwtkm gases and pawlabe mather.

Emissions bo atmosphere are \Fented via cyclones into an ektmstatic predpbtor (ESP). Bag filters

ate used to control emissions ftrrm other sourn. A new Selective, non catatytk r e d m n (SNCR)

s@mn is em- to redue the missions of oxldw ob ni-ogen (NOx). The detailed disusbn of emissions from this process is p m t e d In Attachment MO E.

7

Noise emissions result from the operation of the kiln and the assadated plant Fans used throughout

the prooess In abatement @ant a b result In nolse missions. The details am d k u d In AtW~ment

No E and F.

Vlbmtion and abatement measures

Thwe are vibrations assuciated with the operation of the kiln. This is d i m & in greater detail in

Attachment No E and F.

The only water LLsed in the p m s is that used for aoollng when the mw mill is not opwating, There Is no wakr dixharged as a result of the p m since this wakr Is e u a p 0 M or redmlated.

3.2.5.4 Wasb

Used refmbv linings from the kiln and cyclones In the pre-hwkr are generated. T h e are disposed of by approved means. This ls further dixussed in Attachment H. Any dust mlleded In the emisskns mntml system is fed back in to the raw meal s i h for reuse, Some waste oils and lubricating and deg-ng fluids a- with maintenance and opwation of the plant, mxhinwy

and trarcsport vehkles may be generated.

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:04

3.2.5.5 Malfuncblon

The only signifbnt matfundion which could result In an unplanned relese to the environment is rnalfuunction of the ESP or delibetate shutdown of the ESP if CO safety threshdd mmntrations are

scoeeded. The CO k monitored aontinuousty and, in the event of safety threshdds klng exceded,

the system wlll be shut dawn and the plant will also be shut down. The cyclones will wntinue to operate and will be in minimising dust emlssions if this malfunction occurs. The emphask Is p h d ~n pre~entkn d m-lnduced ESP trlp~m.

3.2.6 Clinker -ling and handllng

3.2.6.1 P m M p t i o n

A schematic representation of the unit operations involved In thls p m k prwented in Figure 5.

From the end of the kiln, clinker drops out into the dinker cooler. This is a ~ 0 5 s flow heat exchanger:

ambient air is blown thmgh a moving grate and through the dinker to mot it at a f o d hlgh rate

from 1350°C down to 600°C and then on to lower temperatures at a slower pace. All the material

oollecbed Is clinker and is fed back into the pmess.

The dlnker is mushed by a roller-break to r e m large lumps and k transported wfth speebl heat

resistant conveyors to dlnker silos for storage, From the dinker sib, dinker is fed to Ute mmnt mill for grindlng b ament as and when required.

F B h air Intake mntrol from dedicated ml ing fans is the only unlque procesS Control step in the dink codlng stage of the process - the overall process control relating to the producUon of clinker

is the prmes mnml for thls stage.

3.2.6.3 Emissions

Air emlsolorro and abatement measures

Alr from the dinker g m k is fed badc to the kiln to asslst In combustion and dwng, Air emissions from

the d i n k d e r stage and stwage silos am vent& to a bag filter.

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:04

Noise emissions and abatement measurn

Noise emlsslons will be associated with the opratlon of the afr handling unlts whkh will be flUd with

silencers and housed, and also with the operation dthe dink ausher.

Yibration and abatement mea==

There Is no water used in this opemtion and hence no w a t e water will be genemted.

3.2.6.4 Waste

There Is no p- waste gene* during this operation. Partkulak emtslons from the clinker

d e r and dinker sibs bag filters are all fed badr in to tte m. Qinker produced during start-ups

is stored in a separate silo for reintrodudon in to an early sbge of the pmes for reprmsing,

Some waste oils and lubricating and degreasing fiulds assodated wlth mintmane and operation of

the plant, machinery and transport vehides may be generated.

3.2.6.5 Malfmdhn

In the event of pwer loss, ac#ltks in this a m would cease temporarily until poww is restored from

the auxlliary diesel generator or fm the phnt mains ekMcity supply. There are IW s @ k malfunctions which could lead to unplanned release to the envlmnment associated with thls

operabfon, If the Elag Alters were shut down for maintenance or due l~ power loss, the p m ~ ~ would

also be stqqxd.

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:04

3.2.7 Clinker grinding

3.2.7.1 ProoessD€3Krlption

A m a t i c repmentatlon of the unit operations lnvolved in this p m s s is presented in Figure 5 of Appendm I of this Attachment. Cement is produced by grinding the lntermedlate product, dinker, with

gypsum In the m& proporbions. Cem I1 dinker content can range from 80-9446, wlth limestone

comprising 6-2046. Cem I dlnker contents range ham 95% - 100%, with limestone comprising up to 5%. In additin both Cem I and Cem I1 also contain approximately 4% gypsum, which is added at

the dinker grlnding stage to control the settlng characteristics of the final oernent

Cement grlndlng is done In a ball mill, a metal tube lined with special cast steel liner p l a b designed

to help lift the grinding media (&el balk) in the mill as It Is turned. The mill is Internally divided inb

hrvo chambers with a dlaphmgm separablng the unequally sized mnpartments. The first mpartment

pfegrinds the ma= material while the -nd cornpamnt Rnlsh grlnds cement. To I m p m

efflclency, air Wing through the mill oools the material being ground and movw materbl faster

through the systm. Wlth the help of an air separator the fine ground materhi is removed as finlshed

product w h k cuam material is returned to the mill at the feed end, m a l continues cirmbting in

a dosed d m l t untll it m i c k the required f i n e m .

3.2.7.2 Plwresscontrol

The feed into the cement mill is controlled by belt weighers. Addithres, proportioned by weight, are

added depending on the composition of the feed and the grade of cement being manufactured.

3.2.7.3 EM im i o n s

Alr emisslons and ababment measurn

Dust emissions are generated In varbus operations. AH emWm are vented to bag fib, and the

dust oollecbed is fed b& in to the pmess as indlcakd in Figure 5.

Ndde emissions and ababment measurn

Noise is a signlfimnt emlssion assodated with the operation of the cement mill, which is the mist

significant noise souroe assodated with the manufacturing operatiofis. The d&gn of the building has

been specially seleckd to minlmlse the Impact of this rmlse source on nearby nohe sensitive.

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:04

ieceptots. Nolse emlsslons are also assoclatecl wfth the air handling u n b assodakd with the unit

operations and with the bag fitters.

V i M n and abatement measures

Vibration is associated with the operatkn of the m n t mill and the gypsum cnrsher.

W- and absbement nmnsutw

U

3.2.7.4 Wask

There are no prooess wasts associated with this operation, Any dusts collected in the abatement

plant are returned tm the proaws. Some waste oils and lubricating and &greasing fluids associated

with malnknam and operation of the plant, machinery and transport vehicle may be genmted.

3.2.7.5 Mahnction

I n the event of power loss, activities in this area would cease temporarily unM power is restored frwn

the auxiliary diesel generator or from the plant mains electricity supply, TheE are no specMC

malfunctions whlch could lead to unplanned release to the environment associated with this

operation. I f the Bag Filters were shut down for malnhance or due bo power loss, the p w mld

also be stopped.

3.2.8 Storage and handling of oement

3.2.8.1 Prooess Description

A schematic represenkith of the unit opwations Involved In tfiese processw is presented In Figuw 5

of Appendix I of this Atta&ment. From the cement silos, cement is drawn ~urnatka l ty and

conveyed by air slides in to bucket e h b r s far bagging and palkt loadlng In the Wng plant or for

direct loadlng In ID mntainer In&. The packlng machine fills kigs of 25kg bags at a rate of up to 2400 bags/hour, t h e are mnveyed to a palletlslng machine. Pallets are either loaded i m m e d i OT

sbodred.

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:04

3.2.8.2 P m Contml

The process is controlled by weighing.

3.2.8.3 Emidono

AUr emlsslons and abatement measurn

Dust emissions genefated durlng the qmatbns assodated wfth thts praeess are vented to bag filters, -red and reused.

N o b emiodons and a m e n t measums

Ndse k associatd wRh the -ration of the air handling untts and the fans on the bag filters.

Wbratlon and abatement measures

There are no signifimnt vlbtation sources associated with this procws.

Watar and abatement measurn

Watm is not used in or generated in this m.

3.2.8.4 Wask

Thm are no process wastes assodated with this operation. Any dusts collected in the abarwnenr

plant are returned to the process. Some waste oils and lubricating and degreasing fluids assodated with maintenance and operation of the plant, machinery and transport vehides may be generated.

3.2.8.5 Malfunction

In the event of pawer loss, a c t i v i i in this area would mase tempwarily until power is restored from the auxiliary diesel generator or from the plant mains electricity supply. There are no q&fk

malfunctbns which could lead to unplanned release to the environment ass&ated with this

operation. If the Bag Filters were shut down for maintenance or due to power loss, the prooess MUM

also be *ped.

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:04

3.2.9 Coal prepration

3.2.9.1 P m m s a i p t k n

Coal for the cement kiln is stwed in one of two mal sibs. The cwl is conveyed as needed to a feed

bin, which In turn feeds the coal to the coal mill. Coal needs to be gmund to a fine -er to fadlitate combustbn in the kiln. The high temperatures required in a cement kiln and the way heat needs to be transferred to the material in pmess in the kiln requlm a flame with a high

kmperature, and this can onty be achiwed with coal dust blown in through a burner pip. The flame

reaches temperatures of about 2,OOOOC. The coal mill operation is similar to the raw meai mil, only

s i g n k n t l y smaller in capaclty and specially designed to grind ml safely.

Powdered coal is stored in two swially design& silos, of a limited size for safety. The c d is

weighed before king fed pneumathlly to the kiln burner.

In the kiln, mal is burned only when temperaturw are hlgh enough for safe mbusbion. To start-up

the installation fuel ail or natural gas is used to preheat the areas where mal mbustion takes place.

Thls is a matter of safety. For this purpwe special arrangements are made for the fuel supply.

The heat my~lred to dry the axil while being ground Is derived fram &t g a s from the W m r .

These ~ a s e s are low in oxygen content and are used for saw masons. Nevedkless CO is mewured

at the mill outlet and the bag filter outlet. The coal instalbtion is also equipped with a number of thermometers. w r e m e n t the gas anamrs are in the central contrd *m atxi the signals ate used to trigger alarms and safety devioes in the relevant p ~ l c e ~ s areas. If safety limits am 'm alarms are triggmd and the instalhtlon a n be flooded with C O 2 to avert Rre-

0

The silo storing puhrerlsed mal in addition to its special oonstrudion k equipped with thennometers

and a CO analyser. If limits are m, alarms ate trjssered and C O 2 flooding of the m i l takes

p b b render the installati safe

3.2.9.3 Ernisions

Air emissions and abahment rnwisuwu

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:04

and entrains the coal, Thwe gases a n y small quantities of dust e~caping frun the preheater, which

Is mixed into the coal and returned to the kiln thmugh the burners. Expbsbn relW venb are fitted in

the Mill and Coal Store which, if acthmted, will result in emissions of mal dust.

Wsa emldons and abatement measures

Noise will be ’ with the operatton of the eoal mlll and the air handling systems.

Vibration and abatement inemsums

Vibration will be associated with the ooal mill operation.

Water and abatement measwms

Wakr is not wed in or generated in the proaess,

3.2.9.4 Waste

There Is no pmess waste gemrated in this process. All d u e adkckid in the abatement pbnt am used in the process. Some waste oils and lubricating and degreasing fluids assmhted with

maintenance and operation of the plant, machinery and transporl rrehlclw may be generated.

3.2.9.5 Malibnetion

I n the event of an exploslon In the coal mill or In the coal store, explwton did vents would be adhated and a release of mal dust muld occur. The contmls in operation are sensitive so that at first

warnlng of a potentially dangerous situation, the carbon dloxlde extlnguishlng system w l d be

operated thus eliminating the risk of ff re and assodated explosions.

In the event of loss, acbMties In thls area muld c e a ~ temporarily until power is m b e d fmn

the adllary diesel generator w from the plant malns elearicity supply. There are no speclfk matfuunctions which could lead tn unplanned release to the environment associated with this

operation. If the k g F i b w m shut dawn for maintenance or due b pwer loss, the process would

also be stopped.

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:04

3.2.10 Use 0fAlternadw Raw Matarials

3.2. IO. 1 Prucess Bscription

Lagan Cement Ltd has permission t~ use renewable raw materials in the cement manufacturing

production pmcess. The atkernathe raw materials include m y d d m m s , fitter oke f m the

drinking water treatment industry, recycld glass, and recjckd ash.

The recycled gypsums will be used ID replace the imporbed gypsurn that ts currentiy klng used In the cement manuhctun'ng m. It is planned to eventually replace up to 100% of the cumnt gypsum

requlments depending on OOntfnuouS supply of hlgh quality mcyded ar synthetk gypsum. Lagan

m n t Lnd add 3.0-5.096 gypsum to the oemenf to make the Rnal m t product Cem I and Cem

11.

The gypsum material will be stored In a wvered shed at the raw M a l intake area, far the final

mnent milling sbge of the p-, actjamnt to the other Intake maberials and will be handled

exactly the same as the c u m used gypsum material. All gypsum material will meeP the specf& qwtii mnb-01 guidelines and will have full and proper traddng doarmntatkn m p a n y l n g

it. Thii will allow for verification of the source, quantity and quality of the materkit acclepted omk at

Lagan Cement. All tmking documentation will be maintained on SHE for future audlting and

vemt lon.

The alum f i b cake rnateiial Is a waste product genemtd from the sludge produced by drinking

water Merit mnk and has been w&Iy used for land-sptwdlng in the agricultural m r . Thls material is mm-hazardous and the high alumina levds present make this m t d a l a vwy effective

repkemnt for some of the alumina m material requiremen& In oement paoductbn. This rnakrial

will be LLsed to replace up tn 5W of the shale a d bauxite currently used in the manukturing

-.

Alum f l k r ake materlal will only be accepted from water treatment plants w h it has been f i b

pressed. All bansport of the rnakrial wt-site will be via a transport shovel. The alum filter wke material will be stored in a covlered shed at the raw material intake a m , m n t to the other inbke mterlals Including shale and day, and will be fed inb the se#mdary ausher at the required dose mte, A stockpile of 200 - 400 brines would be maintained for this p u m . The material will then be

delivered to the blending shed a h with the other makerials and be p r m s e c l In the raw mill.

. . . f .', .. , . . i. , . , . , . .y . . ~. . . .

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:04

lagan Cement LM a h has permission to use ash 85 a raw m M a l at theJr facility. It is pmpwed

that thls ash wlll be s w d from coal and p a t fired power statlow, the timber prooessing industrj

and other large-scale producers of ash.

Ash is an adlent mw material for the cement industry as it a n be a very good soure of cakium,

sillca and aluminium, which are required for the manufacture of cement. The ash used on site will

displace non-renewable raw makriak such as overburden and limestone in the producblon of m e n t .

It can also k added as an additional constituent at the cement milling stage of the process.

All ash m M a l delivered to the s k will be dassified as non-hamdous and wlll be stared in a

covered shed at the raw material intake am, adjaoent tn the other intake materials including shale

and day, and will be fed into the d a w crusher at the requlred dose E&. The material wlll then

be delivered the blending shed abng with the other materials and be p m in the raw mill.

The recycled glass mabrial is non-hazardous wlth a hlgh slllca mntent and has similar chemical

composition b that of sand or clay. It o n therefore k used as a tepkement for part ofthe sand requlmmts In mmnt manufacture.

The materla1 wlIl be eas4ly managed and will be transporbed from its wlnt of &rage in the cwwed raw material intake area In its introducbion inb the p m e s using a h q r t stwel. All transport of the material on-site will be via a transport shovel.

3.2.10.2 Prooess Conlml

Each delivery of alternative raw material from ail suppliers is visually examlned far the p e n c e of

any montamimtbn. Delivery bads are regularly sampled and analysed to verlfy that the &t

parameters are within the specified quality oontrol ranges.

Alternative raw materials are only be m p t e d at the installatbn from known suppliers, which have

been approved by the Agency, or new suppliers subject to initiil profiling, and analysis off- and

apprrwal by the Agency. The w m records of this off* waste profiting and characterkathn shal

be retained by Lagan Cement Ud for all active suppliers and for a *year period following

termlnation of licenzee/supplier agreemenb.

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:04

Wask materials for remwy as ahnative taw materials are at Lagan Cement only from

suppliers who are holders of a waste collection permit, unless exempted under the Was&

Management (Collection Permit) Regulations.

3.210.3 Emissions

Sulphur dioxide emissions origlnak from the sulphur in the fuels used in the combustSon p m . The sulphur content of the alternative raw materials Is veery signifmm lower than that d the exWng

on= used and therefore sulphur dloxlde emissions will be the Same as or lower than the existing

S i t w t i o n .

Nitrogen oxidw are present In the emission stream as a result of the mbustion and

nitrogen dioxide h l s will not i n c m due to the use of akrnabhre raw materials. An SNCR system

k emploved to redurn m

Partkubte matkr and PMlo

levels will not i m s e as a result of the use of attematk raw materials.

se In the emkbn sbmm rcwn me combustkn process but again

There are no odours a- with the activi since the atkmabve rawmakrhlspropowdare

completely odourbs. There are IW other missions of any consequence as a resut ofthe use ofthe renewable aknabve * raw material souroes.

3.2.10.4

There will be no wasbe generated as a result of using the akrnative raw materlafs. The alternative

raw materials are fully utllked In the flnal p d u d and result in a reduetion of onsite qwmng

activities and an i n m a s in the M i of the oement manufacturing p m .

0

3.2.10.5 Malfunction

There are no specific rnahncths that wuld lead to unplanned release to the environment

a- wfh this operation.

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:04

3.2.11

3.2.11.1

Lagan Cement

Exlsting Atemath Fuels

Prouss Deseription

i d has permission to use Solid R-mered Fuel (SRF); ask shredded tyre chippings;

Meat and Bone Meal (MBM); recycled wood; agricultural products and residues; dried bio-dudge from

the water tre&ment industry; biomass fuels such as biodiesel and b(oethanol and Liquid Recovered

Fuels as alternative fuels to produce heat energy for the operation of the mment manufacturing

process.

SRF is d w i primarily from non-recyclable househdd and cunmerdal waste, a stgnfhnt

proportion of which Is mprised of Momass. SRF has a dorffk value, whkh is approximately two- thirds that of ml and has excellent fuel properties. . SRF for use at the Lagan Cement fadlity is prepared otWe by a third party waste aontrador and then dellvered to the site as a prepared fuel,

The SRF manufxturlng process imrohres a state of the art xreenlng and segregation p m e s used b

remove undwirable materials sudr as myclable plastics, i M M a l s and metals and the rewltlng

material is finely a d d e d , to a mfetti consistewy for use In the cement kiln. TDF has a Slighdy higher cabdfic value than that of mal and agaln Is an excellent ahnative to coal as a fwl in

cement rnanutixture. TDF for use at the lagan cement fadlky is prepared offsite by a thlrd paw wask oon-r and then dellvered b the sk as a prepared cfilpped tyre fuel.

Planning permlsslon was granted to bum Meat and Bone M a l (MBM) at the m e n t plant b help

Lagan Cement reduce b dependence on imported fossil fuels and improve its sustainability in tmms

d dudng CO1 emlsslons. MBM Is dwsified as a arbon-neutral renewable energy source

Lagan Cement LM have permission to ure waste wood materlal as an altemtive fuel sou= at their

fadlity. The wask wood material is generated f m wood chlps, recyded wood indudlng construction

and demolition (C & D) timber, sawdust and residues derived fnrm the sawmill and forestry industry.

Thii material is rron-hazardous and has a high calorific value, Is c a M n neutral and is an Ideal fuel

s u m In the manufacture of cement. The waste wood material is stored in an existing coved

shed and shredded on site. Sh- material Is transported from its point of stofage bo its

lntroductson into the p m e s uslng cwered conveying systems. All transport of shredded wood

material o n e is via a covered mnveying w.

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:04

Lagan cement Ltd hw pemlssbn In use biomass matertal dew fmn the agrkubral Seaor as a

fuel at their facility. Thwe Mamass fuels will indude energy mops, meals and grains that would otherwFse requln disposal as a waste material due to damage inarmd.

This material is non-hazardous and has a high calorif~ value and Is an Ideal fuel substiMe in the manufacture of aement. The agricultural biofuels are transpod b the site In a cowed, sealed

oontainer and are stored in an exIstlng sib ar oovered shed and are trans- from its point of starage b Its Introduction into the process using a m r e d conveying system.

Lagan Cement Ltd also has permission to use dried non hazardous biological sludge that Is d e w frcnn the treiatment of waskwater as a fuel. This matdal when dry Is an mllent ~plwenmt for Wt fuels in the m e n t kiln. The material Is ddhrered to site with a moisture mntent of k than

109b and is sb-ed in existlng cwered sheds ar sibs and is blended with ooal for wmkrstion In the

kiln. This material is tramporbed to the site in a mered ba lk . Dried sludge is transported within the

hcliity vla coved conveying systmns.

Lagan M e n t Ltd also has permission to use biomass fuels such as biodiesel and bloethanol, and

their derlWws at their fsdlity. T k e carbon nwtral b W s are derived from waste vegetable oll

and will only be aoDeptwd at the instalbtion from known suppliers, whkh have been a- by the Agency. All blofuels amepted on &e meet speclfic qualii mtml guidelines and haw a set of

mplete tracking dacumentatlon m p a n y i n g it.

Lagan Cement LM has added M U M Recowed Fuel (LRF) and additfonal akmatfw fuels to their list

of fuels for use at their facility in line with ib strategy to reduce its emissions of greenhouse gas

emkions and improve ib wetall sustalnability in line with the EPA's National Wask Hazardous

Management Plan.

Lagan Cement use up to a maximum of 95,OOO brines per annum of any cambinatfon of the full list

of non-fossll, altematii fuels, but with LRF usage being limited to 20,000 tonnes per annum. LRF Is a

blend of hgh okrlfk value liquid waste and Is ciassMed as a hazardous waste, by vlrtue of its high

calorific value, which makes it a fire risk. It Is the flammable nature of the material whkh makes it

attracthe as a mal replacement in the oement kiln. m a n Cement Ltd bums LRF in the peheater and m n t kiln. Through its sustainable fuels programme, lagan Cement has already d m a

sfgnllhnt porbion of the coal once required to heat its proaess. See atbdment H for a full llst of European Waste Oitabgue codes.

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

3.2.11.2 Existing Pmass Contd

Existing Alkmative fuels will only be accepted at the Instaltatlon from known suppliers, which have been approved by the Agency, and any new suppllers will be subject to I n k 1 profiling and analysis

offsite and approval by the Agency. The written records of thls M-site wask profiling and

c h a r m s a t b n shall be retained by Lagan Cement Ltd for all active suppliers and for a two-year

p l o d following ternination of liaense4supplier agreements.

Wasbe materlals for energy reoovery wlll be acmpted at Lagan Cement only from suppliers who are

holders of a waste collection permis. unless exempted under the Waste Management ( W e d o n

Permk) Regulations, sub- to the approval ofthe Agency,

Each delkry of alternative fuels from all suppllers is visually exarnlned for the presence of any

wntarninabion. Delivery loads are regularly sampled and analyd to venfy that the test parameters

am within the spedfled quality oontrol ranges. Frequency of sampling and analysls is determined

based on the consis&ncy of the mults obtained and the satlsfadon of the aeptance criteria.

I m i n g material whkh is outside the agreed tolerance specified to the supplier, is Issued a 'Non-

Conformance certifiate' as Is denned in the WsUng QLwtity Management System at m a n Cement

for any m-mfomfng incoming materials, and is mmed to the supplier if deemed unsuitable

materlal.

1

A specialist environmental m n t r a m @My prepares a liquid reoovered fuel Ideally SUM to tagan

Cement's specific requirements at an M facility and transports the fuel to the Lagan site in

Kinnegad. A number of these spedallst contractors m'st and all currently receive and p m s s high

calorific liquid wasks from a variety of sources a m Ireland. These are blended liqukls to manufacture a varlety of different grades of fuels suitable for use in cement kilns. Normally all

opetabrs who blend hazardous wastes into m n t klln fuels opefate under IS09001 and IS014001 aocredttatlon, Blendlng hazardous liqulds to produce LRF k a precise prooess, carefully mtmlled by

m e n d on-site managers. Sampling, analysis and compatfbility tests are married out by qualified

chemists In the Environmental Labatory. Every step of the blending p d u m is str idy mntmlled

and documented with the relwant legal paperwork and health, safety and quallty cedfmtbn. Prior

to dispatch each consignment is analysed In a fully equipped environmental laboratory. The supplier

ensures that &re Is complete and amrate analysis of the load prior to dehninlng aaptance into the blending facility and subsequently ib suitablllty for the Cement Kiln.

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

t

Upon approval for dispatch the LRF is tranqmted in roBd tankers to Mnnegad. At the Lagan &e, the

road tankers are unloaded inb dedimkd tank for use as a kiln fuel replxemnt The solvent Is stored under a nitrogen gas bbnket as a fire prevention method. The tanks are built to the highest

international standards. Bunding and mnstructh Is fully compliant with all EPA requirements.

There is no p m n g of LRF on the Lagan site and =age k mpt b the mlnimum requfred to sewice daily use. LRF is stored in a dedicated buildlng with ODVwed loading and unloading. The LRF is

broadly slmllar to gas-oll in terms of its flammability. In m m n wlth all flammable IlquMs the LRF

wit1 come under Lagan Mews fire safety wt i fmte and approptiate fire prerention measures wlll

be t a b . The new imtallatbn m p l l s wfth the requirements of the A T M directSve.

The Waste lndnerabion Dlrectk l m m stringent requiments on plants proposing b -incinerate

was& m e a l as part of its production proaess. These requirements indude types of waste, del-

and -on of wastes, combustion furnaces, abatement ptant, residue handling, monitoring

equipment and emlsston limit values. There is no residue a m wtth the burning of LRF in the

kiln as it is inmprabed within the final product. The residem time for rnahrial in the kiln at the cement ptant is 20 minutes and all materlaf Is contained in the Burner Zone of the kiln with a

minimum tempatum of 1,400oC. The Waste Incineration Dlrecbive requlm that pfants shall be

equipped to operate in such a way that the gas resulting from the procws wlll b raised to a

temperatw of 850OC for a rnlnimum of 2 seconds. M is a gas analyser for 0 2 and C O 2 antent at the kiln inlet whieh shows the quality of combustion in the kiln. These gases are also measured at the

outlet of the preheater. Gas volumes are controlled through the whole kiln syskm and a- kept at the minimum required level of energy M i g . Maintaining low gas volumes will result in r e d u d

emissions. These measurements are recorded along wlth the values used to control the mbustion

and p r o k t the installation against the risk of a gas explwlon. If safety l imb are exoeeded for any of the essential parameters, alarms are triggered and the relevant p m is controlled or in m cases shut off.

Slmllarly, the mill outlet and the bag filter outlet a- with the ml grinding is continuously

monitored and has strict p r o m s mntrds in place. These measurements are used to warn operators

of abnormal condkions whlch mld lead to an explwion. Measurements of the gas a n a m and the temperatures are recorded and this data is used to trigger alarms and safety devm. Once the

alarms are bigged, the insbllation is flooded with C O 2 to prevent a fire or expksion. Similar

mntrols and safety measures are in plaoe for the slb whkh &res pulverised -1. Fuel will be fed . - 3

. .. . . . - . . .

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

3.2.11.4 Waste

There will be no waste generated as a resut of using the akernatlve fuels. The alternative fuels will

be fully utiiised In the production p w and will not result in the genetation of any waste.

3.2.11.5 Mahndon

There are no specMc malfunctions that auld h d to unplanned release to the environment

d a t e d with this operation.

into the syskm via an automated supply mechanism. The fuel supply system can be remotely shut

of! Ifthere are any problems with production or l f f p r a t u r e is belwv the level.

3.2.11.3 Emissions

Sulphur dioxlde emisions originate from the sulphur In the fuels used in the ambustion m. The sulphur content of the existing alternathre fuels is very signifimndy lower than that of the previously

U& fuels, mal, and therefore sulphur dioxide missions am lowered through the use of a b n a t i w fuels.

Nitrogen oxides are present in the emlssion stream as a result of the combustion process and

nitrogen dioxide levels are not expected to increase due to the use of alternative fuels.

Particulak matter and PMlo may arise in the emission stream from the combustion process but again

levels will not increase as a result of the use of alternative fuels.

llwe are no odours assodated wlth the Hi since the akernatk fuels are aompletdy odourless.

The use of LFlF has resulted in no change in emissions from the fadlity as a mutt of the proposed

use of ahnative fuels. fhere are no odours a m wlth the actMty sine the a h t i v e fuek

proposed are compleldy odourless. There are no other emissions of any consequence and there has

been 1w3 change in the &sting emission profile for the facility as a mft of the use of these renewable alternative fuel swrres.

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

<: . I ., .

Lagan Cement Ltd. has a quality W n g la various stages of the cement manufacturing p~~cess and the final product.

itrycnemsaremr xed on the

lagan Cement tM operates a Quality Management System In a d a m wRh IS EN I S 0 9001:2MH1.

All Lagan cement k manufadud in acoordance with the Eu-n Standard EN 197-1:2001 and

thereby quality assured by third paw Independent testing. In sdditlon Lagan Cement bears ttw II mark,

U Alternative raw materials and fuel suppliers wllf be sub- to pmflling and regular auditing.

Mabrlals and fuels will k Ins- and where ne~ssary sampled. Materials that do not meet the

required spdl id jon will be and returned to the supplier,

Lagan Cement has contmcted an external m p a n y to prwlde Uquld Fuel (LRF) as an

akmatlve fuel sou= to bum in their Cement Kiln. The &HMI waste limn& faclllty oprab a

state of tk art Wwts and cement fuel p-lng plant. In 2007,58,000 tonnes was handled at the fadlity. fhe approved conttador spdaffy prepam a fuel ideally SUM to Lagan

W s s-c requiremenb. Blending hamdous tiqulds tn produae IN is a predse p m s ,

~ ~ u l l y controlled by experknd o n e m a m a . Sampling, analysis and mptlbl l i ty tests are carried aut by quallfkl chemists in the Environmental Latmratory. Evwy step of the blending

@ure is strictly controlled and documented with the relevant legaf papwork and Veolia

health, safety and quality certification.

hior to dispatch each m i g n m n t is a n a m In a fully equipped emrimmental bboratory which

ensures that there Is mplete and m m t e analysis of the load prior to determining aaceptanoe

inb the blending fadlw and subsequently itr sultabllity for the Cement Kiln. All anabis Is in

mpllance with the USEPA standards.

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

.' :7 =: +'

4.0 Qua i v i t b

4.1 PmjectDescription

IPPC k e r n W 7 - 0 6 granted on 12' March 2012 has included for the extension of the dsblng

quarry O\F~T lands to the north, east and south. The proposed &m&n to the exlstlng llrnestone

quarry will be to a depth of 1 bench at appro>dmately 70 metrw AOD. Thts extension will increase

the surfa& area of the quaw by approximately 52.45 -res over 3 No. phases, The proposed

derelopment wlll mult in a final overall extracted area of 77.25 twctam and extend the llfe of the

quarty by up to 20 years. The proposed quarry extension will not result in any in- to the p e r m W production opacity ofthe cement plant.

The propwed atemion of the qwrw ww a single bench will safeguard the strategic limestone

e w e available ID Lagan Cement Ltd. The propwed quarry extendon wlll also help Lagan Cement

Ltd to producre m n t more elTidentiy, based on the fdk lng:

1) It makes betber eoonomlc and operational sense to quarry the limesbone from a wider footprint, before starting to quarry at greater depths. For example, a ansequence of golng tu deeper benches is that m a n Cement Ltd m l d have ID IncreiaE the size of thelr vehicle fleet, at aonsidemble cost, bo mpensatR for the longer journeys between the wwking quarry W and the

crusher. This would also result in hlgher a emlsskns.

2) Working a quarry over a single bench for a longer period simplifks quarry management and will reduae the number of times that the existing mushing plant and oonvqing equipment will have in be moved. Moving installed crushing and mnveying plant is W n s i v e and tlm mmuming, and the relocation of this plant a n take ~ r a l months.

The workings of the proposed quarry area will be conblnued as follows:

Blasb'ng of rock faces,

Transport to crusher,

Stockplllng, and

Conveying to the oement plant. j

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

Each of these steps Is summarised below.

1. B l a $ t l n c l o f m k ~

To provide li-ne feed to the oement mill, the a- mek face must be Mas&!, at regular

intzwals, uu'ng an ammonium nitmte fuel oll mix. Uslng spedalIst blasting oontraebors, hole are drllled in the mk facie and the Masting mix is added.

2. T r a m to c r w k

O n e blasting has occurred, brge rack chunk are transpotted, using wry brge (60 ton=) moblle

equipment, to a crusher, whieh is bated on the quarry fbr.

3. Them are two crushlng stages, prlmary crushing and seoondary crushing. Each ausher ~ S L S I ; S or a

set of electrically o m rotatlng drums, which function In redm the particle slze of the m k to a

-le that m n tx easily transpted using belt mwyors.

4, -lnq

An essential part of quarry m a t i o n is the stockprllng of wshed makdal. These act as in the event of a crLLsher or mobile equipment failure.

5. A long beft-conveyor Is attached to the out feed pint of the crushlng quipment. Thii wnwyw barn the crushed m k In the oement mill far further p m l n g .

4.1.2 Proposed Operational Plan

The operational plan for the application site has been upgraded in light of this proposed development,

Each of the three phases af the papposed operation are summarised below,

InitJalIy, Jirnmne will be &mcW in a northedy direction to the maxlmum permitted tateral extent

of the qww. This bench will be worked to a depth of approximately 70 metres A 0 0 and therefwe r e m & a continuation of the first producblon bench currently being wrked at the quarry. The producboon b e w k will be at least 30 metres wlde and will have sub-vertical W. All production

will t>e subject to ongoing geo-mhnlcal monMng on a regular basis in keeping with the

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

k * Cement

highest Industry standards, best i n d u m pracblae, and current health and safety regulations and

guidelines (am, f&s& and wel)care at W& (9rwmies) R ~ y u & m , m ( S . 1 , No, 28 of 2008)).

Onae the production benches have k e n extended to their permitted limits, tw new haul

ds/ramps WIN k coonstru- to a maximum width of 20 metres with sumdent space for a

protecbhre bader and drainage, wlth a down-ramp slope of 1 in 12 to the 70 metres A 0 0 level along

the W r n side of the quarry. These mmps will act as the main a m mutes to both the northern

and southern parts of the quarry void.

e On reachlng their maximum p e r m W extmctbn limits, production bendws wlll hwe final bench

widths of 7.5 metms, final maximum bench heights of 15 metres and final bench slopes of about -70'

fmrn the horizontal, depending on the geo-technical quallty of the rodc. This will ensm the long-

term stability, lnkgdty and safetv of the final quarry design.

Overburden will be strlpped In a controlled and phased manner ahead of the quarry f e with bttms

of 1 In 2 belng propwed. Makriak from the strlpplng will be used in the mnstnrctkn of additional

screening bem along the northern slde of the site (with batters of 1 In 2.5 being proposed).

Berms are a mmn tml used in the qwrrylng prooess. These landforms am constmckd of 'overbuden' ma&ial recwered from atme the rwk suitable for extraction. This wrburden mnslsts

of topsoils and subsoils which are valuable for final -ration purposw. The material Is therefore

caarebulty malntatned and managed In bem or bunds which are usually M at the boundark of

quarry sk, The berms (bunds) W r m a number of tasks k k k that of maintalnlng soil fertility, in

that they a d as vlsuai, aural and environmental bawlers for netghbourimg land u s e .

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

Figure 1.2 Phase 1 of Prqmmd Quarry Extension (North%m Exbnslm)

I

Source: SM Bennet & CO LM (kcmber 2008)

Towards the completton of Phase 1, overburden wlll be dripped in a contdled and phased manner In

a south-eastedy and swth-westerly direction and will be used In the oonstrucbn of m n i n g berms

amnd the &+&ern and south- boundaries of the site. Topsoil and overburden used In the construction of the xmning berms will be used In the final redmation of the quarry vojd and the ske as a whole.

Um-ne wlll be ex tmkd in a swth-w&erIy and south-eastedy direebfon towards the maximum

peomitkd Metal extent of the quarry down to a depth of about c . 7 h AOD and will be a mnUnuatbn

of the production bench curmtly being worked at the quarry.

The production benches will be at teast 30 metre wide and wlll have sub-wrtical faces. pductian knches will be s u m to ongoing geo-technid monbring on a regular bads.

:$$ +,A

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

Production benches will have final bench widths of 7,5m, final mamum bench heights ob 15m and

final bemh of about -mO from the horizontal, depending on the geo- tdwbl quality of the rock. This will ensum long term stabili, Integrity and safety of the final faoes.

It is proposed to extract Ilm-ne from around the asphalt plant m p l e x during thts phase of the development.

Flgum 1.3: Pham 2 of Proposed Q u a y Ex#ension (South-EaSmWn and SOuth-Webtern

Ext0nsiona)

<----

Source: SM Bennet & CO Ltd (December 2008)

As Phase 2C of the proposed development nears completion, R is propQsed to decommission and

remolre the asphalt plant (Phase 3A). Once the plant is removed, the area around It will be exhcted

to the 70 metres AOD W (Phase 38).

fawards the mnpleblon of Phase 2 and the removal of the asphalt plant complex, overburden will be

stripped in a contrdled and phased manner in a wuthetiy dimtiin and will lx used In the

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

c o n m o n of smeenlng berms around the xruthwn boundads of the site. The timing and

xhedullng of the topsoil and owburden stripping will be dependent on the prevailing economlc

conditions at the tlme. For the purpww of this applldon, the stripping of -1 and ovwburden

has been dMdd into 6 subphases (XI to x6). Topiall and werburden used In the consbuctlon of the screening berms will be used In the final restaration of the qwm vold and the site as a whole.

The ppoductlon badws will be at least 30 tn&m wide and will have subdl fa-. All

production be- will be subject to ongoing geo-technical monitoring on a regular basis.

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

As already outlined, production benches will have flnal k r u h wldths of 7.5 metres, final maxlmum

bench heights of 15 mtm and final bench slopes of about -70' from the horizontal, defmding on

the geo-bxhnkal quality of the rodL This will ensure bng-term stability, inkgrlty and safety of the final quarry deslgn.

The phasing of the extradon allows for multiple faces to be opened-up and worked at any given

time, thereby enabling the blending of materiak from the quarry, essential to the mntlnued effldent opemtlon of the cement plant.

Early and ongoing mbmtion and plantlng of final benches wkh stwkplkd makrbls, induding

previously strlpped and &red ave&urden and t o p d will occur as areas of the quav become

wrked wt.

The dmakcl m m levels within the area of the propwed quarry extendon suggest that the

subject site will take between 15 and 20 years to exavate olrer a single bench level. G i n this

pmjected life span for the development and the unknown emnomk mondltlom its lifettme, the creation of more than 3 prlmary operational phases would be arbitraw and would m p l h t ~ and

compromise the operational e#kiency of the site.

4.1.3 Overburden Disposal

Overburden will be removed to permanent landscaped Imtions whlch will act as new screening

berms for the southern and eastern ar~as of the proposed quany extension. The overburden to be

removed includes a signifimnt proportion of free draining materials. The mounds will be constructed

with long-term stability being a key consideration. Detailed stability and construction reports will be

prepared prior to bund construcbion to ensure that the structures are secure.

soff clays, silts and mty materiats wlll be bunded ins& containing aell walls and where appropriate,

drainage blankets will be plaoed following the ~moval to top and sub-soils from the a m s where

bunds are to be built. Top and sub-sails will be separabely stored to assM In mvegetatlon of

m p l e t d screening banks and bunds. Since silt may be suspended in surface water r u n 4 from

the large xreening bunds, silt traps will be employed M o w d i d r g e into &sting wabmurses until surfam pbnt growth has been established.

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

4.1.4 Quarry Operations

It Is proposed that the quarry &ension will be ow- along the same lines as the exIsblng

permitted quarry operation. In thls regard, the worklng of the quamy extension will take p k e

between 07:OO and 1900 burs on Monday to Saturday. kept In emergency, and then on advioe to the Planning A u t h t y , wrklng will not take pboe on Sundays and Bank Holidays. Pumping may take p l a continuously and xrme maintenance will m x r at mkends.

The reef lknestone wlll require g m n d preparation by drilling and blasting. Initblly, the quarry

ion will be worked using mnventkmal hard-mk equipment including hydraulk loading shovels

- 70 h n e dump trucks.

Blast cksgn will be based on careful monbrlng of the initbl blasts using bw charge weights of

explosive per delay. Based on the exprience of the exkUng operational quarw, Mast vibratrons a n be kept below 12mm per SeQOnd at a disbnce of 300m wing a maximum charge delay of 1OOkg. A

maximum charge per deby of 5Okg would maintain the same vibrabion llmit at a distance of 140m

from the point of blasting.

4.1.5 Quarry Safety & Security

llm are a number of safety and security measum in p l e for the exisb'ng quarrying opesatfons on

the subjed site. ln this regard, fences are M and regularty maintained around the primeter of the site inside exisblng hedgerows, thereby dlxouraging i n a d e n t a m s s to the qwrrles and the

water mtention structures.

The screening berms being msbucted as part or me pmpbsed quarry extmsion wfll be s u m to *prate investigatian and reporting before construdbn. There is suffldent granular material tn ensute adequate drainage in the slructures, with weaker, &er AIS being conbind in Internal cells.

4.1.6 Quarry Restoration

The restoration of the proposed quarry extension will be undertaken in accordance with that of the existing permkW quarry. I n accordance with the restoratJon pmposal for the exIsllng limestone

quarry, a Restoratlon Plan has been prepared by David Jawis & A s s d i and Is submitted as part of the Planning Application Oocumentation (Attachment K).

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

All hardstandings and plant will be moved at the end of the quarrying’activities. Smening banks

will be used to mder the wakrslde bank safe in the ewnt of accidental e n b inb water.

4.1.7 Emissions

There will be 110 signifbrit change in emissions fnrm the site as a resut of the p r o m quarry

edension a m . During the phased appmch to the quarrying extraction there wlll be perlods of time

when operations a= in closer proximity to ceertain nearby receptors than others. This will increase

the tmtential for dust deposition nuisanm at certain propwties. However, Lagan Cement Ltd. wlll

maintaln a*sting site practias aimed at reduclng windblown dust impacts and therefore, the

potential for dust impct will be sgnifmntly reduced. There are no other emlssbn scrum of any

consequene and there will therefore be no change in the misting emission profile for the s b .

The main sources of dust from the quarrying operation are assocbkd with the raw material

&&ion, transprt of raw material to the crusher and the crusher itself. The crushing and material conveying operations are encksed, and local wtmction w r n s vent to Rag Filters which mntml dust

emissions from these mums. Imported materials are stored under wver further minimising dust emissions.

The raw

emissions at the si& and the following m m n g measures aiz orried out: extrxtbn and stockpiling operations are the most slgnifbnt sources of dust

Efkdhe d d g n and management of the Masts to prerent fly m k and s ignbnt particulate

emissions

Fixed and mMle water sprays are used tn mntrol dust emissions f m Internal haul roads, material st&piles and storage ard pbnt yard surfaces.

Loose loads of maberials entering the site are cowed and a dedicated wheel wash is l m k d

at the entrance In the shale quarry.

A full vehlde wash spray and wheel wash is sited near the m n t works entrance.

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

Noise Emlsslons and abatement measurn

Noise from the Raw Materials preparation stage of the pmess Is a&& wlth the m a t l o n ,

recovery, transportation and mushing of raw material. Noise from the quarry workings is minimised

by ensuring that all plant and equfpment meets stringent spedfications for noise emksbns.

Amustic m n i n g bun& are provided

and plant operations resulting in a barrier attenuation of at least 15 dB(A).

the nearest noise sens i t i i mceptor and the quarry

he most signmflcant ptential impact a- with the quarrjlng operabl~n is the noise and vibration impacts with W n g for the purpose of wxuvery of raw materials. Hasting

is not generally required for ground preparation In the shale quarry alttrough one or two Wash per

year may be required to m m Reef LIm&one; m e ripping of shaley timstone at depth may also

be required. The blask in the limestone are IlWy to quarry a u r once mry 1 - 2 week on

average. By areful design of the blasts folkwing trial blasts to establish the local s b charadwish,

it is possible b ensum that the vibration a m with the blast do not ex& the limb impwed at nmrby sensitive -IS.

Waterand abatement meammi

The proposed quarry exmatbns will extend to a maximum depth of about 70m AOD. While

pumping of in-flowing groundwater is requlred to fadlltate existing quarrying operatbns of both the

misting shak and ~imstone quarries it is not predicted that there will be any further slgnlfimnt

changes in the hydrogeology. Ongdng analysls usfng pumping kds ad water level o w n s will

be mndu&d to ellsure that any effea of furthw quarrying remains minimal.

Run-off from the roads near the quarries will continue to be dralned In to the q u a m . Surface water

run* from the undisturkd lartddscaped screening banks will also drained through the neaarest

quarry. Wakr run off and ground water pumped out does not contain harmful substan=. H-

since some sol1 and Rne matter may be in suspension Settlement ~ o o n s will allow thls b be settled

before dfxharge to the Kinnegad River,

The drainage arrangements for the site ensure that no uncontrolled dlxharge of drainage f m the

site can oocur at any time. Water pumped frwn the quarries is directed tn the settlement L a g m

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

where a residerim time of 28 hours ensurw adequate settling aapadty. Most of the pumped wakr Is groundwater whkh Is free from any contamination.

4.1.8 Was&!

No process waste is generated at thls stage of the prooess. Some waste oils and lubiiating and degreasing fluMs associated with maintenance and operation of the plant, machinery and transport

vehkles may be generated.

4.1.9 Malfunction

There am no specific malfunctions whkh could result in wcldental or unplanned emissions ar discharges, In the unlikely event of a power failure, the Bag Fikers rrahd awe to fundlon

temporarlly but so would the uushing m&lnes, so the emissions potential Is e l l m i d . Detans of oontrol measures far prevmtlng unplanned discharges to the Klnnegad River are outlined In

Attachment F.

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

5.0 Rep0

Lagan Cement Ltd have not k e n convicfed M p w under the Emironmentat P-on Ad,

1992 or the Protdon of the Environment Act, 2003. lagan Cement Ltd have not been mnvi&d or

p w under the Waste Management Act 1996, or the b l Go\rernment (Warn Pollubion) Acts 1977 and 1990. Lagan Cement LM has had rw) other prosmtions brought against them.

The b a n Cement LM. Annual Envimmental Reprt for 2011 is induded in Appendk D.2.

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

Process Flow Schematics

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

L LaganCement

%-

!Figure l a Prcass Flaw Schematic

* I t U

I I

I

I I I

a m a6 KILN

LRF TANKS

7-

PM = P M T I U U l E RAlTER

Q = GWHWSEMWONS

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

a d

b

0

0

0

0

0

0

0

0

0

0

rn

a a

0

I

4 4 0

rn

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

Process Flow Schematsc: Raw Material Anabis and Blending'

PM t

I RAW MIX

FEED Bpss

MATERIAL RDW

GAS- ............... +

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

I .

Figure 3 Prooess Flow schematic: Raw MIX Mllling & Mixing

a m RAW MIX FEED BIN

I

.............

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

Procws Ftm Schna&: Raw Meal Kiln & Cllnker cooling & Handling

PM

RAW ME& SILOS

Fl ..............+*..-..... ---+

I PM t

..... -. .....U ............. -...-. + I j ..+... -*.. * ...... F

.......... .-* ~ .........

,*...*..4

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

Figure 5 Prooess Flow schemabic: Qinker grinding, *rage & handling of oement

I

PM PP

t H t

BAG CoNvflOR RLTER

BAG FiLTER A345 m-07

- .......I

I

t i

I ........ .. .... "-

BUCKET ELEVATORS I

-..... ...- .........

..... ....--

............ - GASFLOW w

I I

WG

A3-10 puHT FILTER B.nK

LOAOING ............................................

I DIslRmmoN I

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

Appendix D.11

Lagan Cement Lffl. Annual Environmental Report 2011

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

r -11s that am highlighted blue coni

guidance docu ment llnk ' . - cells that contain underlined text c

xj table headings followed by a symb

I

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

main a dropdown menu click to select one option from the list

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

U

c

:

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

i

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

I- !

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

r

e

1 1 1 1 1

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

r JJ

1 8

e

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

'c f ,...

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

1

,. . ,. ,

C

!

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

1 -

4 - 1

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

ptl . lY

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

E

I

e

I

I

r

I

I I e

I f

p1 m u m

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

r :

e

0

f 1

,

I

! I

, .

! :

i

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

r 'a

AER Returns Workbook

." , . . . -2 ldM

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

ZPRfRnAmvnlkeTlVmeb Activity Number AcUvlty Name 3k)II) Cement clinker in rotary kilns

Installations for the disposal of non hazardour waste

I

I I

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

' Y

Y

U

U

Y

Y

Y

Y

Y

U

Y

U

Y

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

I I .

I

Y

Y

U

U

Y

v U

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

a

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

U

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

M

On

P I

oa

W

W

W Od

Do

M

U

04

um

an

an an

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

ntitics In th15 scctdon ir

I

I I ntilies In thi

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

Y

m a

MPII m Y

YIP m

M Q m

I

I

Y

e

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05

'.--

Y

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 25-03-2017:02:10:05