KMK Operational Report · 2018-05-03 · KMK Metals Recycling Ltd, Moate Road, Kilbeggan, Co....

KMK Metals Recycling Ltd, Moate Road, Kilbeggan, Co. Westmeath

IE Licence Application No. LA001418

Q.E.D.Engineering Ltd, Unit 5, M-TEK Building 1, Armagh Road, Monaghan

Tel: 047 72060

4.8 Operational Report

Introduction

The main activities of KMK Kilbeggan operations are the sustainable treatment of metallic and

WEEE waste for the purpose of efficient recovery and reuse of valuable secondary raw

materials.

Specific metallic waste accepted from industry and other off-site waste treatment facilities

will be recycled and recovered in appropriate production processes incorporating all

necessary and statutory environmental controls.

WEEE will be treated in accordance to European Union (Waste Electrical and Electronic

Equipment) Regulations 2014, Statutory Instruments S.I. No. 149 of 2014. Treatment

Standards and recovery targets will be as per S.I. 149 Part 3, Section 22 ii (b) and Schedule 10.

Preparation of WEEE for re-use will be in accordance with Schedule 11.

The KMK site in Tullamore has ISO 14001:2004 Environmental Management System, ISO

9001:2008 Quality Management System and OHSAS 18001:2007 Health and Safety

Management Standard. The treatment of WEEE at KMK Tullamore is also WEEELABEX (“WEEE

label of excellence”) approved; a European standard adopted under CENELEC with respect to

the collection, sorting, storage, transportation, preparation for re-use, treatment, processing

and disposal of all kinds of WEEE, that provides a harmonised set of rules and procedures for

conformity verification. KMK Kilbeggan will operate to standards equal to that at KMK

Tullamore to ensure that processes are managed based on best practice industry standards.

All standards on the Tullamore site will apply to the Kilbeggan site operations also, to ensure

that the process is managed to the highest standards. Recycling certificates are issued upon

completion of the collection order and treatment process. KMK has 100% traceability of all

materials received.

The hours of waste acceptance and operation of the facility for this application will be 06:00

to 22:00 Monday to Friday inclusive and 06:00 to 14:00 on Saturdays, with no operational

works on Sundays or Bank Holidays. Production will operate over two shifts; 6am-2pm & 2pm-

10pm, with office based staff working 08:00 to 17:00 primarily.

Process Operations

The KMK Kilbeggan site is to consist of two large existing buildings and a proposed covered

yard area. A number of dedicated treatment processes will take place in buildings A and B

with storage of WEEE proposed for Yard C at the locations shown in Figure 1.

The main elements of the KMK Kilbeggan facility will comprise of the following:

• Flat Panel Display (FPD) Unit Treatment

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• Fines Treatment

• Large Household Appliances (LHA) Treatment

• Storage of Fridges, Freezers and WEEE Fractions

• Preparation for Re-use activity

Each activity is described in the following sections, with process flow diagrams.

Figure 1. KMK Kilbeggan Processes Layout Map

A1

C3

C2

C1

B3

B2

B1

A3

A2

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Flat Panel Display (FPD) Unit Treatment

The treatment of FPD units will be carried out in accordance with the technical requirements

and specifications of the CENELEC EN/TS 50625 standards on the treatment of WEEE

containing flat panel displays. Part III of the S.I. No. 149/2014 - European Union (Waste

Electrical and Electronic Equipment) Regulations, 2014 on the management of waste

electrical and electronic equipment will be adhered to at all times.

FPD units (comprising of televisions and monitors) will be delivered to area A3 where they

will first undergo a manual dismantling activity. This entails putting the FPD unit onto a

dismantling table, removing any external plugs and cables and the plastic stand. The plastic

stand is sent to KMK Tullamore for recycling. LED units and FPD monitors will be appropriately

packaged, weighed and labelled in accordance with all relevant transport regulations and

loaded for outward transport to an authorised treatment facility by an approved haulier.

LCD TV units are placed onto the infeed conveyer of the Votechnik Trumaster-ALR machine.

This is a new technology for WEEE recycling in Ireland. The machine is a fully automated, high

through-put technology that can process sixty LCD TV units per hour. All processing is carried

out at one central location at a rate of one LCD TV unit every sixty seconds. An extraction and

carbon filtration system is proposed to extract air from within the machine via proposed stack

A-3, which will be positioned at the back of the site. All fractions resulting from the process

will be sent to Yard C for suitable storage prior to transport. A schematic of the Votechnik

machine is shown in Figure 2.

Figure 2. FPD Processing Machine

All waste streams arising from the FPD process sent for recycling include:

• LCD panel and diffusers sheets

• CCFL tubes

• LCD carcass

• Circuit boards

• Transformers

• Speakers

• Plastic

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• Cable

• Steel (light iron) and

• Plastic/metal mixes from the shredding process of the carcasses will be directed to

area B3 for Fines Treatment

The process flow diagram for the FPD process is shown.

Figure 3. Flow Diagram for Flat Panel Display Process

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Fines Treatment

A fines treatment process is proposed to be located in area B3, which will comprise of feed

hoppers, air table and a screen. This screen will accept waste fractions and separate them

into smaller, uniform fractions, suitable for recycling on the air table. The air table uses a

technology that will separate heavy (concentrated metal) and light (concentrated plastic)

materials. The output materials generated from the process will be metals, plastics, sand/grit

and filter dust. Extracted air from this process will be directed to a dust extractor located

externally at the back of the site, with emission point A-1.

Large Household Appliances (LHA) Treatment

Large Household Appliances will be delivered to area B1 and manually dismantled to remove

the plug, cable, plastic, pump, motor and transformer, capacitors, plastic / wood top panels

and rubber hosing, which are sent for storage to Yard C.

After removal of these fractions, the LHA carcass is to be sent to the VRS Shredder and sorting

cabin, which manually and mechanically sorts the shredded material into separate fractions

of carcass, mineral waste (concrete, sand and glass mix), glass, steel (light iron), motor, cable

and electronic components. These final fractions will be directed by conveyors to dedicated

storage bays in Yard C.

The site proposes to install a second shredding system in area B3 suitable for shredding the

steel fraction from the above process. This will create an end-of-waste steel output. It can

also be used for shredding other large WEEE assemblies, creating a size reduction and value-

added metal extraction. It reduces high-volume input materials and items with a large unit

weight. This unit will be linked to a dust extraction system proposed to be located at the north

facing back wall of the site, which will have emission point A-2.

A flow diagram for the LHA process is shown.

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Figure 4. Flow Diagram for Large Household Appliance Process

Storage of Fridges, Freezers and WEEE Fractions

The storage of fridges, freezers and WEEE fractions will be carried out in accordance with

Schedule 8 of the S.I. No. 149/2014 - European Union (Waste Electrical and Electronic

Equipment) Regulations, 2014 and the technical requirements of the CENELEC EN/TS 50625

standards on the collection, logistics and treatment of WEEE.

These requirements include, but are not limited to:

− Weatherproof covering;

− Provision of spillage collection facilities;

− Impermeable surfaces;

− Appropriate storage containers;

− H&S considerations (i.e. safe stacking);

− Weighscales for weight measurement and recording.

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As fridges and freezers require the application of advanced processes for effective treatment

(i.e. refrigerant gas containment/extraction and specialist technology), the proposed

processing of these appliances within the proposed KMK Kilbeggan facility will be limited to

their intake at Yard C, inspection, decontamination (if necessary) and sending off-site to a

dedicated and fully authorised treatment facility. Fridges and freezers will be appropriately



WEEE fractions resulting from all other processes on-site will also be transferred to Yard C.

These may be subject to further processing throughout the LHA shredding activity for the

purposes of resource recovery and added value. WEEE fractions will be appropriately



Figure 5. Flow Diagram for Fridges & Freezers

Preparation for Re-use

“Preparation for re-use” means checking, cleaning or repairing recovery operations, by which

products or components of products that have become waste are prepared so that they can

be re-used without any other pre-processing.

Preparation for re-use will be carried out in accordance with the technical requirements of

the current PAS 141:2011 Re-use standard. KMK Kilbeggan also intend to prepare IT and FPD

units for re-use in accordance with the requirements of the CENELEC EN 50614 standard on

re-use once published by the European Standardisation Organisations.

For this activity, it is proposed that IT equipment and FPD units will be delivered initially to

area A3. They will then undergo a selection criterion to determine if they are suitable for the

preparation for re-use activity. If they are not suitable, flat screens (televisions and monitors)

will remain in area A3 and go through the FPD unit processing operation. IT equipment will

be transferred to KMK Tullamore for recycling.

If the selection criterion deems that the IT equipment and FPD units are suitable for the

preparation for re-use activity, they will be sent to Workshop 2 in area A2 for testing.

− If they pass all tests, they are deemed as products ready for sale.

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− If they fail tests, spare parts will be harvested from other IT equipment / FPD units to

repair the units and if they pass this time around, they are deemed as products ready

for sale.

− If they fail all tests, they will be transferred to area A3 for appropriate recycling.

In compliance with data protection regulations, a secure data security workshop (Workshop

1) has been created to meet forthcoming management security standards.

Figure 6. Flow Diagram for Preparation for Re-use

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Abatement Systems

There will be three direct emission (stacks) to air from this activity.

1. A-1 from an already installed dust extractor serving the fines treatment process in

building B, located at the north facing back wall of the site.

2. A-2 from a proposed dust extractor serving a proposed shredding system in building

B, to be located at the north facing back wall of the site.

3. A-3 is from a proposed emission point from the Votechnik machine, which is located

in the Flat Panel Display (FPD) area in building A. The machine is being installed internally and

the emission point will discharge to atmosphere at the at the north facing back wall of the

site.

A map of air emission points is provided in Figure 7.

Figure 7. Process buildings with Air Emission points

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Emission points A-1 and A-2

Dust and particles generated in building B from the fines treatment process and from the

proposed shredding system will be vented via enclosed ducts to dust extractors at the back

of the site. Two dust extractors will be located at the north facing back wall of the site with

emission points A-1 and A-2.

A dust extractor has bag filters internally, in which air from the processes in building B pass

through and the dust is collected on the bags. Clean air is then vented to atmosphere.

Periodically, a short intense pulse of air blasts into the soiled filter element. Dust and loose

dirt from the filter fall to a dust collection hopper. Following the short cleaning cycle the filter

is ready and the filter system can again operate at full capacity. The hopper is emptied on a

daily basis, stored in bags and waste is sent for a waste to energy recovery facility.

Dust extractors are fitted with differential pressure meters, which indicate if a fault occurs in

the system e.g. a torn or inadequately fitted bag, which would result in elevated dust

emissions to atmosphere. The dust extractor will be maintained by site personnel and once

all bags are in place, the system is successful at preventing dust emissions to atmosphere.

A dust extractor is operational in KMK Tullamore and similar units will be operational in KMK

Kilbeggan. Monitoring of the discharge from the dust extractor in Tullamore is carried out

quarterly for particulates and metals, as required under IED licence. Results of quarterly

monitoring for the Tullamore site are minimal from the unit and well under the limit value set

in IED licence W0113-04 for particulates is 10mg/m3. Metal results are also low and not

problematic. Therefore the dust extractors to be used at KMK Kilbeggan will be sufficient at

prevention dust emissions to atmosphere.

Emission Point A-3

Emission point A-3 is from a Flat Panel Display (FPD) processing machine called a Votechnik,

which is a new technology for WEEE recycling in Ireland. It is an automated machine which

separates the LCD panel and diffuser sheets and the CCFL tubes (which contain mercury) from

LCD TV units. Mercury is associated solely with the fluorescent tube recycling of LCD

televisions and monitors. The Votechnik is an enclosed machine and it is extracted to

atmosphere via a stack A-3, to be located at the back of the site. Internally in the machine,

the extraction system has one particle filter to remove dust and 24 carbon filters to remove

potential mercury vapours from the CCFL tube removal process.

Dust emissions will not be problematic from the FPD processing machine. The machine

processes LCT TV monitors which are not dusty by their nature. The automatic dissection of

the monitors within the unit may generate a limited amount of fragments, but there is a

particle filter and 24 carbon filters that air passes through before discharge to atmosphere,

so dust emissions will not be significant from the unit.

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Drainage

There is no process water generated on the site.

Yard and roof drains drain to an attenuation tank at the northwest corner of the site (233.7m3

capacity). Overflow from this tank drains along the back of the site to a silt trap and

interceptor at the north eastern corner, before discharge off-site to the adjoining premises,

which discharges to a field drain and eventually to the River Brosna.

At the proposed new site entrance there will be a drainage channel which will connect to two

soakaways located in the proposed grassed areas adjacent to the proposed entrance.

The site is on the Kilbeggan public town Mains and foul wastewater is discharged to the

Kilbeggan public sewer network.

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KMK Operational Report · 2018-05-03 · KMK Metals Recycling Ltd, Moate Road, Kilbeggan, Co....

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