annual environmental report for period january 2008 ... · annual environmental report for period ....

Annual Environmental Report 2008 Cavanagh Foundry Ltd ______________________________________________________________________

Annual Environmental Report For Period

January 2008 – December 2008

Cavanagh Foundry Ltd

Licence Register No. P0479-02

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Annual Environmental Report 2008 Cavanagh Foundry Ltd ____________________________________________________________________________ Table of Contents

Section Contents Page__

1. Introduction 3

2. Report Structure 5

3. Summary Information 12

4. Management of the Activity 26

5. Licence Specific Reports 30

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Annual Environmental Report 2008 Cavanagh Foundry Ltd ____________________________________________________________________________

Section 1

Introduction

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Annual Environmental Report 2008 Cavanagh Foundry Ltd ____________________________________________________________________________ Section 1 – Introduction This Annual Environmental Report (AER) for Cavanagh Foundry Ltd relates to the environmental performance and achievements of the company in the period 1st January 2008 to 31st December 2008. The report has been compiled in accordance with condition 2.8.2 of Integrated Pollution Control licence number P0479-01 and EPA guidance notes for AER’s. P0479-02 was issued by the EPA on the 6th November 2008. Given that the business operated the vast majority of 2008 under P0479-01 this AER is compiled in accordance with conditions of same. Future AER’s shall be compiled and submitted in accordance with conditions specified in P0479-02. ______________ Brian Kelly Manufacturing Systems Manager 27th March 2009

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Annual Environmental Report 2008 Cavanagh Foundry Ltd _________________________________________________________________________________________________________

Section 2

Report Structure

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Annual Environmental Report 2008 Cavanagh Foundry Ltd ____________________________________________________________________________ Section 2 – Report Structure Section Contents Page_ Section 1 Introduction 3 Section 2 Report Structure 5 2.1 Licence Number 2.2 Name and location of site 2.3 Description of activities on site 2.4 Company Environmental Policy 2.5 Company Organisation Chart for Environmental Management Section 3 Summary Information 12 3.1 Monitoring Data

3.1.1 Emissions to waters 3.1.2 Emissions to atmosphere 3.1.3 Waste management

3.2 Agency Monitoring and Enforcement 3.3 Energy and Water Consumption

3.3.1 Energy consumption 3.3.2 Water consumption

3.4 Environmental Incidents and Complaints 3.5 AER Summary Data Table

Section 4 Management of the Activity 26 4.1 Introduction 4.2 Schedule of Environmental Objectives and Targets 4.3 Environmental Management Programme Report 4.4 Environmental Management Programme Section 5 Licence Specific Reports 30 5.1 Noise Monitoring Report 5.2 Groundwater Monitoring Report 5.3 Environmental Management Plan

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Annual Environmental Report 2008 Cavanagh Foundry Ltd Section 2 – Report Structure 2.1 Licence Number - I.P.C Licence Registration Number P0479-02. 2.2 Name and Location of Site - Cavanagh Foundry Ltd, Birr, Co. Offaly. 2.3 Description of the activities on site:

The product is basically made of 2 no main component parts: - Ductile Iron Cover. - Fabricated Frame. (for alternatives)

Details of the manufacturing process are outlined below.

Raw Materials The furnace charge (raw material) at Cavanagh Foundry Ltd is characterised by the use of virgin or clean metals along with foundry returns. Ductile iron is manufactured from pig iron, scrap steel and foundry returns. Various ferro alloys such as silicon, magnesium and copper are added to treat the iron. Foundry returns are a mixture of the runners from castings and off spec products which are recycled. All foundry returns are self generated at the foundry. Scrap steel is made up principally of baled trimmings from new uncoated car panels and off-cuts from engineering shops. One tonne of molten iron is made of approximately 57% steel scrap, 21% pig iron, 16% returns and 6% ferro alloys. Ferro alloys are used to treat the iron and the addition rate is determined by analysis of each batch during production.

Melting of Raw Materials The current melting equipment consists of two 2-tonne capacity electric induction furnaces. The metal is heated to a temperature of approximately 1500°C. It is then poured from the furnace to a ladle which is used to transport the iron within the foundry. A series of metallurgical tests is carried out on the molten metal prior to pouring of the molten metal.

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Annual Environmental Report 2008 Cavanagh Foundry Ltd _____________________________________________________________________

Electric melting furnaces represent the cleanest melting technology used in the foundry industry. The other main melting system used by foundries in Cupola melting which is associated with significantly greater environmental emissions.

Pouring A ladle is used to transfer molten metal from the furnace to the casting line. This ladle is moved by gantry crane and the molten metal is discharged into the mould. Magnesium is added directly to the ladle just before molten iron is poured from the furnace. The magnesium is a catalyst for a structural change in the molten metal from flake graphite to Sphereoidal graphite/ductile iron. Casting The molten metal is poured from the ladle into moulds which are made from sand, bentonite clay, coal dust and water. This moulding sand is termed “greensand”. The metal is poured from the ladle into the moulds which are moving on a casting trolley. The casting trolleys move the moulds from the mould preparation machine through the casting area where they are cast and back to a knockout area. During the transfer of the moulds from the casting area to the knockout area, the molten metal cools and a product is formed.

Knock-out The mould containing the casting is transferred to a knockout machine where the sand mould and product casting are pushed from the moulding flash. The used sand is collected on a rubber belt conveyor after falling through the knockout machine and conveyed back to the sand preparation plant for re-use. The now empty moulding flask is returned to the mould preparation area where it is again prepared for a further casting. The casting is moved to the finishing / assembly area where it is finished and assembled.

Painting All castings manufactured are coated with black bitumen primer.

Sand preparation and mould making Coal dust and clay are currently delivered to site in bags and stored in the courtyard. Sand is delivered in bulk.

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Annual Environmental Report 2008 Cavanagh Foundry Ltd _________________________________________________________________________

All the above materials are blended in a mixing mill which takes a proportion of each material from storage hoppers and mixes the material with greensand returned from the knock-out machine. Water is added to the mill and the blended material is conveyed by conveyor to the moulding machine where it is used to fill the moulding flasks in preparation for casting. The blend of moulding material is carefully monitored by carrying out a series of control tests in the laboratory.

Moulding

The mould flask, after the knock-out machine is moved into a moulding flask station prior to the mould preparation machine. Here the moulding flask is split into two parts. Each half is returned to the mould preparation machine where it is placed over an aluminium tooling pattern. Blended moulding sand is dropped into the moulding flask covering the tooling plate where it is compressed using air onto the pattern. Each moulding flask takes an impression of the tool and is then rotated where it can be inspected for quality. Cores may be added at this time. After exiting the mould preparation area the first half of the moulding flask is turned over and placed on top of the second flask. The completed mould is then placed in line onto the casting trolley at the start of the casting line where it awaits delivery of molten metal from the furnace.

FRAME MANUFACTURE Raw Materials The raw material consists of 46 X 46 x 3mm angle (min) iron to BS1449 and is attained from various suppliers. Certificates of conformity are requested from suppliers for the material.

Fabrication All frames are fabricated in jigs. The angle iron section is placed into the jig where it is clamped prior to welding.

Galvanising All fabricated frames are dispatched for galvanising where they are galvanised in accordance with the customer specification. Certificates of conformity to the galvanise specification are provided by the galvaniser.

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Annual Environmental Report 2008 Cavanagh Foundry Ltd ________________________________________________________________________________ 2.4 Company Environmental Policy

Environmental Policy

Cavanagh Foundry Ltd is committed to conducting all its activities such that they have a minimal effect on the environment.

All levels of management are committed to implementing and maintaining an environmental management system in compliance with BS EN ISO 14001:2004.

The company’s key objectives are :- (i) To commitment to compliance with the spirit as well as the letter of environmental legislation and approved codes of practice. The company will co-operate fully and maintain open relationships with all regulatory authorities. (ii) To develop procedures for the continuous assessment of the environmental impacts of our products and processes thus demonstrating our commitment to continual improvement and prevention of pollution. (iii) To develop procedures to set and review objective targets for the reduction of the company’s significant environmental effects. (iv) To pro-actively seek waste reduction and recycling measure. (v) To seek continual improvement in the efficient use of energy and natural resources. (vi) To train and educate all employees in the skills and understanding necessary to minimise any risk to the environment from the company’s activities. (vii) To make available to our employees and the public this policy and information

concerning the environmental performance of the company as detailed in EMP/23.

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Annual Environmental Report 2008 Cavanagh Foundry Ltd ________________________________________________________________________________ 2.5 Company Organisation Chart for Environmental Management

Sales RepresentitiveSales Co-Ordinator

Transport Staff

SalesManager

SalesDepartment

Debtor ClerkReceptionist

Secretary

AdministrationDirector

AdministrationDepartment

Environmental ManagementCo-Ordinator

Product DesignEngineer

TechnicalDepartment

Production PersonnelMaintenance Personnel

ProductionDirector

ProductionDepartment

Managing Director

Cavanagh Foundry defines and documents the responsibility authority and interrelationships of all key personnel who manage, perform and verify work affecting the environment. Key personnel are informed of their responsibilities in order to facilitate an effective environmental management system. The Environmental Management Co-Ordinator (Manufacturing Systems Manager) reports to the Managing Director with whom overall responsibility for environmental issues rest.

________________________________________________________________________________

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Annual Environmental Report 2008 Cavanagh Foundry Ltd

Section 3

Summary Information

_______________________________________________________________________________

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Annual Environmental Report 2008 Cavanagh Foundry Ltd Section 3 – Summary Information 3.1.1 Surface Water Emissions Summary Table 1: Summary Table for Surface Water Emissions at SW1 and SW6: Emission Reference Number SW1 Emission Reference Number SW6 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 TOC mg/l 5.23 10.40 5.23 6.84 2.48 2.60 4.18 3.12 Total Copper mg/l 0.006 0.001 0.003 0.027 0.009 0.009 0.006 0.007 Total Iron mg/l 0.923 2.112 0.338 0.741 0.874 0.158 0.042 0.010 3.1.2 Emissions to Atmosphere Table 2 : Summary Table for Emissions to Atmosphere (Mass Emissions (kg) & Average Emissions (mg/m3):

EMISSION POINT PARAMETER

MASS EMISSIONS

LICENCED MASS

MASS EMISSIONS

MASS EMISSIONS

MASS EMISSIONS

MASS EMISSIONS

MASS EMISSIONS

REFERENCE 2008 (kg) EMISSIONS

2008 (kg) 2007 (kg) 2006 (kg) 2005 (kg) 2004 (kg) 2003 (kg)

A2-1 FURNACE EXTRACTOR

Total Particulates 902.02 2529.03 960.93 982.76 550.00 455.74 1179.08

A2-2 DRY BAG FILTER

Total Particulates 72.55 2072.93 67.20 495.70

770.54 180.81 517.45

A2-3 SURFACE COATING VENT

TA Luft Organics Class

II 4266.36 16283.81 4808.58 5596.11 10230.83 6333.43 2409.36 EMISSION

POINT PARAMETER AVERAGE

EMISSIONS LICENCED EMISSIONS EMISSIONS EMISSIONS EMISSIONS EMISSIONS

REFERENCE 2008(mg/m3) EMISSIONS 2008(mg/m3) 2007(mg/m3) 2006(mg/m3) 2005(mg/m3) 2004(mg/m3) 2003(mg/m3)

A2-1 FURNACE EXTRACTOR

Total Particulates 10.70 30 9.81 10.15 5.25 6.84 12.90

A2-2 DRY BAG FILTER

Total Particulates 0.73 20 0.75 4.97 10.18 3.95 6.03

A2-3 SURFACE COATING VENT

TA Luft Organics Class

II 39.32 150 40.12 40.50 72.5 45.25 41.25

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QUARTERLY FURNACE STACK AIR EMMISION RESULTS (A2-1)

0

5

10

15

20

25

30

35

Monitoring Period

EMIS

SIO

NS

mg/

Nm

3

Emission ResultEmission Limit

Emission Result 13 13 9 10 20 20 0.7 11 3.6 6.6 12 5.3 4 15 0 2 9 13 7.9 11 8 10 14 7.4 6.6 11 8.9 16Emission Limit 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30

Q1 '02

Q2 '02

Q3 '02

Q4 '02

Q1 '03

Q2 '03

Q3 '03

Q4 '03

Q1 '04

Q2 '04

Q3 '04

Q4 '04

Q1 '05

Q2 '05

Q3 '05

Q4 '05

Q1 '06

Q2 '06

Q3 '06

Q4 '06

Q1 '07

Q2 '07

Q3 '07

Q4 '07

Q1 '08

Q2 '08

Q3 '08

Q4 '08


QUARTERLYSAND PLANT PARTICULATE AIR EMISSION RESULTS (A2-2)

0

5

10

15

20

25

30

35

40

Monitoring Period

Emis

sion

s m

g/N

m3

Emission Result 4.9 1.5 1 1.1 11 8.2 2.4 2.1 3.3 2.5 4.6 5.4 5.5 14 11 11 8 0.4 0.5 1.1 0.7 0.6 0.6 0.3 0.5 1.4 0.7

Emission Limit 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20

Q1 '02

Q2 '02

Q3 '02

Q4 '02

Q1 '03

Q2 '03

Q3 '03

Q4 '03

Q1 '04

Q2 '04

Q3 '04

Q4 '04

Q1 '05

Q2 '05

Q3 '05

Q4 '05

Q1 '06

Q2 '06

Q3 '06

Q4 '06

Q1 '07

Q2 '07

Q3 '07

Q4 '07

Q1 '08

Q2 '08

Q3 '08

Q4 '08

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QUARTERLY SURFACE COATING VENT EMISSIONS RESULTS (A2-3)

0

50

100

150

200

250

300

350

Monitoring Period

Emm

isio

ns m

g/N

m3

Emission Result 6.9 0.1 14 0.5 42 7.3 57 59 44 53 41 43 67 30 63 130 27 24 65 46 8.5 55 49 48 6.1 70 31 50

Emission Limit 300 300 300 300 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150

Q1 '02

Q2 '02

Q3 '02

Q4 '02

Q1 '03

Q2 '03

Q3 '03

Q4 '03

Q1 '04

Q2 '04

Q3 '04

Q4 '04

Q1 '05

Q2 '05

Q3 '05

Q4 '05

Q1 '06

Q2 '06

Q3 '06

Q4 '06

Q1 '07

Q2 '07

Q3 '07

Q4 '07

Q1 '08

Q2 '08

Q3 '08

Q4 '08

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3.1.3 Waste Management Table 3: Summary Table of Wastes Generated at Cavanagh Foundry Ltd in the Period 2008. European Waste Catalogue Code

Hazardous (Yes/No)

Description of Waste Quantity /t

Disposal/ Recovery Code

Location of Disposal/ Recovery

Name of Waste Disposal Recovery Contractor & Waste Collection Permit No.

15 01 01

No

Cardboard

1.77

R3

AES Ltd, Co. Laois. AES Ltd, Naas, Co. Kildare. Permit 053(2)/OY/351/06 (Issued by Offaly County Council)

10 09 08

No

Used Greensand

1799.75

R3

Hinch Plant Hire, Nyra, Mountmellick, Co. Laois.

Hinch Plant Hire, Mountmellick, Co. Laois. Permit WCP-OY-03-0159-03(Issued by Offaly County Council)

15 01 04

No

Empty Steel Barrels

7.49

R4

Hammond Lane Metal Company Ltd. Ringsend, Dublin 4.

Hammond Lane Metal Company Ltd. Permit 050(2)/OY/540/07 (Issued by Offaly County Council)

20 03 01

No

General Refuse

31.78

D1

Offaly County Council Landfill, Derryclure, Tullamore, Co. Offaly.

AES Ltd, Naas, Co. Kildare. Permit 053(2)/OY/351/06 (Issued by Offaly County Council)

15 01 04

No

Packaging Material (other than Cardboard)

9.69

R4

Hammond Lane Metal Company Ltd. Ringsend, Dublin 4.

Hammond Lane Metal Company Ltd. Permit 050(2)/OY/540/07 (Issued by Offaly County Council)

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European Waste Catalogue Code

Hazardous (Yes/No)

Description of Waste Quantity /t

Disposal/ Recovery Code

Location of Disposal/ Recovery

Name of Waste Disposal Recovery Contractor & Waste Collection Permit No.

15 01 03

No

Pallets

45.19

R4

CJ Sheeran Ltd, Mountrath, Co. Laois.

CJ Sheeran, Co. Laois. Permit 189(2)/OY/467/06 (Issued by Offaly County Council)

16 11 04

No

Spent Linings and Refractories

6.00

R3



10 09 03

No

Furnace Slag

211

R3



10 09 99

No

Foundry Returns

925.61

R4

Cavanagh Foundry LtdCo. Offaly.

Cavanagh Foundry Ltd, Co. Offaly.

13 01 13

Yes

Waste Oils

1000 (litres)

R9

Enva Ireland Ltd, Portlaoise, Co. Laois

Enva Ireland, Co. Laois. Permit 033(2)/OY/281/05 (issued by Offaly County Council)

20 01 21

Yes

Fluorescent Tubes

0

R13

Irish Lamp Recycling,Co. Kildare.

Irish Lamp Recycling, Co. Kildare. 035/OY/80/03 (issued by Offaly County Council)

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________________________________________________________________________________ 3.2 Agency Monitoring and Enforcement

Euro Environmental Services carried out air monitoring on behalf of the Agency on 6th May 2008. Their analysis showed a breach in the emission limit value for total organic carbon at A2-3, as total organic carbon was detected at a concentration of 224.7mg/m3, against an emission limit value of 150 mg/m3. Independent monitoring of A2-3 conducted by Axis Environmental who are engaged by Cavanagh Foundry Ltd demonstrated compliant emission limit values at A2-3 on quarterly occasions during 2008. Cavanagh Foundry have outlined a commitment in various correspondence to Agency to convert to water based paint within nine months of dated of revised IPPC licence dated 6th November 2008.

3.3 Energy and Water Consumption 3.3.1 Energy Consumption Summary

Table 4: Summary of Fuel Usage 2008

FUEL USAGE Electricity (MW/h) 38333 Natural Gas (litres) 55336 Light Fuel Oils (litres) 43434

3.3.2 Water Consumption Table 5: Summary of Water Usage 2008

WATER SOURCE USAGE m3

On-site Ground Water 1750 On-site Surface Water 0 Municipal Supply 0

Annual Environmental Report 2008 Cavanagh Foundry Ltd ________________________________________________________________________________ 3.4 Environmental Incidents and Complaints 3.4.1 Environmental Incidents

None.

3.4.2 Environmental Complaints

None.

3.5 Submission of Summary Information

AER summary table has been completed and emailed to EPA Headquarters as required. 3.6 AER Emission Data Return Worksheet

AER emissions data return worksheets were uploaded to EPA website 26.03.09 as required. Printed copies of uploaded information is detailed overleaf.

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Annual Environmental Report 2008 Cavanagh Foundry Ltd ________________________________________________________________________________________

Section 4

Management of the Activity

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Annual Environmental Report 2008 Cavanagh Foundry Ltd _____________________________________________________________________________________ 4.1 Introduction

Cavanagh Foundry Ltd Environmental Objectives and Targets have been determined by incorporating IPPC licence, ISO 14001 and business environmental initiative requirements. The company has been operating an Environmental Objective and Targets programme since 1999.

4.2 Schedule of Environmental Objectives and Targets

In accordance with the facilities IPPC licence and ISO 14001 requirements an Environmental Management Programme operates on an ongoing basis within the business. This EMP has been updated to reflect additional business environmental targets and objectives (ref section 5).

Table 8: Summary Table of Environmental Objectives and Targets for 2008 ENVIRONMENTAL OBJECTIVES ENVIRONMENTAL TARGETS

Construct ancillary building to make provision for internal water based painting system.

Elimination of solvents associated with existipainting process (refer section 5).

Construct and install new furnaces and associated building incorporating dry bag filtration technology for furnace

30% reduction in total particulate discharge levels from furnaces (A2-1).

emissions.

Relating to objectives and targets outlined above 4.3 below detailed a summarised account of progress in 2008.

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Annual Environmental Report 2008 Cavanagh Foundry Ltd ________________________________________________________________________________

4.3 Environmental Management Programme Report

4.3.1 Construct ancillary building to make provision for internal water based painting

system.

During the November - December of 2003 plans for an ancillary building which would incorporate internal painting facilities were established and were submitted to Birr Town Council along with an Environmental Impact Statement for planning permission in March 2004. Planning permission to construct ancillary building facility was obtained during September 2004. Tenders for construction were sought during November and are were reviewed by company environmental engineering consultants but project was postponed at the time. In November 2008 fresh tenders were sought from construction companies to build the ancillary building. Construction is underway at time of writing and it is expected that a water based painting system will be commissioned in new building by August 2009.

4.3.2 Construct and install new furnaces and associated building incorporating dry

bag filtration technology for furnace emissions. New furnaces were installed during August 2008. Furnace discharge dry bag filtration system is scheduled to be installed during the annual shutdown period in August 2009.

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Annual Environmental Report 2008 Cavanagh Foundry Ltd _______________________________________________________________________________

4.4 Environmental Management Programme

In accordance with the facilities IPPC licence and ISO 14001 requirements an Environmental Management Programme operates on an ongoing basis within the business. This EMP has been updated to reflect additional business environmental targets and objectives (ref section 5).

Table 9: Summary Table of Environmental Objectives and Targets for 2009

ENVIRONMENTAL OBJECTIVES ENVIRONMENTAL TARGETS

Construct ancillary building to make provision for internal water based painting system.

Elimination of solvents associated with existipainting process (refer section 5).

Install dry bag filtration abatement Equipment at A2-1.

80% reduction in total particulate discharge levels from furnaces (A2-1).

Install Class I full retention oil/silt Interceptor in rear yard area.

Upgrade existing provisions to mitigate risksassociated with unlikely event of oil/ petroleum spillage in yard.

Conduct Iron impact assessment of Milbrook stream.

Ensure no detrimental impact from iron discharge on Milbrook stream.

Discharge laboratory washings from soak pit to foul sewer/

Remove discharge from GW to foul sewer Treatment plant.

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Section 5

Licence Specific Reports

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Section 5.1

Noise Monitoring Reports

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________________________________________________________________________________

Section 5.2

Groundwater Monitoring Report

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Annual Environmental Report 2008 Cavanagh Foundry Ltd _______________________________________________________________________________

Section 5.3

Environmental Management Plan

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