919-30 v2.00 ANNUAL ENvIRONMENTAL REPORT · PDF fileANNUAL ENVIRONMENTAL REPORT 2009 for ... Heidelberg Harris 850 B Printing Press has been decommissioned and the Heidelberg Harris

Tel: 353 1 276 1428 Fax: 353 1 276 1561 Email:[email protected] www.enviro-consult.com

Registered Office as above. Registered Number 243 412

ANNUAL ENVIRONMENTAL REPORT

2009

for

Boylan Print Limited,

New Found Well, Terminfeckin Road,

Drogheda, Co. Louth

IPPC Licence Number: P0784-01

Document Number (919-30 v2.00)

Boylan Print Limited Annual Environmental Report 2009

Environmental Efficiency (Ire) Ltd Page 2 of 67

Document No. 919-30 v2.00

QF 1. v2 Document Lead Sheet

Document Title Annual Environmental Report 2009

Project No. 919


Client Boylan Print Limited

Address New Found Well, Terminfeckin Road, Drogheda, Co. Louth

Signed for and on behalf of Issue Status Date Author Environmental

Efficiency Client

1.00 Approved 15/03/2010 POS

2.00 Approved 24/03/2010 POS

Where it is a requirement that this report be issued to a regulatory or other authority,

then the client should sign the appropriate place in the above table and, unless

specifically agreed in writing to the contrary, forward copies to the appropriate

authority (e.g. EPA).

EEC Project Manager: Bob Sutcliffe, CEng, MIMechE

EEC Document Author: Pádraig O’Shea, BA, MA

Conditions relating to the issue of this report:

1. No alteration to this report by third parties is permitted

2. Where this report is reproduced, it shall only be reproduced in full.

3. Reports remain the property of Environmental & Efficiency Consultants

(Ireland) Limited until paid for in full.




Table of Contents

1 Introduction ..................................................................................................... 5 1.1 Company Information ................................................................................ 5

1.2 Company Organisation Chart ..................................................................... 6

2 Site Description................................................................................................ 7 2.1 Company Profile ........................................................................................ 7

2.2 Environmental Policy................................................................................. 7

2.3 Manufacturing Process............................................................................... 7

3 Summary of Emissions .................................................................................... 9 3.1 Emissions to Atmosphere........................................................................... 9

3.1.1 Emissions to Atmosphere - monitoring programme ............................ 9

3.1.2 Emissions to atmosphere – Monitoring results...................................10

3.2 Waste Management...................................................................................10

3.3 Surface water monitoring emissions..........................................................11

4 Resource Consumption.................................................................................. 12 4.1.1 Water Consumption...........................................................................12

4.1.2 Energy Consumption.........................................................................12

4.1.3 Raw Materials Consumption .............................................................12

5 Environmental Incidents and Complaints .................................................... 13 5.1 Reported Incidents Summary ....................................................................13

5.2 Complaints Summary................................................................................13

5.3 EPA Site Inspections.................................................................................13

6 Environmental Management of activity ....................................................... 13 6.1 Report on Environmental Objectives and targets for 2009 .........................13

6.2 Environmental Management Programme 2010..........................................19

7 Licence Specific Reports (IPPC licence P0784-01) ....................................... 21 7.1 Noise Monitoring Report 2009..................................................................21

7.2 Bund (Printing Inks) .................................................................................21

7.3 Solvent Management Plan/ Fugitive Emissions Programme ......................21

7.4 Residuals Management Plan......................................................................21

7.5 Firewater Retention...................................................................................21

7.6 Programme for Public Information............................................................21

7.7 Environmental Improvements during 2009 and financial provisions..........23




Tables

Table 1-1 Company details ........................................................................................ 5

Table 1-2 Summary of IPC licence and site history.................................................... 5

Table 3-1 Air Monitoring Programme (IPPC licence P0784-01) ................................ 9

Table 4-1 Energy Consumption ................................................................................12

Table 4-2 Raw Material Consumption 2009..............................................................12

Table 5-1 EPA Site Inspection..................................................................................13

Table 6-1 Report on Objectives and targets for 2009 ................................................14

Table 6-2 Summary of Environmental Management Programme for 2010................19

Table 7-1 Programme for public information............................................................22

Table 7-2 Environmental Improvements on site........................................................23

List of Figures

Figure 3-1 Storm water emissions (COD).................................................................11

Figure 3-2 Storm water emissions (ph) .....................................................................11

Appendices

Appendix 1 Environmental Policy ............................................................................24

Appendix 2 Specification for new printer (M600) with built in thermal oxidiser.......25

Appendix 3 Certificates of analysis ..........................................................................27

Appendix 4 EPA surface water analysis....................................................................36

Appendix 5 AER / PRTR Emissions Data information .............................................38

Appendix 6: Fugitive Emissions 2009 ......................................................................42

Appendix 7 Details of calculation of the quantities of solvent based products put into

the process ............................................................................................53

Appendix 8: Annual Noise 2009...............................................................................56




1 Introduction

Environmental Efficiency Consultants (EEC) was commissioned by Boylan Print Ltd.

to complete their Annual Environmental Report for 2009 to fulfil the requirements of

condition 11.6 of their IPPC licence (P0784-01).

1.1 Company Information

Table 1-1 Company details

Company Boylan Print Limited

Address Newfoundwell,

Terminfeckin Road,

Drogheda,

County / City Co. Louth

Business Production of magazines and leaflets for the

Irish market

Employees 47

Contact Name Denise Hughes

Position(s) Environmental Officer

Telephone 041 983 9905

Fax 041 983 4827

Email [email protected]

IPPC Registration Number P0784-01

Table 1-2 Summary of IPC licence and site history

IP(P)C Licence Reg: No. Period

112 (Thermal Heat Exchangers) Unknown

P0784-01 16th

April 2007 to present

Boylan Print Ltd. hold an IPPC licence granted by the Environmental Protection

Agency (EPA) (Licence Register Number P0784-01) in 2007. In accordance with

Condition 11.6 of this licence Boylan Print Ltd. are required to have a documented

Annual Environmental Report (AER). Boylan Print Ltd. moved into the property at

the start of April 2005. For two years prior to Boylan Print Ltd. acquiring the premises




the site lay derelict. Before this time the factory was owned by Thermal Heat

Exchangers (Ireland) Ltd. who manufactured coil heat exchangers.

1.2 Company Organisation Chart

Group Chairman

Financial Controller Director of Labels Director of Print

Quality Co-Coordinator/

Environmental Manager

Accounts Rec.

Manager

Accounts Payable

Manager

Labels Customer

Service Manager

Print Customer

Service Manager Print Manager

Originator Manager

Production

Personnel

Production

Personnel




2 Site Description

2.1 Company Profile

The primary activity of Boylan Print Ltd. is the printing of magazines and leaflets for

the Irish market.

2.2 Environmental Policy

Boylan Print Ltd. have a documented environmental policy in relation to the activities

carried out at the site (Appendix 1).

2.3 Manufacturing Process

The printing process is done via the heatset web. Boylan Print Ltd. currently operates

a hot air web offset dryer with the functions of drying, chilling and guiding the web

integrated in one single system and is named emission point A2-4. The Agency is

aware of the operation of this printer, which at present is a non-licensed emission

point. Boylan Print Ltd. have formally requested of the Agency a technical

amendment for the inclusion of emission point A2-4 in the licence. The specification

for this machine with a built in Thermal Oxidiser is attached in Appendix 2. The

Heidelberg Harris 850 B Printing Press has been decommissioned and the Heidelberg

Harris M300 Printing Press was operated on a part-time basis in 2009. The M600

printing press (A2-4) is the primary printing press on site. The M300 printing press is

currently based on Boylan Print Limited’s IPPC licence.

Flowcharts of the printing process used in the company are shown in Figure 1 and

Figure 2 below.







3 Summary of Emissions

The company has the following licensed emissions:

� Emissions to atmosphere

� Waste emissions

� Storm water

3.1 Emissions to Atmosphere

3.1.1 Emissions to Atmosphere - monitoring programme

The monitoring of emissions to atmosphere at Boylan Print Ltd. for emission points

A2-3 and A2-4 (non-licensed) was carried out in quarters two, three and four of 2009.

The first quarter of 2009 was missed.

In accordance with the company’s IPPC licence, Boylan Print Ltd. monitors air

emissions for total organic carbon compound(s), nitrogen oxides and carbon

monoxide. A summary of emission limit values and allowed flow rates for the stacks

and the RTO on site are provided in the following table.

Table 3-1 Air Monitoring Programme (IPPC licence P0784-01)

Emission point

reference Parameters

Monitoring

Frequency

Volumes &

Concentrations

Licensed Volume

Flow Rate 2,625m3/

hr

A2-1 Total Organics 115mg/m3

Flow Rate 1,460m3/

hr A2-2

Total Organics

Note3

50mg/m3

Flow rate 9,000m3/

hr

Total Organics (as Carbon) 20mg/m3

Nitrogen Oxides (as NO2) 100mg/m3

A2-3 (RTO)

Carbon Monoxide

Quarterly

100mg/m3

Flow rate

Total Organics (as Carbon)

Nitrogen Oxides (as NO2) A2-4

Note1

Carbon Monoxide

Quarterly

Note2

Note1: A2-4 is not a licensed emission point but the Agency are aware of its existence. A test programme for the new M600 printer and its

associated emission point is currently being undertaken. Environmental Efficiency Consultants carried out monitoring of A2-4 for the year 2009.

Note 2: Emission limits were based on the TA Luft standard

Note 3: A2-1 has been decommissioned.




3.1.2 Emissions to atmosphere – Monitoring results

Certificates of analysis for monitoring of emissions to atmosphere in 2009 at Boylan

Print Ltd. are attached in Appendix 3.

Emission Point A2-3 A2-4

Period Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4

ELV TOC as C

concentration

(mg/Nm3) 20

- 6.93 9.15 9.6 - 6.86 10.86 0.46

ELV Nitrogen

Oxides

(mg/Nm3)

100 - 22.6 18.5 0.0 - 0.0 0.0 0.0

ELV Carbon

Monoxide

(mg/Nm3)

100 - 5 3.75 120 - 25 17.5 10

Carbon Monoxide exceeded the emission limit value in Quarter 4 2009. This was

addressed to the Agency in correspondences dated the 4th

and 9th

February 2010.

3.2 Waste Management

The following are the waste types collected from the premises of Boylan Print Ltd. in

2009.

Table 3-2 Waste Generation 2009

Waste type Hazardous Quantity (t) Contractor Permit/licence

Paper No 9,376 Panda Waste WCP/MH/2001/01D /W0140-02

Wood No 0.48 Panda Waste WCP/MH/2001/01D /W0140-02

In relation to hazardous waste, waste ink is put into buckets of ink and these buckets

are returned to the supplier as recyclable black ink. There was insufficient information

available to produce exact figures for 2009 for hazardous waste at Boylan Print Ltd,

other than Boylan Print Ltd. have their suppliers take back hazardous ink waste

drums.

A summary of all emissions from the AER / PRTR emissions data information is

attached in Appendix 5.




3.3 Surface water monitoring emissions

The following are the storm water emissions for Boylan Print Ltd.

Emission point SW1

0

200

400

600

800

1000

1200

Dec-08 Feb-09 Mar-09 May-09 Jul-09 Aug-09 Oct-09 Dec-09 Jan-10

Co

nce

ntr

ati

on

COD mg/litre

MDL mg/litre

Figure 3-1 Storm water emissions (COD)

Emission point SW1

0

2

4

6

8

10

Dec-08 Feb-09 Mar-09 May-09 Jul-09 Aug-09 Oct-09 Dec-09 Jan-10

Co

ncen

trati

on

pH

Figure 3-2 Storm water emissions (ph)




The Agency visited the site on the 22nd

July 2009 and collected a sample at SW1. The

Agency visited the site again on the 2nd

December 2009, the discharge point was dry.

Results of analysis are in Appendix 4.

4 Resource Consumption

This section of the Annual Environmental Report details the total annual usage levels

of water and energy at the site.

4.1.1 Water Consumption

Total water consumption was 559.5m³ for 2009. This is based on a fixed rate set at

1.55m³ per day by the number of working days (361).

4.1.2 Energy Consumption

Energy is provided by figure sources at the company namely:

� Natural gas

� Electricity

Table 4-1 Energy Consumption

Source Consumption

2007

Consumption

2008

Consumption

2009 Units

Natural gas 8,949,822 4,620,135 2,388,777 kWh

Electricity - 4,045,969 4,094,989 kWh

4.1.3 Raw Materials Consumption

The following is the list of the raw materials for 2009.

Table 4-2 Raw Material Consumption 2009

Source Consumption

2008 (tonne)

Consumption

2009 (tonne)

Total Heatset Inks 225.03 220.2

White Spirits 10.8 4.9

MRC - 0.047

Fountain Solution 12.8 2.7

Heatset Fount - 8

Blanket Wash - 0.09

Coolbind Glue - 3

Paper 4,335 4,146




5 Environmental Incidents and Complaints

5.1 Reported Incidents Summary

There are no known reported incidents for the year 2009.

5.2 Complaints Summary

No environmental complaints were received by Boylan Print Ltd. in 2009.

5.3 EPA Site Inspections

There were two site inspections by the EPA in 2009 of Boylan Print Limited’s

premise. The details of which are outlined in Table 5-1.

Table 5-1 EPA Site Inspection

Date of

Inspection

EPA, Inspection Reference

No

Number of

Non

conformances

Number of

observations

31st March 2009 (P0784-01)09AREC 13 8

22nd

July 2009 P0784-01/09/si02ec 2 3

6 Environmental Management of activity

6.1 Report on Environmental Objectives and targets for 2009

A report on the implementation of the 2009 EMP is provided in Table 6-1 below.




Table 6-1 Report on Objectives and targets for 2009

Objective

reference

No.

Objective Target Achievement

Difficulty

Additional Comment

1 M600 printer with built-in

Thermal Oxidiser (RTO)

� Produce a fugitive

emissions

programme

� Produce a test

programme

� Ensure sampling of

printer (M600)

The following shall be

submitted by Boylan Print

Ltd. by the end of May 2009

� Completed Tables

E.1 (ii) and E.1 (iii)

of the IPPC

application form.

� Details of emission

levels prior to and

after the burner

� Solvent usage and air

throughput

� Details of the

operation of the

burner and possible

by passes;

� A fugitive emissions programme was achieved

� A test programme for the M600 (A2-4) was

produced and is presently being agreed with

Boylan Print a suitable timeframe for this to

take place to allow for working operations

� Sampling of M600 (A2-4) printer was carried

out in 2009.

� IPPC licence application sections E.1 (ii) and

E.1 (iii) were completed by year end 2009

Yes - -




Objective

reference

No.


Difficulty

Additional Comment

� Details of possible

fugitive emissions

2 Ensure the correct disposal

of all waste

A licensed waste contractor who deals in the

recovery of solvent rags used by Boylan Print Ltd.

No Suitable

licensed

waste

contractor

Suitably licensed waste

contractors are being

spoken to by Boylan

Print Ltd. to engage

their services

3 Implement

recommendations outlined

for raw materials efficiency

and waste reduction

assessment report (EEC

doc. No 919-10)

A solvent recovery unit will not be purchased by

Boylan Print Ltd. upon investigation.

No Unviable

under

current

operating

process

-

• Waste management records for all non

hazardous waste are kept on site. Details in

relation to non hazardous waste at the site are

unknown to EEC. EEC is aware all inks used in

the production process are used and when the

totes containing the inks are finished they are

returned to the supplier to be refilled.

Yes

4 Ensure all relevant waste

documents are maintained

on site

� Ensure all mixed solvents waste consignments

are analysed in accordance with Schedule C:

Control & Monitoring of licence. Arrange for

consultants to sample and analyse the waste

stream.

Unknown




Objective

reference

No.


Difficulty

Additional Comment

� Investigate whether all ‘green’ wastes classified

under the EU Transfrontier Shipment of Waste

Regulations, consigned for abroad for recovery

are held on site in accordance with requirements

of Condition 11.7 of licence.

Unknown

� Sump pallets for storage of hazardous materials

(ink trays etc.) on site are regularly cleaned out

by a licensed waste contractor

Yes - -

� All empty drums/buckets and containers, and

are collected by suppliers or by an authorised

hazardous waste collector and stored in a

suitably bunded hard standing location prior to

collection.

Yes - -

� Maintain the storage area for the temporary

storage of empty containers/drums, ensure this

area remains bunded in accordance with

requirements of Condition 3.5

Yes - -

5 Ensure all hazardous

materials are stored

appropriately

� Carry out regular checks to ensure that

hazardous wastes are being stored correctly on

site i.e. on sump pallets, bunds or bunded

flooring.

Yes - -

6 Protect drains on the

factory floor

� No absorbent booms placed around the drains

until a suitable plan can be implemented to

securely seal the drains on the factory floor

Yes

- Drains on the factory

floor were suitably

blocked so no booms

are required. These

works took place in

early 2010.




Objective

reference

No.


Difficulty

Additional Comment

7 Draw up and implement a

solvent management plan

upon full and correct

operation of the M600

printer

This will incorporate

fugitive emission

programme

� Review solvent management plan as part of the

2009 AER

� Review fugitive emissions as percentage of the

total solvent input

� No recommendations given as part of the SMP

Yes

No

No

-

-

-

-

-

-

8 Implement measures

proposed for water

conservation/reduction on

site as outlined in Water

Use Reduction Audit (EEC

doc. No. 919-09)

� No investigation into installing spray head taps

or faucet aerators was carried out

� No investigation into installing cistern volume

adjusters and the compatibility with existing

toilets on site was carried out.

No

No

- -

9 Ensure proper

management and

monitoring of storm water

emission point.

� Arrange to have a drainage map of the site

prepared this should indicate surface and foul

water drainage on site. Ensure connection points

to council sewers are included.

� A visual inspection of storm water discharge on

a weekly basis when taking samples for weekly

analysis

� Document the visual inspection in the weekly

site inspection record form & log

Yes

Yes

Yes

- This had been

previously been carried

out prior to being an

action to be carried out

in 2009

10 Ensure Compliance with

Condition 9: Accident

Prevention and Emergency

Response:

� Emergency Response Procedures are known to

all staff from being posted at various locations

throughout the site

Yes

- Safefire review

documention on behalf

of Boylan Print Ltd.




Objective

reference

No.


Difficulty

Additional Comment

11 Label sampling and

monitoring points

� Licensed emission points are labelled at the site. Yes - -

12 Ensure the protection of

groundwater

� EEC checked wells on site in 2009 and checked

to establish if they could be used. A response on

behalf of Boylan Print Ltd was issued to the

Agency on the 30th November 2009. Boylan

Print Ltd. awaits a response on this matter.

Ongoing at

present

- -

13 Residuals Management

Plan

� The residuals management plan was reviewed as

part of the AER for 2008 and n changes were

required.

Yes

-

14 ELRA � An ELRA was submitted to the Agency in 2009

(Ref:919-24 v3.00)

Yes

- -

15 Ensure all documentation is

readily available for the

purposes of inspection

� A folder pertaining to all required environmental

documentation is maintained and kept on-site

for the purposes of inspection by Boylan Print

Ltd.

Yes - -




6.2 Environmental Management Programme 2010

Table 6-2 Summary of Environmental Management Programme for 2010

Objective

reference

number

Objective Responsibility Method Target

completion date

1 Reduce fugitive emissions to air.


Investigate possible sources for the cause of

fugitive emissions on site and reduce emissions

to the level stated in condition 5.6 of the IPPC

licence (P0784-01)

December 2010

2 Investigate the feasibility of

installing a port in a section of

straight ducting between

emission point A2-2 and A2-3 to

measure volume flow.

Director /Environmental

Manager

Request from the Agency if this is possible. March 2010

3 Seal drains on the factory floor

so spillages won’t go to receiving

waters

Environmental Manager Place suitable absorbent booms on a temporary

basis around exposed drains until drains can be

sealed on the factory floor.

Completed in

February 2010

4 Ensure all relevant waste

documents are maintained on

site

Environmental Manager Ensure C1 forms for all hazardous waste sent

off site are filed and kept on record.

Ensure a waste management record is held on

site at all times with all waste documentation

correct and up to date.

Investigate whether all ‘green’ wastes classified

under the EU Transfrontier Shipment of Waste

Regulations, consigned for abroad for recovery

are held on site in accordance with

requirements of Condition 11.7 of licence.

Immediately




Objective

reference

number

Objective Responsibility Method Target

completion date

5 Ensure all hazardous materials

are stored appropriately by

visual inspection Environmental Manager

Carry out regular checks to ensure hazardous

wastes are being stored correctly on site i.e.

containers containing solvent are kept on sump

pallets, bunds or bunded flooring.

Immediately

6 Request a technical amendment

of IPPC licence for the inclusion

of the M600 printing press.


/ Director

Get a technical amendment of IPPC licence

(P0784-01) to include M600 printer as an

additional source of emissions to air under the

IPPC licence.

Immediately

7 Groundwater monitoring Environmental Manager

/ Director

Liaise with the Agency upon an agreement of a

program of works to carry out groundwater

monitoring of current wells on site.

May 2010

8 Conduct annual noise survey

2010 Environmental Manager Carry out an annual noise survey as required

under condition 6.12.2 of IPPC licence P0784-

01

March 2010

9 Review waste management

operations and practices. Environmental Manager

Review in accordance with condition 11.7 of

licence. September 2010

10 Commission platform at air

emission point

Environmental

Manager/Director

Set up permanent platform as per AG1 standard April 2010




7 Licence Specific Reports (IPPC licence P0784-01)

For the PRTR reporting at the facility the following data and results are based on

quarter two, three and four monitoring periods in 2009 (i.e. a quarter). Please see

Appendix 5.

7.1 Noise Monitoring Report 2009

EEC carried out a noise survey at Boylan Print Ltd. (Doc. No. 919-22) on the 2nd

June

2009 as required under condition 6.12.2 of their IPPC licence (Appendix 8).

7.2 Bund (Printing Inks)

A correspondence from the agency on the 27th

October 2009 (Ref:P0784-01/ak02ec)

in response to the correspondence submitted by Boylan Print Ltd. on the 7th

October

2009 stated a water retention test was not required provided appropriate measures are

in place so that the bund is rendered impervious to the inks within. Measures included

epoxy coating of the bund walls.

7.3 Solvent Management Plan/ Fugitive Emissions Programme

A solvent management was prepared by EEC on behalf of Boylan Print Ltd. The

report is attached in Appendix 6.

7.4 Residuals Management Plan

A residuals management plan was prepared on behalf of Boylan Print Ltd. by EEC

(Doc. No. 919-13). The original initial report is with the Agency. A review of the plan

was completed and there is deemed to be no necessary changes.

7.5 Firewater Retention

The above plan was revised and prepared on behalf of Boylan Print Ltd. by EEC

(Doc. No. 919-06 v 4.01). A copy of this report is also with the Agency.

7.6 Programme for Public Information

A programme for public information has been implemented. This programme is

subject to continual review and regular updates to ensure it is fully comprehensive and




representative of all relevant measures and environmental effects/issues. The

measures contained in the programme are outlined in Table 7-1 below:

Table 7-1 Programme for public information

Measures Progress to date

Website

Environmental Policy

Notice/Bulletin boards

Maintenance of information notice board to

include:

� Opening hours

� Phone numbers and names of various

relevant personnel: site manager,

environmental/health and safety manager

etc.

� Licence reference number

Achieved

Communications programme

Ensure all environmental information is available

on request to public:

� Monitoring Results

� Pollution Emissions Register

Achieved

Public Complaints procedure

� Ensure complaints record form is available

from reception

Achieved




7.7 Environmental Improvements during 2009 and financial provisions

A statement of measures in relation to the prevention of environmental damage and

remedial actions (environmental improvements 2009) is provided in Table 7-2 below:

Financial provision remains the same as that outlined in the residuals management

plan (Doc. No 919-13 v1.00). There are no changes in the amount of financial

provision.

Table 7-2 Environmental Improvements on site

Measures Progress to date

Equipment maintenance

� All equipment in use is regularly checked in order to identify and

remedy any faults, which may compromise the health and safety of

staff or have a negative impact on the environment.

Ongoing

Environmental Monitoring

� Emissions to water and emissions to air are monitored regularly as

required by the IPPC licence (Reg. No.P0784-01)

Ongoing




Appendix 1 Environmental Policy




Appendix 2 Specification for new printer (M600) with built in thermal oxidiser







Appendix 3 Certificates of analysis




























Appendix 4 EPA surface water analysis







Appendix 5 AER / PRTR Emissions Data information

| PRTR# : P0784 | Facility Name : Boylan Print Limited | Filename : P0784_2009.xls |

Return Year : 2009 | 3520 15/03/2010 16:41

Version 1.1.10

REFERENCE YEAR 2009

1. FACILITY IDENTIFICATION

Parent Company Name Boylan Print Limited

Facility Name Boylan Print Limited

PRTR Identification Number P0784

Licence Number P0784-01

Waste or IPPC Classes of Activity

No. class_name

12.2.2 #######################################################

Address 1 New Found Well

Address 2 Terminfeckin Road

Address 3 Drogheda

Address 4 Co. Louth

Country Ireland

Coordinates of Location -6.32709 53.7253

River Basin District IEEA

NACE Code 2030

Main Economic Activity

Manufacture of paints, varnishes and similar coatings, printing ink

and mastics

AER Returns Contact Name Denise Hughes

AER Returns Contact Email Address [email protected]

AER Returns Contact Position Environmental Officer

AER Returns Contact Telephone Number 041-9839905

AER Returns Contact Mobile Phone Number

AER Returns Contact Fax Number 041-9834827

Production Volume 0.0

Production Volume Units

Number of Installations 0

Number of Operating Hours in Year 0

Number of Employees 47

User Feedback/Comments

Web Address

2. PRTR CLASS ACTIVITIES

Activity Number Activity Name

50.1 General

3. SOLVENTS REGULATIONS (S.I. No. 543 of 2002)

Is it applicable?

Have you been granted an exemption ?

If applicable which activity class applies (as per

Schedule 2 of the regulations) ?

Is the reduction scheme compliance route being

used ?

AER Returns Worksheet




4.1 RELEASES TO AIR | PRTR# : P0784 | Facility Name : Boylan Print Limited | Filename : P0784_2009.xls | Return Year : 2009 | 15/03/2010 16:41

8 8 16 17 25 25 6 6 6 7

SECTION A : SECTOR SPECIFIC PRTR POLLUTANTS

QUANTITY

No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year

0.0 0.0 0.0 0.0

* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button

SECTION B : REMAINING PRTR POLLUTANTS

QUANTITYA2-3 A2-4

No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 Emission Point 2 T (Total) KG/Year

A (Accidental)

KG/Year

F (Fugitive)

KG/Year

02 Carbon monoxide (CO) M PER Flue Gas Analyser 3244.5 1323.0 4567.5 0.0 0.0

08 Nitrogen oxides (NOx/NO2) M PER Flue Gas Analyser 1035.7 0.0 1035.7 0.0 0.0


SECTION C : REMAINING POLLUTANT EMISSIONS (As required in your Licence)

QUANTITYA2-3 A2-4

Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 Emission Point 2 T (Total) KG/Year

A (Accidental)

KG/Year

F (Fugitive)

KG/Year

351 Total Organic Carbon (as C) M PER FID 647.1 458.1 1105.2 0.0 0.0


Additional Data Requested from Landfill operators

Landfill: Boylan Print LimitedPlease enter summary data on the

quantities of methane flared and / or

utilised

additional_pollutant_no T (Total) kg/Year M/C/E Method Code

Designation or

Description

Facility Total Capacity m3

per hourTotal estimated methane generation (as per

site model) 0.0 N/A

Methane flared 0.0 0.0 (Total Flaring Capacity)

Methane utilised in engine/s 0.0 0.0 (Total Utilising Capacity)

Net methane emission (as reported in Section

A above) 0.0 N/A

POLLUTANT METHOD

Method Used

For the purposes of the National Inventory on Greenhouse Gases, landfill operators are requested to provide summary data on landfill gas (Methane)

flared or utilised on their facilities to accompany the figures for total methane generated. Operators should only report their Net methane (CH4)

emission to the environment under T(total) KG/yr for Section A: Sector specific PRTR pollutants above. Please complete the table below:

Method Used

Method Used

RELEASES TO AIR

POLLUTANT METHOD

Method Used

POLLUTANT

RELEASES TO AIR

RELEASES TO AIR

METHOD




4.2 RELEASES TO WATERS | PRTR# : P0784 | Facility Name : Boylan Print Limited | Filename : P0784_2009.xls | Return Year : 2009 | 15/03/2010 16:41

8 8 16 16 24 24 6 6 6 6 6 6

SECTION A : SECTOR SPECIFIC PRTR POLLUTANTS Data on ambient monitoring of storm/surface water or groundwater, conducted as part of your licence requirements, should NOT be submitted under AER / PRTR Reporting as this only concerns Releases from your facility

QUANTITY


0.0 0.0 0.0 0.0


SECTION B : REMAINING PRTR POLLUTANTS

QUANTITY


0.0 0.0 0.0 0.0


SECTION C : REMAINING POLLUTANT EMISSIONS (as required in your Licence)

QUANTITY

Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year

0.0 0.0 0.0 0.0


RELEASES TO WATERS

RELEASES TO WATERS

Method Used

POLLUTANT

Method Used

POLLUTANT

POLLUTANT

RELEASES TO WATERS

Method Used

4.3 RELEASES TO WASTEWATER OR SEWER | PRTR# : P0784 | Facility Name : Boylan Print Limited | Filename : P0784_2009.xls | Return Year : 2009 | 15/03/2010 16:41

8 8 16 16 6 6 6 6

SECTION A : PRTR POLLUTANTS

QUANTITY


0.0 0.0 0.0 0.0


SECTION B : REMAINING POLLUTANT EMISSIONS (as required in your Licence)

QUANTITY

Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year

0.0 0.0 0.0 0.0


OFFSITE TRANSFER OF POLLUTANTS DESTINED FOR WASTE-WATER TREATMENT OR SEWER

OFFSITE TRANSFER OF POLLUTANTS DESTINED FOR WASTE-WATER TREATMENT OR SEWER

Method Used

Method Used

POLLUTANT METHOD

POLLUTANT METHOD

4.4 RELEASES TO LAND | PRTR# : P0784 | Facility Name : Boylan Print Limited | Filename : P0784_2009.xls | Return Year : 2009 | 15/03/2010 16:41

8 8 16 16 6 6 6 6

SECTION A : PRTR POLLUTANTS

QUANTITY

No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year

0.0 0.0 0.0


SECTION B : REMAINING POLLUTANT EMISSIONS (as required in your Licence)

QUANTITY

Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year

0.0 0.0 0.0


POLLUTANT METHOD

Method Used

RELEASES TO LAND

RELEASES TO LAND

POLLUTANT METHOD

Method Used




5. ONSITE TREATMENT & OFFSITE TRANSFERS OF WASTE | PRTR# : P0784 | Facility Name : Boylan Print Limited | Filename : P0784_2009.xls | Return Year : 2009 | 15/03/2010 16:41

5 6 3

Quantity

(Tonnes per

Year)

Haz Waste : Name and

Licence/Permit No of Next

Destination Facility Non

Haz Waste: Name and

Licence/Permit No of

Recover/Disposer

Haz Waste : Address of Next

Destination Facility

Non Haz Waste: Address of

Recover/Disposer

Name and License / Permit No. and

Address of Final Recoverer /

Disposer (HAZARDOUS WASTE

ONLY)

Actual Address of Final Destination

i.e. Final Recovery / Disposal Site

(HAZARDOUS WASTE ONLY)

Transfer Destination

European Waste

Code Hazardous Quantity T/Year Description of Waste

Waste

Treatment

Operation M/C/E Method Used

Location of

Treatment Name and Licence / Permit No. of Recover er / Disposer / Br oker Addr ess of Recoverer / Disposer / Broker Name and Address of F inal Destination i.e. Final Recover y / Disposal Site (HAZARDOUS WASTE ONLY) Licence / Per mit No. of Final Destination i.e. Final Recovery / Disposal S ite ( HAZARDOUS WAST E ONLY)

Within the Country 15 01 01 No 9376.0 Paper R5 M Weighed Offsite in Ireland

Within the Country 15 01 03 No 0.48 Wood R5 M Weighed Offsite in Ireland

* Select a row by double-clicking the Description of Waste then click the delete button

Method Used

Tel: 353 1 276 1428 Fax: 353 1 276 1561 Email:[email protected]

www.enviro-consult.com


Appendix 6: Fugitive Emissions 2009

Table of Contents

1 Introduction ....................................................................................................43

2 Methodological Assessment of the Fugitive Emissions..................................44 2.1 Determination of the different Inputs and Outputs:....................................45

2.2 Determination of the environmental significance of the fugitive emissions47

3 Calculations.....................................................................................................47 3.1 Determination of I1...................................................................................47

3.2 Determination of O1 .................................................................................48



3.4.1 Empty containers ..................................................................................50

3.4.2 Solvent contaminated rags.....................................................................51

3.4.3 Calculation of O6..................................................................................51


3.6 Determination of F....................................................................................51

4 Conclusion.......................................................................................................52

Boylan Print Ltd. Annual Environmental Report 2009

Environmental Efficiency Consultants Page 43 of 67

Document No.: 919-30 v2.00

1 Introduction Boylan Print Ltd. was issued with an Integrated Pollution Prevention and Control

Licence (IPC Licence Reg. No. P0784-01) in April 2007.

Boylan Print Ltd. fall under the scope of the Solvents Directive (1999/13/EC), which

was implemented, into Irish Law via the Emissions of Volatile Organic Compounds

from Organic Solvent Regulations 2002 (S.I 543 of 2002). The company is classified

under Activity 1 of the 2002 Regulations (Schedule 2 of 2002 regulations) i.e. Heatset

web offset printing (and which has a solvent consumption > 25 tonne per year). The

obligations that the solvents regulations have imposed on the company have been

incorporated into the conditions of the company’s IPPC licence i.e. Condition 5.6 of

the IPC licence states that:

“Fugitive emissions to air of volatile organic compounds shall be reduced to less

than or equal to 30% of total solvent input no later than 31st October 2007.”




2 Methodological Assessment of the Fugitive Emissions

It is proposed to assess the fugitive emissions from the site according to Schedule 6 of

the Solvent Regulations of 2002. The calculation of the fugitive emissions can be

done by mass balances, using one of the two following equations:

• F = I1 – O1 – O5 – O6 – O7 – O8

• F = O2 + O3 + O4 + O9

The definitions for the terms used in these equations are as follows:

Inputs of organic solvents (I)

• I1: The quantity of organic solvents or their quantity in preparation purchased

which are used as inputs into the process in the time frame over which the

mass balance is being calculated

• I2: The quantity of organic solvents or their quantity in preparations recovered

and reused as solvent input into the processes

Outputs of organic solvents (O)

• Emissions in waste gases (O1)

• Organic solvents lost in water (O2)

• The quantity of organic solvent which remains as contamination or residue in

produces output from the process (O3)

• Uncaptured emissions to organics solvents to air (O4)

• Organic solvents lost due to chemical or physical reactions (O5)

• Organic solvents contained in collected waste (O6)

• Organic solvents or organic solvents contained in preparations which are sold

or are intended to be sold as a commercially valuable product (O7)

• Organic solvents contained in preparations recovered for reuse but not as input

into the process, as long as not counted under (O8)

• Organic released in other ways (O9)

These inputs and outputs can be seen in Figure 3.




Figure 3 Solvent mass balance framework

(Source: EPA July 2003, Best Practice guide produced by the Environmental Protection Agency draft

date 17th

July 2003 www.epa.ie)

2.1 Determination of the different Inputs and Outputs:

The information that is available at the site and from the limited monitoring carried

out suggests that the following equation is the most suitable to determine the fugitive

emission value for the site:

F = I1 – O1 – O5 – O6 – O7 – O8

It is therefore proposed that this equation be used for the assessment.

The different parameters of this equation will be calculated as TOC as C and for the

same period to be comparable.

I1: The quantity of solvent purchased during the given period:

I1 = Opening Stock + Purchases during the period – Closing Stock The TOC as C contribution of the solvent-based products will be calculated with

reference to the Material Safety Data Sheets (MSDSs) sheets for each of the

individual substances and the molecular formula of the constituents.

O1: Emissions in waste gases:

The emissions in wastes gases will be calculated using the results of air monitoring.

The concentration of TOC as C obtained from this monitoring will be multiplied by

the working hours of the printers for the studied period.

O5: Organic solvents lost due to chemical or physical reactions:




In this specific process, the O5 quantity represents the amount of solvent which is

destroyed in the thermal oxidiser (A2-3) and in the M600 afterburner (A2-4). For each

point, the O5 value can be calculated as follows:

1

1

5..1

OndestructioofEfficiency

OO −

−

=

The O1 figure is not available for the thermal oxidiser A2-3 and thus the

corresponding O5 value cannot be calculated.

This calculation was done for the M600 printer (A2-4). A conservative figure of 90%

is assumed for the efficiency of the afterburner in the M600 printer as this was

unavailable from the technical specification. Most regenerative thermal

oxidisers/afterburners have a destruction efficiency of 95% and thus the 90% figure

can be considered conservative. The actual efficiency of the afterburner will be

available once the test programme is carried out.

O6: Organic solvents contained in collected waste:

• Waste solvent: From the information available from the company, there is no

waste solvent generated at the site.

• Solvent residues on empty containers: From the information available from the

company, the empty containers are sent back to the supplier for refill.

According to 40 CFR 261.7, a container holding non-acute hazardous waste

can be considered as empty if:

o all wastes have been removed using practices commonly employed

industry-wide to remove wastes from containers or liners, such as

pouring, pumping, aspirating, and draining (§261.7(b)(1)(i)), and

o no more than 2.5 centimeters (1 inch) of material remains in the

container or liner (§261.7(b)(1)(ii)), or

o no more than 3 percent by weight of the container remains for

containers with a capacity of 110 gallons or less, and no more than 0.3

percent by weight remains for containers with a capacity greater than

110 gallons (§261.7(b)(1)(iii)).

• Solvent residues on cleaning rags: No information was available on the

quantities of cleaning rags that were disposed.

O7: Organic solvents or organic solvents contained in preparations which are sold or

are intended to be sold as a commercially valuable product: Some part of the oils (5 -

15% estimated) is absorbed by the paper and/or remains in the dried up ink film.

(Source: Boylan Print Ltd suppliers)

O8: Organic solvents contained in preparations recovered for reuse but not as input

into the process, as long as not counted under O7: The company does not recover

solvent on-site.




2.2 Determination of the environmental significance of the fugitive emissions

As suggested in Schedule 6 of the Regulations, the fugitive emission value obtained

following the methodology outlined in Section 2 is expressed as a proportion of the

input, which can be calculated according to the following equation:

I = I1 + I2

With

• I1: The quantity of organic solvents or their quantity in preparation purchased

which are used as inputs into the process in the time frame over which the

mass balance is being calculated

• I2: The quantity of organic solvents or their quantity in preparations recovered

and reused as solvent input into the processes.

Determination of the environmental significance of the fugitive emissions at the site:

The obtained figure will then be compared to the fugitive emission value threshold set

out in Schedule 2 of the same Regulations. For the activity carried out at Boylan Print

Ltd, the maximum value for the fugitive emissions is 30%.

3 Calculations

3.1 Determination of I1

The quantities of solvent-based products purchased in 2009 were reviewed in order to

calculate the solvent input to the process. All the available MSDSs for the organic

solvent were also reviewed so that the quantities could be expressed in TOC as C. The

TOC as C is expressed based on the information supplied by Boylan Print Ltd. for

2009. The exact quantities for each ink colour were not provided. Instead the total

amount of ink utilised was provided by Boylan Print Ltd. and from this the average

solvent figure was taken for each of the ingredients used to produce the inks. The

summary figures for the calculation of I1 are presented in the following table and the

details of the calculation are provided in Appendix 7.

Total Ink and solvent input into the process

(kg)

98,651

Total Ink and solvent input into the process

(kg of C)

83,230

Total (kg of C) = I1 (kg/yr) 83,230




3.2 Determination of O1

The air emissions for the site were reviewed. The following table summarises these results:

The following are the air monitoring results for Boylan Print Ltd. in 2009. The average TOC as C emission was calculated in kg/hr and multiplied

by the hours of operation of each printer.

A2-3 A2-4*

Period Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4

TOC as

C

concent

ration

2009

(mg/Nm3)

- 6.93 9.15 9.6 - 6.86 10.86 0.46

Air

Flow

(Nm3/h)

- - - - - 6,357 3,664 3,469

TOC as

C

Concen

tration

2009

(kg/h)

- - - - - 0.04 0.04 0.002

Average

emissio

n (kg/h)

- 0.028

Annual

running

hours

1,094 2,031




Note 1

Annual

Emissio

ns

(TOC

as C in

kg/yr)

- 57.5

Total

(kg/yr)

= O1

57.5

Note1: 2,031 running hours for the M600 (A2-4) printer and 1,094 running hours for the M300 printer (A2-3)

*A2-4 is not a licensed emission point


The O5 value was calculated for the M600 printer (A2-4) as follows:

1

1

51

OEfficiency

OO

RTO

−

−

=

5.57%90

5.57

11

1

5 −=−

−

= OEfficiency

OO

RTO

= 517.5 kg/yr





3.4.1 Empty containers The empty containers are sent back to the supplier for refill. As explained in Section

2.1, it is considered that the empty containers still hold:

• 3% of their content when they are empty for the 10L buckets of Unknown Ink

Series, 208L drums of fountain solution.

• 0.3% of their content when they are empty for the 1,025L containers of white

spirits and Series 2000 and 6000 of inks.

TOC as C in Empty 1,025L Containers White spirits Weight of product used (kg) 4,900

Weight of product in empty container(kg) 14.7

TOC as C content of white spirit (%) 0.00017

TOC as C (kg/yr) 0.0025

TOC as C in Empty 208L Drums of Fountain Solution

Weight of product used (kg) 2,700

Weight of product in empty container(kg) 81

TOC as C content of Fountain Solution (%) 0.02

TOC as C (kg/yr) 2

TOC as C in Empty 10L Buckets of unknown series



TOC as C content of inks (%) 35.46

TOC as C (kg/yr) 13

TOC as C in Empty containers of Blanket Wash

Weight of product used (kg) 90




TOC as C in Empty containers of MRC

Weight of product used (kg) 47




TOC as C in Empty 200L Drums of Heatset Fount



TOC as C content of heatset fount (%) 0.1

TOC as C (kg/yr) 24

TOC as C in Empty Containers of series 2000 and 6000 Inks




TOC as C (kg/yr) 233

Total TOC as C Total TOC as C 272.1




3.4.2 Solvent contaminated rags As mentioned in Section 2.1, no information was provided by Boylan Print Ltd. with

regard to the quantity of solvent residues on cleaning rags for 2009. However, this

quantity would be minimal (typically less than 5kg).

3.4.3 Calculation of O6

O6

Solvent residues on empty containers 272

Solvent residues on cleaning rags (kg) Unknown

O6 - TOC as C (kg/yr) 272


As mentioned in Section 2.1, the supplier of the inks has stated that some part of the

oils (5 - 15% estimated) is absorbed by the paper and/or remains in the dried up ink

film. For the purpose of the calculation, the average value of 10% was taken.

Total Ink input into the process (TOC as C

kg) = I1

83,230

O7 - TOC as C (kg/yr) 8,323

3.6 Determination of F

As previously mentioned, the formula used to calculate the fugitive emissions is:

F = I1 – O1 – O5 – O6 – O7 – O8 = I1 – O1 – O6 – O7

F = 83,230 – 57.5 – 517 - 272 -8,323 = 74,060 kg

Fugitive emission value=230,83

060,74

21

=

+ II

F= 88.9% of solvent input

One of the main reasons for this high percentage of fugitive emissions is the air

emissions results, i.e. only three of the four quarters could be monitored during the

calendar year 2009 and flow measurements could not be established at emission point

A2-3 in order to calculate quarterly TOC as C. Further monitoring of the atmospheric

emissions in the future will provide a better insight into the day-to-day atmospheric

emissions from the site once the issue of establishing flow measurements at emission

point A2-3 has been resolved by the licensee.




4 Conclusion

The annual solvent input for the year 2009 was calculated at 73,967kg. The fugitive

emissions represent 88.9% of the solvent input and thus exceed the fugitive emissions

limit value.




Appendix 7 Details of calculation of the quantities of solvent based products put into the process

The quantities of solvent based products were obtained and the MSDSs were then

consulted and the composition of each product was thus available. From the MSDSs,

the proportions of the known volatile organic compounds were taken into account and

their contribution to the total weight of solvent-based products was calculated.




Product Ink Consumption(kg) Ingredients Conc (%) CAS# Avg Conc(%) Consumption(kg)Input as C (kg)Molecular for% C

Premoterm 2000 Black Distillates (Petroleum), hydrotreated light 25-50 64742-47-8 32.5 C10-14 0.857143

Carbon black pigment 25-50 - 0

Butylated Hydroxytoulene 1 128-37-0 1 C15H24O 0.731707

Premoterm 2000 Cyan distillates (petroleum), hydrotreated middle35-50 64742-46-7 42.5 C12-20 0.857143

isotridecanol <25 68526-86-3 12.5 C13H28O 0.78

Premoterm 2000 Magenta Distillates (Petroleum), hydrotreated light 25-50 64742-47-8 32.5 C10-14 0.857143

Butylated Hydroxytoulene 1 128-37-0 1 C15H24O 0.097561

Premoterm 2000 Yellow distillates (petroleum), hydrotreated middle35-50 64742-46-7 42.5 C12-20 0.857143

1-phenanthrenecarboxylic acid,1,2,3,4,4a,9,10,10a-octahydro-1,4a-dimethyl-7-(1-methylethyl)-, [1r-(13 to 7 1740-19-8 5 C20H28O2 0.800000

Kaolin monohydrate 2.5-10 1332-58-7 6.25 C12-20 0.857143

Butylated Hydroxytoulene 1 128-37-0 1 C15H24O 0.731707average composition Distillates (Petroleum), hydrotreated light 16.25 26000 22285.714 C10-14 0.857143

Butylated Hydroxytoulene 0.75 1200 878.04878 C15H24O 0.731707

distillates (petroleum), hydrotreated middle 21.25 34000 29142.857 C12-20 0.857143

isotridecanol 3.125 5000 3900 C13H28O 0.78

1-phenanthrenecarboxylic acid,1,2,3,4,4a,9,10,10a-octahydro-1,4a-dimethyl-7-(1-methylethyl)-, [1r-(11.25 2000 1600 C20H28O2 0.800000

Total Annual (2009) 2000 Ink Series 160,000

Premoterm 6000 Magenta distillates (petroleum), hydrotreated middle20-25 64742-46-7 22.5 C12-20 0.857143

distillates (petroleum), hydrotreated middle10-20 64742-46-7 15 C12-20 0.857143

Premoterm 6000 Cyan distillates (petroleum), hydrotreated middle15-20 64742-46-7 17.5 C12-20 0.857143


isotridecanol <25 68526-86-3 12.5 C13H28O 0.78

Premoterm 6000 Toned Yellow distillates (petroleum), hydrotreated middle25-35 64742-46-7 30 C12-20 0.857143

distillates (petroleum), hydrotreated middle<10 64742-46-7 5 C12-20 0.857143

1-phenanthrenecarboxylic acid,1,2,3,4,4a,9,10,10a-octahydro-1,4a-dimethyl-7-(1-methylethyl)-, [1r-(13-7 1740-19-8 5 C20H28O2 0.8

Premoterm 6000 Black distillates (petroleum), hydrotreated middle20-25 64742-46-7 22.5 C12-20 0.857143


Premoterm 6000 Yellow distillates (petroleum), hydrotreated middle25-35 64742-46-7 30 C12-20 0.857143

distillates (petroleum), hydrotreated middle<10 64742-46-7 5 C12-20 0.857143

1-phenanthrenecarboxylic acid,1,2,3,4,4a,9,10,10a-octahydro-1,4a-dimethyl-7-(1-methylethyl)-, [1r-(13-7 1740-19-8 5 C21H30O2 0.802548average composition distillates (petroleum), hydrotreated middle20-25 9 5310 4551.4286 C12-20 0.857143

distillates (petroleum), hydrotreated middle10-20 9 5310 4551.4286 C12-20 0.857143

distillates (petroleum), hydrotreated middle15-20 3.5 2065 1770 C12-20 0.857143

isotridecanol <25 2.5 1475 1150.5 C13H28O 0.78

distillates (petroleum), hydrotreated middle25-35 12 7080 6068.5714 C12-20 0.857143

distillates (petroleum), hydrotreated middle<10 2 1180 1011.4286 C12-20 0.857143

1-phenanthrenecarboxylic acid,1,2,3,4,4a,9,10,10a-octahydro-1,4a-dimethyl-7-(1-methylethyl)-, [1r-(13-7 2 1180 947.00637 C21H30O2 0.802548

Total Annual (2009) 6000 Ink Series 59,000

22.5 C12-20 0.857143

10kg buckets (unknown series) 1,200 distillates (petroleum), hydrotreated middle20-25 64742-46-7 22.5 270 231.42857 C12-20 0.857143

Total Inks 220,200 92070 78088.412 0.848142

0.3546249

Residues in empty containers 2000 and 6000 Series

Solvent residue kg 657

TOC as C kg 233

Residues in empty containers 10kg buckets

Solvent residue 36

TOC as C 13

Total TOC as C 246




Total White Spirits Consumption (kg) Ingredients Conc (%) CAS# Consumption (kg) Input as C (kg) Molecular formula Total C

4900.012 Low boililng point hydrogen treated naphthanaphtha (petroleum) 90 - 100 64742-82- 4655.0114 3897.218847 C6H14 0.837209

Xylene 1-10% 1330-20-7 220.50054 199.6986023 C6H4(CH3)2 0.90566

4875.51194 4096.917449 0.840305

%TOC as C Total Input0.000171

Product Total Fount Consumption (kg) Ingredients Conc (%) CAS#

Heatset Fount 8,000 2-(2-butoxyethoxy)ethanol 10-20% 112-34-5

mixture of: 5-chloro-2-methyl-4-isothiazolin-3-one [EC no. 247-500-7] and 2-methyl-2H-isothiazol-3-one [EC no. 220-239-6] (3:1)0.0015-0.06 55965-84-9

Total heatset fount

Product Blanket Wash (kg) Ingredients Conc (%) CAS# Consumption (kg) Input as C (kg) Molecular formula Total C

Blanket W ash 90 Propylbenzene 1 to 5 98-82-8 2.7 2.16 C9H12 0.8

Mesitylene 1 to 5 108-67-8 2.7 2.16 C9H12 0.8

Xylene 1 to 5 1330-20-7 2.7 2.445283019 C8H10 0.90566

1,2,4-Trimethylbenzene 10 to 30 95-63-6 18 14.4 C9H12 0.8

Naphtha (Petroleum), Hydroteated Heavy 2 30-60 64742-48-9 40.5 0 0

Solvent Naphtha (Petroleum), Light Aromatic 10 to 30 64742-95-6 18 0 0

Total Blanket Wash 58.5 21.16528302 0.3618

%TOC as C Total Input 0.23517

Product mrc (kg) Ingredients Conc (%) CAS# Consumption (kg) Input as C (kg)

Metal Roller Cleaner and Degreaser 47 Pentane 1 to 5 109-66-0 1.41 1.88

Methylcyclohexane 5 to 10 108-87-2 3.525 3.453061224

Cyclopentane 5 to 10 287-92-3 3.525 4.834285714

Ethanol 10 to 30 64-17-5 9.4 19.6173913

Methanol 0 - 1 67-56-1 0.235 0.3525

Naphtha (Petroleum), Hydroteated Light 1 60-100 64742-49-0 37.6 0

n-Hexane 1 to 5 110-54-3 1.41 1.573953488

Total MRC 39.01 31.71119173

Product Fountain Solution Consumption (kg) Ingredients Conc (%) CAS# Consumption (kg) Input as C (kg) Molecular formula Total C

Fountain Solution 2700 Ethylene glycol n-butyl ether 1 to 5 111-76-2 81 65.89830508 C4H9OCH2CH2OH 0.813559

Ethylene glycol 1 to 5 107-21-1 81 125.4193548 CH2OHCH2OH 1.548387

Total fountain solution 162 191.3176599 1.180973

%TOC as C Total Input 0.070858

Tel: 353 1 276 1428 Fax: 353 1 276 1561 Email:[email protected]

www.enviro-consult.com


Appendix 8: Annual Noise 2009

Table of Contents

1 Introduction ....................................................................................................57

2 Summary.........................................................................................................58

3 Sampling Methodology and Analytical Techniques ......................................59 3.1 Instrumentation Used ................................................................................59

3.1 Report Terminology..................................................................................59

3.2 Meteorological Conditions ........................................................................60

3.3 Measurement Positions .............................................................................60

3.4 Measurement Locations ............................................................................60

4 Noise Survey....................................................................................................62

5 Discussion and Recommendations .................................................................65 5.1 Day time ...................................................................................................65

5.2 Night time.................................................................................................65

Figure 3-1: Site Boundary and Noise Locations........................................................61

Table 3-1: Equipment Used ......................................................................................59

Table 4-1: Environmental Noise Monitoring Results ................................................63

Appendix A: Certificates of Calibration....................................................................66


Environmental Efficiency Page 57 of 67

Document 919-30 v2.00

1 Introduction Environmental Efficiency Consultants Limited (EEC) were commissioned by Boylan

Print Ltd. to carry out an environmental noise monitoring survey of their site as

required under condition 6.12.2 and in Schedule B.4 of their licence to assess sound

pressure levels directly related to the sites activities. Noise monitoring locations were

at those locations laid out in the licence.

This environmental noise survey for day time and night time noise was carried out on

the 02nd

June 2009 in accordance with the EPA Environmental Noise Survey

Guidance Document1.

1 EPA (2006) Guidance Note for Noise in Relation to Scheduled Activities. 2nd Edition




2 Summary • The LAeqt recorded at the four points varied from 54.1dB(A) to 66.1dB(A) for

daytime and from 59.8 to 63.0 for night-time.

• The limits stated in the Licence are as follows:

• For the daytime measurements, the recorded noise levels for NSL1 and NSL2

were compliant with respective values of 54.1 and 54.2 dB(A). N3 and N4 were

found to be above the noise emissions limits with respective values of 64.2 and

66.1 dB(A).

• For the night-time measurements, all the recorded values were above of the noise

emissions limits.

• However, it is important to highlight that sound pressure level readings for each of

the noise monitoring locations, in particular for NSL2 and N3, are partly

attributable to the activities and processes carried on at Hilton Foods.

• Further noise mitigation measures like the removal of the alarm sound from the

gate be considered and the erection of sound proof panelling along the western

boundary of the site.




3 Sampling Methodology and Analytical Techniques

3.1 Instrumentation Used

The following equipment was used during the noise assessment:

Table 3-1: Equipment Used

Equipment Model (Cirrus) Serial No.

Sound Level Meter (SLM) (Type 1),

(with windshield attached)

CR:811B C16569FD

Microphone MK:224 20020028

Calibrator CR:511E 035066

Tripod N/A N/A

The sound level meter was calibrated to 93.7 dB(A) on-site immediately before

measurement and checked on completion of the study. No drift in calibration level

was noted.

The Certificates of Calibration for the SLM and calibrator are provided in Appendix

A.

3.2 Report Terminology

The parameters used to assess the noise are as follows:

Leq (t): is the continuous equivalent sound level over a specified time (t),

where t represented a 15-minute period during this survey. This

measure is used to give an indication of the average noise level over

the specified time period.

L10 and L90: are both statistical noise levels. L10 indicates that for 10% of the

monitoring period, the sound levels were greater than the quoted value.

L90 indicates that for 90% of the monitoring period, the sound levels

were greater than the quoted value. L10 is used to express event noise.

L90 is used to express background noise, usually filtering out loud,

intermittent interferences such as traffic noise.

The following terms may be used to describe the characteristics of the noise:

Continuous: noise produced without interruption.




Intermittent: noise that is punctuated with interruptions e.g. equipment operating in

cycles or events such as single passing vehicle

Impulsive: a noise of short duration (typically less than one second), the sound

pressure of which is significantly higher than the background; brief and

abrupt.

Tonal: noise that contains a clearly audible tone i.e. a distinguishable, discrete

or continuous note (whine, hiss, hum or screech, etc.).

The noise measurements were ‘A’ weighted and the time-weighting ‘Fast’ was

applied (to equate to human ear hearing).

3.3 Meteorological Conditions

Weather conditions during the survey did not affect the readings i.e. conditions were

dry and wind speed was less than 5 m/s (the normal upper limit for taking

measurements). The Sound Level Meter was also fitted with a windshield to minimise

interference from meteorological conditions.

3.4 Measurement Positions

All measurements were taken at:

• 1.2 – 1.5 m height above local ground level

3.5 Measurement Locations

The locations of noise monitoring points are described in the following table and

shown in Figure 3-1. All readings were taken during operating hours when nearby

equipment was being used.




Figure 3-1: Site Boundary and Noise Locations

Hilton Foods

Boylan Print Ltd

NSL1

NSL2

N3

N4

Ordnance Survey Ireland Licence No EN 0044606

© Ordnance Survey Ireland Government of Ireland

Boyne Business Park

Residential




4 Noise Survey

Table 4-1 shows the measurement results for the monitoring locations at the site along

with the description of the various noise sources/events recorded at each location

during the course of the day time and night time noise surveys.




Table 4-1: Environmental Noise Monitoring Results

Time

taken

Noise Result

dB(A)

Location

Ref No

Location

Time

(mins)

LAeq L10 L90

Description of On-site Noise

Sources

Description of Off-site Noise

Interference

Day time

NSL1 Site Entrance (NW site boundary) 11:00 30 54.1 60.9 47.8 o Traffic from the adjacent

road

o Gate opened on 4 occasions.

On each occasion a warning

sound occurred for the

opening of the gate.

o Traffic – from nearby road

o Hilton Foods (neighbouring

site) – fans, coolers and lorry

movement

o Birdsong

o Slight breeze

NSL2 Boundary location (SW site boundary) 11:40 30 54.2 62.0 45.7 o Paper extractor fan o Hilton Foods (as above).

o Traffic on road leading to

Hilton Foods

N3 Boundary Location (SE site boundary) 12:15 30 64.2 65.2 62.7 o Paper extractor fan o Hilton Food (as above)

o Noise from neighbouring

sites.

N4 Boundary Location (NE site boundary) 12:50 30 66.1 66.5 65.3 o Cooling system

o Reversing forklift

o Hilton Foods (as above)




Noise Result

dB(A)

Location

Ref No

Location Time

taken

Time

(mins)

LAeq L10 L90

Description of On-site Noise

Sources

Description of Off-site Noise

Interference

Night time

NSL1 Site Entrance (NW site boundary) 5:45 30 60.4 63.0 48.8 o Traffic from the adjacent

road

o Gate opened on 3 occasion

– which is alarmed (beeps)

on opening

o Traffic – from nearby road

o Hilton Foods (neighbouring

site) – fans and coolers

o Bird song

NSL2 Boundary location (SW site boundary) 6:20 30 59.8 60.3 55.9 o Fan

o Paper extraction

o Continuous and tonal noise

events from fans and coolers.

o Traffic on road leading to

Hilton Foods

o Bird song

N3 Boundary Location (SE site boundary) 6:55 30 63.0 65.8 62.2 o Paper extractor fan

o Factory noise

o Continuous – (Coolers and

fans).

o Bird song

o Hilton Foods

equipment/machinery

(fans/coolers)

N4 Boundary Location (NE site boundary) 7:30 30 61.8 62.8 60.9 o Cooling system

o Factory noise

o Hilton Foods (as above)

o Bird song




5 Discussion and Recommendations

• The LAeqt recorded at the four points for both day and night time varied from

54.1dB (A) to 66.1dB (A).

• The licence states that the noise recorded at boundary locations should not be

higher than 55dB(A) for day time and 45dB(A) for night time.

5.1 Day time

• At points NSL1 and NSL2 the predominant noise sources were attributable to

Hilton Foods. Indeed at NSL1, with the exception of the gate alarm, there was no

audible noise from the Boylan Print site. It should also be noted that the L90

recorded at NSL1 was 47.8 for day time. This is below the limit.

• The major noise sources at N3 were the paper extractor from the Boylan Print site

and the continuous noise (fans and coolers) coming from Hilton Foods.

• The noise from N4 was dominated by the cooling system in place at Boylan Print.

• Table 4-1 predominantly highlights there to be mixed noise sources at each

receptor point.

5.2 Night time

• The results for the noise sensitive locations (NSL1 and NSL2) are above the night

time limit of 45dB(A).

• The sound pressure levels for N3 and N4 are also above the night time limit of

45dB(A).

It should be noted for the purposes of this report that sound pressure level results in

this report are partly attributable to the activities and processes carried on at Hilton

Foods. Further noise mitigation measures like the removal of the alarm from the gate

along with sound proof panelling along the western boundary of the site should be

considered.




Appendix I: Certificates of Calibration




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