Annual Environmental Report for 2009rebonded foam. Annual Environmental Report for 2009. Fronville Ltd. 9 3.1.2 Energy and Water Usage 3.1.2.1 Energy usage Electricity usage: 310,380units

Annual Environmental Report for 2009. Fronville Ltd.

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Annual Environmental Report for 2009

Fronville Ltd.

Licensee No. 59

Kinsale rd.

Cork


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Table of Contents. Page No.

1.0 Introduction 3

1.1 Environmental Policy 3

2.0. Site description. 4

3.0. Data

3.1. Summary Information 5

3.1.1 Emission data 5 3.1.1.1. Emission to Waters/Sewers 5

3.1.1.2 Emissions to Atmosphere. 6

3.1.1.3 Waste Management. 7

3.1.1.4 Noise 9

3.1.2 Energy and Water Usage 9 3.1.2.1 Energy usage 9

3.1.2.2 Water usage 9

3.1.3 Environmental Incidents and Complaints. 10

3.1.4 Spending on Environmental Protection. 11

3.2 Pollution Emission Register. 12

4.0 Environmental Management

4.1 Fronville Ltd. organisational structure for environmental

management 13

4.2 Environmental Management Programme Progress

Report for 2009 14

4.3 Environmental Management Programme 15

4.4 Schedule for 2010 Environmental Management

Programme 25


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1.0 Introduction

Licensee Register Number: 59

Site name and Address: Vita Cortex, (Fronville Ltd.,)

Kinsale Rd.,

Cork

1.1 Environmental Policy

It is the policy of Vita Cortex Ltd:

To use its resources to promote a healthy environment both in and outside its

premises and to comply with all relevant regulations.

To keep emissions to an absolute minimum, and at least within the levels as set by

legislation, during process which emit materials into the atmosphere.

To keep noise levels at the absolute minimum so as to not to cause nuisance to the

local residents.

To dispose of all waste in a suitable manner, to avail of all possible methods in

minimising waste generation and to recycle waste where possible.

To keep housekeeping to the highest possible standard.


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2.0. Site description.

The facility located at Kinsale Rd., Cork manufactures slabstock polyurethane foam.

There are 44 persons employed on-site at Kinsale Rd.

The site is situated in the outskirts of Cork city. Local environmental conditions are

those of a residential area.

Additional activities that occur at the Kinsale Rd. site are block foam conversion into

products such as cushions, mattresses etc. and Polyethylene conversion for the

packaging industry.


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3.0. Data

3.1 Summary Information

3.1.1 Emission data 3.1.1.1. Emission to Waters/Sewers

Period Date pH COD

(mg.lit-1) January 09 N/A N/A N/A February 09 N/A N/A N/A March 09 N/A N/A N/A April 09 27/3/09 5.5 <1 May 09 14/5/09 5.6 <1 June 09 11/6/09 7.3 <1 July 09 14/7/09 5.2 <1 August 09 18/8/09 5.2 <1 September 09 1/9/09 4.8 <1

October 09 22/10/09 5.7 <1 November 09 19/11/09 5.9 <1

December 09 15/12/09 6.3 <1


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3.1.1.2 Emissions to Atmosphere.

PERIOD EMISSION GRADE RUN RUN EMISSION POINT DATE

NO. TIME EF 101 EF 104 EF 107

MINS PPM KG/HR PPM KG/HR PPM KG/HR

Methylene Chloride

Jan-09 M.C. Ascort2 1419 20 150 4.73 600 29.23 1100 53.58 23/1/09

Feb-09 M.C. CM35S 1437 18 50 2.63 250 13.53 600 32.47 13/02/09

Mar-09 M.C. Cm26 1458 20 50 2.356 500 24.35 800 38.97 19/03/09

Apr-09 M.C. Cm24 1471 20 100 4.73 1000 48.71 1500 73.07 15/04/09

May-09 M.C. CM26 1495 16.0 100 5.91 300 18.26 500 30.44 1/05/09

Jun-09 M.C. CM24 1656 18. 100 5.25 800 43.3 1200 64.95 9/06/09

Jul-09 M.C. Cm22H 1667 23. 120 4.93 800 33.88 1300 55.06 2/07/09

Aug-09 M.C. CM22H 1678 17. 150 6.34 700 40.11 1200 66.77 14/08/09

Sep-09 M.C. CM22H 1704 23 100 4.11 500 21.18 1200 50.83 1/10/09

Oct-09 M.C. Cmt24 1564 22 100 4.3 500 22.14 1150 50.92 13/11/09

Nov-09 M.C. Cmt24 1578 27 150 5.25 550 19.84 1200 43.30 12/12/09

Dec-09 M.C. Ascort2 1581 23 100 4.11 500 21.18 1200 50.83 18/12/09

Toluene Di-Isocyanate

1ST Quarter TDI CM26

1585 23 .001 0.000333 .001 0.000333 .001 0.000333 9/01/09

2ND Quarter TDI Cm26 1627 12 .001 0.000333 .001 0.000333 .001 0.000333 8/04/09

3RD Quarter TDI Cm26 1653 25 .001 0.000333 .001 0.000333 .001 0.000333 2/06/09

4TH Quarter TDI Cm26 1720 25 .001 0.000333 .001 0.000333 .001 0.000333 24/11/09

100% compliance was reported for 2009.


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3.1.1.3 Waste Management.

Waste Log

Name of Recycling Company : TED O Donoghue & SONS LTD

MOUNTAINE VIEW HOUSE WATERFALL CORK

Destination: Recycling

Person responsible for disposal of waste: Ted O’Donoghue

Period Number of Loads Tons

January 09 3 9.16 February 09 4 8.50

March 09 6 12.20 April 09 9 14.82 May 09 6 11.20 June 09 5 8.14 July 09 4 7.72

August 09 2 4.42 September 09 2 8.64

October 09 2 6.84 November 09 2 6.74 December 09 4 10.58

Total 108.96

Total waste tonnage sent to landfill:

Tonnes of baled off-cuts sold to rebond manufacturer produced by Fronville

183,268

Tonnes of baled off-cuts sold to rebond manufacturer produced by companies other than Fronville

15,42t

All waste reacted to stable polyurea’s/polyurethane’s

100 %


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Annual waste arising, Non-hazardous waste. Waste

material

EWC

code

Source On site

recovery/reuse/recycling

Off-site disposal

Production

waste

150105 Foam manufacture Reaction to stable

urethane/polyurethane’s

Landfill

Site waste 150105 Factory waste None Landfill

Conversion

waste

150105 Foam off-cuts from

conversion

None Baled and sold for

use in the

manufacture of

rebonded foam.


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3.1.2 Energy and Water Usage 3.1.2.1 Energy usage Electricity usage: 310,380units

Natural Gas: 11960kwh

3.1.2.2. Water usage

All water taken from municipal supply.

Total water consumed for 2009: 517 m3

(Process water is minimal. approx. 30 m3.)


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3.1.3 Environmental Incidents and Complaints.

No environmental incidents occurred during 2009.

No complaints were received during 2009.


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3.1.4 Spending on Environmental Protection.

Capital project costs: Time spent on investigating the use of environment friendly

products made from renewable resources such as Soya bean and Bamboo.

Pilot testing the use of a natural Polyol for bedding and furnisher in 2009

Not applicable as company decided that due to market conditions it would run down

and mothball production plant in 2010 Trials were undertaken but unconclusive.

Testing and analysis:

Total: Euro

Total cost ignores labour hours for equipment installation and compliance procedures,

which would be considerable but difficult to quantify.


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3.2 Pollution Emission Register.

Facility identification:

Facility Name: Fronville Ltd.,

IPC register number: 59

National Grid reference: 16

Reporting period: 01- 2009 to 12- 2009

Production units / amount: Tonnes,

Employee Number: 29

Pollutants summary:

Pollutant

name

Cas No. Input Gross

Usage

Outputs Eco-

Productivity

Indices

Air MOM Liquid

effluent

MOM Waste MOM Product MOM Recovery

Treated Un-

accounted IGEE INEE

Toluene

di-isocyanate

26471-62-5 203.26t 203.26t . 0009 E 0 0 B --- 0 0

Methylene

chloride

75-09-2 13.40t 13.40t 30.5kg B 0 0 0 0 100 100

MOM = Method of measurement

Method Code

Direct measurement M

Other O

Material balance B

Engineering estimates E


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4.3 Environmental Management

4.3 Fronville Ltd. Organisational structure for environmental

management

Tony Owens

Safety/ Quality

Coordinator

Ian Kirby

Managing Director.

Louis Keegan

Unit Business Manager

Patrick O’Reilly.

Block foam

production supervisor

Kay Cornally

Group Chemist


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4.3 Environmental Management Programme Progress Report

Progress on items listed in environmental management programme.

Section Description No. Specified

Date

Comment

4.3.1 Process

Modifications

I Ongoing Investigation

II Ongoing Investigation

III

IV

2007

2008

In progress

Completed

4.3.2 Equipment

Cleaning

procedures

I

II

III

IV

2007

2008

Ongoing investigation

Completed


In progress

4.3.3 Treatment /

Abatement systems

I Cost prohibitive at the moment

4.3.4 Recovery, reuse,

recycling

I In progress

II In progress

III

IV

V

VI

VII

In progress

In progress

In progress

In progress

Ongoing Investigation

4.3.5 Fugitive emissions I 2007 Completed.

4.3.6 Savings in energy

and material

I Ongoing

II Ongoing

III

V

2009

Ongoing

Complete

4.3.7 Employee Training I 2009 On-going

II 2009 On-going

III

IV

V

2009

2007

2009

On going

Completed

In progress

4.3.8 Dichloromethane

emission reduction.

I

II

Refer to 4.3.3

Reduced

On-going investigation

4.3.9 Alternative

foaming agents

I

II

III

2008

2009

Still involves excessive costs.

Ongoing Research

Mothballed

4.3.10 Elimination of

contamination in

surface water

discharge

I

2009 Ongoing


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4.3 ENVIRONMENTAL MANAGEMENT PROGRAMME

4.3.1 PROCESS MODIFICATIONS

The areas identified, where possible yield improvements and waste reductions could be achieved include: (1) Possible reduction in paper waste being generated by recycling of bottom

paper used on conveyor during foam run. (2) Continue to Investigate into the use of side films rather than side papers,

in order to reduce the amount of paper waste from production runs.

(3) Investigate the use of recycled paper for production. (4) Introduction of new closed T65 system used to manufacture Conform foam

grades so as to avoid cross contamination with T80 and improve the yield of foam produced. This has been completed.

(5) Reduced the usage of Methylene Chloride by over 30% from previous

year.

(6) Reduction of TDI by well over 17% from the previous year.

(7) Using water based adhesive , which is more environmentally friendly .

(8) Reduction in the fuel usage in factory site from the previous year.

(9) Currently changing to energy saving tubes and bulbs.

(10) Researching and testing a bio-based polyol from soya bean.


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4.3.2 EQUIPMENT CLEANING PROCEDURES

(I) The use of a heated glycerine “bath” to facilitate the cleaning of

process liquid injector nozzles and holders as opposed to the use of solvent.

(II) Investigation of solvent recovery systems. (III) Installation of steam flushing and ongoing work on this system


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4.3.3 TREATMENT/ABATEMENT SYSTEMS

(I) The possible use of carbon adsorption type scrubber unit for entrapment of Methylene Chloride emissions. However, the expected cost of Euro 500,000 is likely to prove prohibitive to the Company. More investigation is needed. On checking the cost is 500,000 Euro . We reduced the % usage of Methylene Chloride by 30% on the previous year , thus reducing emissions .


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4.3.4 RECOVERY, RE-USE, RECYCLING.

(I) Disposal of steel drums for scrap once all chemicals are

removed. (II) Sale of baled foam scrap for use in manufacture of rebonded foam. (Done) (III) Switch to IBC’s from drums. (Done) (IV) Black paste drums to be lined with plastic (V) Recycling of scrap PU foam from outside the company. (VI) Use of less paste in foam manufacture (VII) Investigation of further uses of reconstituted foam offcuts and

have increased the sales quantity in the off-cut .

(VIII) Only recycled cardboard is being purchased for the packaging of products .

(IX) Recycling of polyethylene plastic used in wrapping foam

products , which is granulated to produce plank and plastic parts .


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4.3.5 FUGITIVE EMISSIONS: IDENTIFICATION, QUANTIFICATION AND

REDUCTION. (I)


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4.3.6 SAVINGS IN ENERGY AND MATERIAL

(I) Use of higher efficiency lighting. (II) Fixing of all compressed air leaks. (III) Fitting of PVC doors at various locations throughout the factory

(IV) Fuel bill reduced by significant amounts

(V) Reduction of one truck from the transport system (Done)


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4.3.7 EMPLOYEE TRAINING

1. Ongoing of process operator training. 2. Process safety training. 3. Chemicals handling and use training. 4. Employees being made aware of the importance of energy

conservation on site.


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4.3.8 (M.C.) DICHLOROMETHANE EMISSION REDUCTION

(I) See 4.3.3 for treatment and abatement. (II) Use of alternative flushing and cleaning agent. (III) Investigation of alternative blowing agents is ongoing


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4.3.9 ALTERNATIVE FOAMING AGENTS.

(I) The possible use of liquid CO2 as an auxiliary blowing agent. This process still involves excessive cost but is being studied by the company to keep abreast of developments with a view to possible adoption if the economics were to change in it’s favour. The following action has been initiated and will be continued:

Review of competitive systems on offer.

Correspondence with British Vita.

Visit from Dow technical person

Information from Shell chemicals for new blowing agents .

Meeting with the PU association and correspondence on new blowing agents on the market.

File set up and meetings


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4.3.10 Elimination of contamination in surface water discharge.

I. Housekeeping


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4.4 Environmental Management Programme for 2011 schedule

Schedule for items listed in environmental management programme for 2010.

Section Description No. Scheduled Date 4.3.1 Process Modifications 1 Ongoing investigation

11

III


2008

4.3.2 Equipment Cleaning

procedures

I

III

IV


2008

In progress

4.3.3 Treatment / Abatement

systems

1 Cost prohibitive at the moment

4.3.4 Recovery, reuse,

recycling

1 In progress

11

III

IV

VI

VII

In progress

In progress

In progress

In progress


4.3.5 Fugitive emissions

4.3.6 Savings in energy and

material

I In progress

II

III

V

In progress

In progress

Completed

4.3.7 Employee Training I On-going

II On-going

III

IV

V

2008

2007

In progress

4.3.8 Dichloromethane

emission reduction.

I See 4.3.3

II on-going investigation

4.3.9 Alternative foaming

agents

I

II

III

Still involves excessive costs

On going investigation


4.3.10 El elimination of

contamination in

surface water

I

On-going

Documents

Annual Environmental Report for 2009rebonded foam. Annual Environmental Report for 2009. Fronville Ltd. 9 3.1.2 Energy and Water Usage 3.1.2.1 Energy usage Electricity usage: 310,380units