Molex Ireland Limited Annual Environmental Report 2010
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MOLEX IRELAND LTD
IPPC LICENCE NO. P0288-02
1.1 ANNUAL ENVIRONMENTAL REPORT 2010
1 MARCH 2011
Molex Ireland Limited Annual Environmental Report 2010
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CONTENTS
1 INTRODUCTION 4
1.1 Employment 4
2 ENVIRONMENTAL DATA SUMMARY INFORMATION 6
2.1 Emissions to Surface Water 6
2.2 Emissions to Sewer 9
2.3 Emissions to Atmosphere 11
2.4 Waste Management 13
2.5 Noise 24
2.6 Energy and Water Consumption 25
2.7 Agency Monitoring and Enforcement 26
2.8 Environmental Incidents and Complaints 28
2.9 AER 2010 Returns Excel Worksheets 28
3 ENVIRONMENTAL MANAGEMENT OF THE ACTIVITY 29
3.1 Environmental Management System – ISO 14001 29
3.2 EMP 2007 Report and Schedule of Objectives and Targets 2010 29 3.3 Pollution Emission Register (PER) 32
4 OTHER REPORTS 33
4.1 Bund Integrity Assessment 33
4.2 Firewater Retention Study. 33
4.3 Environmental Liabilities 33
4.4 Intrusive Hydrogeological Investigation. 33
4.5 CCTV Study. 34
5 SOLVENT USAGE 34
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APPENDIX A
Environmental Policy
APPENDIX B
Reports on Emissions to Atmosphere 2010
APPENDIX C
Pollution Emissions Register Report 2010
APPENDIX D
PRTR 2010 Returns Excel Worksheets
APPENDIX E
Bund Integregity Report 2010
APPENDIX F
Executive Summary of Fire Water Retention Study 2010
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1 INTRODUCTION Licensee: Molex Ireland Limited
Location of Activity: Shannon Industrial Estate, Co. Clare
Licence Register Number: P0288-02
Molex Ireland Limited is based in Shannon Industrial Estate at National Grid Reference E 1397 N 1622, near the town of Shannon. Molex manufactures a variety of electrical and electronic interconnecting devices for the Industrial Market. The facility is involved in the stamping, electroplating of metal connectors and moulding of plastic into housings and the assembly of these parts.
Molex Ireland Limited was granted an Integrated Pollution Control Licence (IPC) on 26th February 1998. This licence was subsequently upgraded to an IPPC Licence on 29th April 2006. One of the requirements of this licence is to prepare an Annual Environmental Report for submission to the Environmental Protection Agency (EPA). This report, in compliance with Condition 2.2.1 of the licence, details environmental performance at the site for the period January to December 2010. This report has been prepared in accordance with the EPA Guidance Note for Annual Environmental Reports, 2000.
Condition 2.2 of Molex’s IPPC Licence requires the licensee to establish and maintain an Environmental Management System (EMS). Molex have established the elements of an EMS as relevant to the conditions of the IPPC Licence and the ISO 14001 Environmental Management System Standard and were awarded ISO 14001 Accreditation in September of 2000.
An Environmental Policy has been prepared and is located at the employee entrance within the company. The Environmental Policy is also displayed within the Molex Ireland website. A copy has been included as Appendix A.
In accordance with Condition 6.5 of the IPPC Licence, Molex can confirm that there was no significant change in solvent usage (i.e. no solvents on site) or work practices on site during 2010.
There was one environmental incident during 2010 and this was brought to the attention of the Agency in accordance with licence conditions and is dealt with in the report.
The Shannon Site experienced a significant change in the product portfolio during 2010 which resulted in five plating lines becoming excess to the business needs and these lines were sold to a German Company specialising in plating, which has resulted in a downsizing of plating operations and the elimination of copper and pure tin (Culmo) plating processes.
1.1 Employment There are currently 300 persons employed by Molex Ireland Limited (Shannon). The factory is a significant employer in the Shannon region. Figure 1.2 outlines Molex’s organisation for Environmental Management on-site.
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Figure 1.2: Staff Organizational Chart
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2 ENVIRONMENTAL DATA SUMMARY INFORMATION
2.1 Emissions to Surface Water A surface water run-off sampling system is in place at Molex Ireland Limited. It allows for the collection of surface water runoff which is ultimately discharged to the estuary.
The surface water sampling points are inspected on a daily basis, sampled and analysed for pH and conductivity in accordance with Schedule C.2.3 of the IPPC Licence.
On a quarterly basis the sample is also analysed for COD, tin, cadmium, arsenic, copper, nickel, lead, zinc, cobalt and iron.
2.1.1 Summary Information For the purposes of this section, an average value for the pH and conductivity results obtained over each month during 2010 is provided.
Note: There are two Surface Water Sampling Points; results shown are the averaged for the two sampling points.
Table 2.1: Emissions to Surface Water: pH and Conductivity
Month 2010
SWSP1 SWSP2
pH Conductivity (µµµµS)
pH Conductivity (µµµµS)
January 7.24 242 7.38 371
February 7.25 190 7.25 282
March 7.28 137 7.29 150
April 7.03 130 7.33 219
May 6.79 154 7.16 199
June 6.88 150 7.26 185
July 7.2 148 7.27 252
August 7.07 248 7.27 171
September 7.39 210 7.52 191
October 8.43 955 7.34 310
November 8.42 310 7.72 356
December 7.48 539 8.71 1,690
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Table 2.2.1: Emissions to Surface Water: COD and Heavy Metals at location SWSP1
Parameter
Date
20-Jan-10 07-May-10 20-July -10 13-Oct -10
COD (mg/L) 15 50 13 201
Tin (µg/L) 2.9 6.3 ND 15.6
Cadmium (µg/L)
ND ND ND 0.06
Arsenic (µg/L) 0.3 0.3 0.2 5.3
Copper (µg/L) 19.2 82.5 10.3 219.8
Nickel (µg/L) 36.5 56.6 10.7 87.5
Lead (µg/L) 1.5 2.1 ND 6.4
Zinc (µg/L) 17.3 24.6 6.1 33.2
Cobalt (µg/L) 0.3 0.9 0.2 2
Iron (µg/L) 47.9 135.7 17.1 135.4
Table 2.2.2: Emissions to Surface Water: COD and Heavy Metals at location SWSP2
Parameter
Date
20-Jan-10 07-May-10 20-July -10 13-Oct -10
COD (mg/L) 17 60 13 36
Tin (µg/L) ND ND ND ND
Cadmium (µg/L)
ND ND ND ND
Arsenic (µg/L) 0.3 ND ND 0.3
Copper (µg/L) 7.5 ND 1.4 1.7
Nickel (µg/L) 3.5 0.8 4.1 5.2
Lead (µg/L) 0.3 ND ND 0.3
Zinc (µg/L) 22.4 8.8 22.2 11.1
Cobalt (µg/L) 0.3 0.1 1 1.3
Iron (µg/L) 101.5 328.6 1,431 2,329
2.1.2 Details of Non Compliance There were no non compliances with respect to emissions to surface water from January to December 2010, however high levels of conductivity were measured in SWSP1 during the October to December especially following dry spell periods. The cause of this was the fact that the water chillier units 1 & 2 were emitting a water spray which was high in salt (sodium chloride) which was being used as a water softener. This practice has been discontinued and has now been substituted with reverse osmosis water.
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High levels of conductivity were measured on SWSP2 during December and this was attributable to the gritting of the local roads during the cold winter period.
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2.2 Emissions to Sewer Effluent is discharged from reference point SE1 following treatment in the on-site wastewater treatment plant. Flow, temperature and pH are recorded continuously in accordance with Licence requirements. A daily composite sample is analysed for a variety of parameters. The sample is analysed weekly for sulphates, tin, copper, nickel, iron and total heavy metals. The remaining parameters; COD, BOD, suspended solids, nitrates, sulphide, chlorides, total phosphorus, total nitrogen, detergents, oils/fats/grease, cadmium, arsenic, lead, zinc, cobalt and organohalogens are analysed on a quarterly basis. All parameters are monitored in accordance with the requirements of the IPPC Licence.
On the 10th of October 2006, Molex forwarded a request to the EPA including justifications as to why the monitoring frequency of the following parameters should be reduced:
Parameter IPPC Monitoring Requested Frequency Frequency Change
Sulphates Daily Weekly
Sulphide Monthly Quarterly
Cadmium Monthly Quarterly
Arsenic Monthly Quarterly
Lead Weekly Quarterly
Zinc Weekly Quarterly
Cobalt Monthly Quarterly
The EPA subsequently granted permission to Molex on the 13th of June 2007 (EPA Ref. P0288-02/gc 03ld.doc) to reduce the monitoring frequency in accordance with Molex’s request.
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2.2.1 Summary Information
Table 2.3: Total Emissions to Sewer (Ref. Point SE1) 2008 - 2010
Parameter Mass Emissions (kg)
(01.08 – 12.08)
Mass Emissions (kg)
(01.09 – 12.09)
Mass Emissions (kg)
(01.10 – 12.10)
% COMPLIANCE
Sulphate 10,484 6,978 5,565 100
Sulphide 0.009 ND 0.03 100
Tin 1.885 1.069 0.975 100
Cadmium ND ND ND 100
Arsenic ND ND 0.011 100
Copper 0.639 0.129 0.279 100
Nickel 2.566 1.787 1.710 100
Lead 0.069 ND 0.003 100
Zinc 0.017 ND 0.044 100
Cobalt ND 0.00798 0.024 100
Iron 1.337 0.613 1.575 100
COD 258.1 350.7 279.1 100
BOD 587.3 36.9 240.3 100
Suspended Solids
124.7 53.6 173.3 100
Detergents 0.115 0.50031 1 100
Chloride 3,633 3,007 1,950 100
Fat/Oil/Grease ND 8.631 ND 100
Total Nitrogen 151.8 121 62 100
Nitrates 5 4.9392 2.2 100
Total Phosphorus 7.816 0.9245 0.495 100
Organohalogens ND 0.0214 ND 100
Volatile Organic Compounds
0.048 100
2.2.2 Details of Non Compliance. During the period January-December 2010, there was no exceedance of the discharge limits
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2.3 Emissions to Atmosphere Monitoring and analysis of emissions from Vents A3-3 & A3-4 in the electroplating department was carried out in May and October 2010 as required by Schedule C.1.2 of the IPPC Licence. Schedule C.1.2 requires Molex to analyse for TA Luft Inorganic Particulate Matter Class II & Class III, and TA Luft Inorganics Class II & III twice a year, and for ammonia monthly.
As part of Molex’s effort to introduce cleaner technologies on-site, during February 2006 Molex removed ammonia from the electroplating processes resulting in negligible ammonia emissions to atmosphere. As a result Molex wrote to the EPA in June 2006 requesting that the monitoring frequency for Ammonia as per Schedule C.1.2 be reduced from Monthly to biannually, the EPA subsequently granted this request.
Two atmospheric emission points, A3-3 & A3-4 were sampled, both of which extract from the plating lines. Each vent was assessed for the following substances:
• trace metals
• chloride as HCl
• sulphate as H2SO4
• cyanide as CN-
• ammonia as NH3
Monitoring was carried out whilst all the plating lines were running. Sampling was undertaken over 1 hour sampling intervals. Table 2.4 below summarises the mass emissions to the atmosphere for 2010.
2.3.1 Summary of Results The following tables summarise the results obtained from the monitoring and analysis of emissions from the plating department. Detailed copies of the 2 Atmospheric Emissions Surveys in 2010 are included as Appendix B.
2.3.2 Details of Non Compliances 2009 - 2010. During the September 2009 analysis of the volume flow from Emission Point Ref A3-4 a flow of 10,326 Nm3/hour was recorded. The Agency was made aware of this and Molex fitted an inverter to regulate the fan motor to ensure compliance with the emission volume set in the licence. The installation of this inverter has resulted in a stable compliant volume flow from this emission point during 2010.
During the October 2010 analysis the level of 15.4 mg/Nm3 hydrocyanic acid was detected from Emission Point Ref A3-4, the Agency was informed of this incident.
This level appears to be well out of character with the levels to be expected from the plating process. Molex therefore will investigate this further, which will involve a number of studies to establish what level of hydrocyanic acid is typically generated from the plating process. The published literature does not reference the generation of hydrocyanic acid as part of the electrolytic process. Therefore airing on the side of caution, Molex calculated the total hydrocyanic acid generated from the site, the calculations used in this report are based on the total equivalent hydrocyanic acid purchased during the year.
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Table 2.4: Mass Emissions to Atmosphere 201 0*
Parameter
Mass Emissions (kg/yr) 1
Vent A3-3 Vent A3-4
Cobalt ND ND
Copper ND ND
Nickel ND ND
Lead ND ND
Tin ND ND
HCl 0.8 1.55
Ammonia 1.44 ND
Hydrogen Cyanide
3.33 156.67
2.3.3 Trend Analysis Results for scheduled emission point, Vent A3-3 for 2009 and 2010 are compared in Table 2.5 below.
Table 2.5: Comparison of Mass Emissions to Atmosphere from Vents A3-3 and A3-4: 2009 and 2010
Parameter Mass Emissions (kg/yr) for vent A3-3
Mass Emissions (kg/yr) for vent A3-4
2009 2010 2009 2010
Cyanide 28.49 3.33 51.07 156.67
Cobalt ND ND ND ND
Copper ND ND ND ND
Lead ND ND ND ND
Nickel ND ND ND ND
HCl ND 0.8 ND 1.47
Tin ND ND ND ND
Ammonia ND 1.44 ND ND
. 1 The annualised figures are based on a 80 hour week, 48 weeks year (3,840 hours).
* Results used are averaged between the biannual emissions to air monitoring.
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2.4 Waste Management Tables 2.7 and 2.8 overleaf have been completed for Molex Ireland, in accordance with the Guidance Note for the Annual Environmental Report, for the period January to December 2010.
2.4.1 Waste Analysis Two hydroxide sludge loads were collected and removed off-site during 2010. Table 2.6 below summarises the analytical results obtained from a set of samples taken from each waste load.
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Table 2.6: Hydroxide Sludge Analysis 2010
Parameter
(ppm) or %
18/05/10 16/09/10
Aluminium 4.043 2.03
Antimony 0 0
Arsenic 18 6
Barium 136 129
Beryllium 1 1
Bismuth 0 0
Lead 0.01 0.01%
Cadmium 0 0
Calcium 89,900 107,600
Chloride 0.07% 0.22%
Chromium +6 N.D ND
Chromium 0.01% 0.01%
Cobalt 0.00% 0.00%
Hydrogen Cyanide NP NP
Cyanide CN ND ND
Fluoride 0.13% 0.07%
Iron 12.32% 13.65%
Copper 0.20% 0.08%
Magnesium 3.151 3.226
Manganese 437 430
Nickel 1.02% 0.58%
Mercury 0 0.0
Selenium 0 0.0
Silver 299 2,010.9
Sulfur 1.37% 1.11%
Thallium 31 0
Tin 3.44% 4.25%
Zinc 0.03% 0.04%
Gold 345.1 330.5
Platinum 0.4 0.0
Palladium 137.9 173.8
Solid Content 48.7% 46.0%
Tonnage (T) 10.760T 9.870T
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Table 2.7: Non Hazardous Waste Arising for 2010
Description of Waste
EWC Code
Tonnage Waste Haulier Waste Contractor
Waste / IPC/Permit Licence No.’s
Final destination Contact Person/ Tel no./email
& Recovery / Disposal Code
Waste metal from
machinery
16 01 17 3.025 Hegarty Metal Recycling
Ballysimon, Tipperary Road,
Limerick
Hegarty Metal Recycling
Ballysimon, Tipperary Road,
Limerick
Waste Permit: WP05-04
Recycling of metals R4
Michael Bergin 061 401743
Non ferrous metal filings and turnings
12 01 03 0.484 Hegarty Metal Recycling
Hegarty Metal Recycling
Waste Permit: WP05-04
Recycled R4
Michael Bergin 061 401743
Metal not otherwise specified
12 01 99 22.908 Hegarty Metal Recycling
Hegarty Metal Recycling
Waste Permit: WP05-04
Recycled R4
Michael Bergin 061 401743
Copper, bronze, &
brass
17 04 01 31.611 Hegarty Metal Recycling
Hegarty Metal Recycling
Waste Permit: WP05-04
Recycled R4
Michael Bergin 061 401743
Iron and steel 17 04 05 5.02 Hegarty Metal Recycling
Hegarty Metal Recycling
Waste Permit: WPO5-04
Recycled R4
Michael Bergin 061 401743
Cardboard and paper
20 01 01 92.812 Veolia/Greenstar Ballykeefe Dock Road,
Limerick
Waste Licence W0082-02
Recycled R3 Trina Buckley 021-4328031
Mixed Packaging
15 01 06 1 Veolia/Greenstar Ballykeefe Dock Road,
Limerick
Waste Licence W0082-02
Recycled R3 Trina Buckley 021-4328031
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Timber 20 01 38 78.2 Veolia/Greenstar Ballykeefe Dock Road,
Limerick
Waste Licence W0082-02
Production of fuel R1 Trina Buckley 021-4328031
Compost 20 02 01 2.84 Veolia/Greenstar Ballykeefe Dock Road,
Limerick
Waste Licence W0082-02
R3 Organic substance recycling/reclamation
Trina Buckley 021-4328031
Plastic Waste 20 01 39 99.9 Veolia/Greenstar Ballykeefe Dock Road,
Limerick
Waste Licence W0082-02
Recycled R3 Trina Buckley 021-4328031
Mixed Municipal
waste (General Waste)
20 03 01 259.16 Veolia/Greenstar Ballykeefe Dock Road,
Limerick
Waste Licence W0082-02
Landfill D1 Trina Buckley 021-4328031
Soil and stones
(Rubble)
20 02 02 20.54 Veolia/Greenstar Ballykeefe Dock Road,
Limerick
Waste Licence W0082-02
Recycled R5 Trina Buckley 021-4328031
C & D Waste 17 01 07 7.56 Veolia/Greenstar Ballykeefe Dock Road,
Limerick
Waste Licence W0082-02
Recycled R5 Trina Buckley 021-4328031
Waste canteen oil
20.01.25 1.16 Frylite Frylite, Kilcolgan,
Co. Galway
Waste Permit: WR-77 (Galway)
LN/08/01 (Tyrone)
Oil re-refining or other re-uses of oil
R9
Sally O Kane 028-7138 3133 (ext 236)
Mixed LDPE Film
15.01.02 2.01 Danelle Danelle, Kilnock, Ballon,
Co. Carlow
Waste Permit: WP01/08
R3
Kay Fennelly +35359 9159680
Hard plastic 15.01.02 6.3 Danelle Danelle, Kilnock, Ballon
Co. Carlow
Waste Permit: WP01/08
R3
Kay Fennelly +35359 9159680
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Clear LDPE Plastic
15.01.02 0.5 Danelle Danelle, Kilnock, Ballon
Co. Carlow
Waste Permit: WP01/08
R3
Kay Fennelly +35359 9159680
Scrap Assembly
product with precious
metal
20 01 40 44.93
Veolia Mastermelt Refining Services
BL 1312, Recovered R4 Refined
Jeni Alcock +44(0) 1298 766900
Sanitary Waste
180104 0.898 Cannon Hygiene, Unit 2 Richmond Ind. Est., 8 North Richmond St
Dublin 1.
Cannon Hygiene, Unit 2 Richmond Ind. Est., 8 North Richmond St
Dublin 1.
Waste Permit WFP-LKC-09-001-01
D15/D1 Storage/Landfill
Linda Murphy 00353 (0)1 7047700
PU 552 FL/10 Natural resin
160509 0.292 Enva Ireland Ltd.
Enva Ireland Ltd.,
Smithstown Industrial Estate,
Shannon, Co. Clare
Waste License
W0041-01
R1-Lindenschmidt, Germany
Ann Marie O'Connell
061-707400
Total Recycled
421.09
Total Disposed (Landfill)
260.058
Total 681.15
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Table 2.8: Hazardous Waste Arising for 2010
Description of Waste
EWC Code
Tonnage Consignment Note No.
Waste Haulier Waste Contractor Waste / IPC/Permit License No.’s
Final destination & Disposal / Recovery Code
Contact Person/Tel no.
Cleaner Filters
150202* 0.192
B576304
B593113
Enva Ireland Ltd.
Enva Ireland Ltd., Smithstown Industrial Estate, Shannon, Co.
Clare
Waste License W0041-01 Waste Collection Permit: WCP-DC-08-116-
01
R1-Lindenschmidt, Germany
Ann Marie O'Connell
061-707400
Copper plating solution
110205* 1.2 B576304
Enva Ireland Ltd.
Enva Ireland Ltd., Smithstown Industrial Estate, Shannon, Co.
Clare
Waste License W0041-01 Waste Collection Permit: WCP-DC-08-116-
01
D9- Enva Shannon Ann Marie O'Connell
061-707400
Gloves/white suits
contaminated with plating
chemicals
150202*
0.463 B576304
B593113
Enva Ireland Ltd.
Enva Ireland Ltd., Smithstown Industrial Estate, Shannon, Co.
Clare
Waste License W0041-01 Waste Collection Permit: WCP-DC-08-116-
01
R1-Lindenschmidt, Germany
Ann Marie O'Connell
061-707400
Tin plating solution
(methane sulphonic
acid)
060405* 1
B576304 Enva Ireland Ltd.
Enva Ireland Ltd., Smithstown Industrial Estate, Shannon, Co.
Clare
Waste License W0041-01 Waste Collection Permit: WCP-DC-08-116-
01
D9- Enva Shannon Ann Marie O'Connell
061-707400
Tin plating solution
(sulphate & 10%
sulphuric acid)
060405* 1.2
B576304 Enva Ireland Ltd.
Enva Ireland Ltd., Smithstown Industrial Estate, Shannon, Co.
Clare
Waste License W0041-01 Waste Collection Permit: WCP-DC-08-116-
01
D9- Enva Shannon Ann Marie O'Connell
061-707400
Anti-tarnish (UN-3244)
110198* 3.446 B593113 Enva Ireland Ltd.
Enva Ireland Ltd., Smithstown Industrial Estate, Shannon, Co.
Clare
Waste License W0041-01 Waste Collection Permit: WCP-DC-08-116-
01
R1-Lindenschmidt, Germany
Ann Marie O'Connell
061-707400
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Nickel Filters 150202* 0.078 B593113 Enva Ireland Ltd.
Enva Ireland Ltd., Smithstown Industrial Estate, Shannon, Co.
Clare
Waste License W0041-01 Waste Collection Permit: WCP-DC-08-116-
01
R4-Lindenschmidt, Germany
Ann Marie O'Connell
061-707400
Nickel Solution
060405* 0.412 B593113 Enva Ireland Ltd.
Enva Ireland Ltd., Smithstown Industrial Estate, Shannon, Co.
Clare
Waste License W0041-01 Waste Collection Permit: WCP-DC-08-116-
01
R4-Lindenschmidt, Germany
Ann Marie O'Connell
061-707400
Tin filters 150202* 0.104 B593113 Enva Ireland Ltd.
Enva Ireland Ltd., Smithstown Industrial Estate, Shannon, Co.
Clare
Waste License W0041-01 Waste Collection Permit: WCP-DC-08-116-
01
R1-Lindenschmidt, Germany
Ann Marie O'Connell
061-707400
Tin Solution 060204* 1.0 B593113 Enva Ireland Ltd.
Enva Ireland Ltd., Smithstown Industrial Estate, Shannon, Co.
Clare
Waste License W0041-01 Waste Collection Permit: WCP-DC-08-116-
01
D9 Enva Shannon Ann Marie O'Connell
061-707400
Wevo Hardener
300M
160508* 0.069 B593113 Enva Ireland Ltd.
Enva Ireland Ltd., Smithstown Industrial Estate, Shannon, Co.
Clare
Waste License W0041-01 Waste Collection Permit: WCP-DC-08-116-
01
R1-Lindenschmidt, Germany
Ann Marie O'Connell
061-707400
Aerosols 160504* 0.06 B592099 Enva Ireland Ltd.
Enva Ireland Ltd. Portlaoise Clonminam
Industrial Estate Co. Laois
Waste License W0184-01
Waste Collection Permit: WCP-DC-
08-116-01
R4 SBH Germany Annemarieke Van Der
Voort 057-8678600
Waste Oil
130208* 9.7 N/A Enva Ireland Ltd
Enva Ireland Ltd. Portlaoise Clonminam
Industrial Estate Co. Laois
Waste License W0184-01
Waste Collection Permit: WCP-DC-
08-116-01
R9 Enva Portlaoise Annemarieke Van Der
Voort 057-8678600
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Dry waste
contaminated with
Hydrocarbons
150202*
4.425
B576571
Enva Ireland
Ltd
Enva Ireland Ltd.
Portlaoise Clonminam Industrial Estate Co. Laois
Waste License
W0184-01 Waste Collection Permit: WCP-DC-
08-116-01
D10 KWA Germany
Annemarieke
Van Der Voort
057-8678600
Fluorescent tubes WEEE
200121*
0.145
B575843 Irish Lamp Recycling Ltd
Irish Lamp Recycling Co. Ltd, Kilkenny Road, Athy,
Co. Kildare
WFP-KE-08-348-01
Recycled R4/R5
Jim Cuddy 059-8631377
Hydroxide sludge
from effluent treatment of plating shop
110109*
18.76
B587204 B592018
Veolia World Resources Company GmbH, D-04808
Wurzen, IndustriesstraBe7,
Germany
SL83A0032 Metal Reclamation D15 & R4
Steve Waite +
441926431444
Waste cloths & filters with
Gold potassium cyanide
110198*
0.0905 0.0945
B576098 B592028
Veolia TES Technical Solutions, Ireland Ltd
Mastermelt Refining Services Ltd
BL 1312 Metal reclaim R4
Jeni Alcock +44(0) 1298
766900
Waste Gold Potassium
cyanide
110198* 2.839 0.7065 0.913
B576098 B592007 B592028
Veolia TES Technical Solutions, Ireland Ltd
Mastermelt Refining Services Ltd
BL 1312 Metal reclaim R4
Jeni Alcock +44(0) 1298
766900
Waste Silver Potassium
110198*
0.8995
B592007
Veolia TES Technical
Mastermelt Refining Services Ltd
BL 1312
Metal reclaim R4
Jeni Alcock +44(0) 1298
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cyanide Solutions, Ireland Ltd
766900
Total Recycled
47.79
Total Disposed
0
Total 47.79
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2.4.2 Waste Minimisation Indices Key annual waste management data for the period January to December 2010 is presented in the table 2.9 below:
Table 2.9: Waste Management Data Required for Calculation of Indices
Period Jan-Dec 2010
Raw Materials Usage (tonnes) 4049.8
Waste Produced (tonnes) 728.94
Waste Recovered (tonnes) 468.88
The following indices have been calculated for the period January to December 2010.
Gross Waste Minimisation Index (Gross WaMI)
Gross WaMI: Waste Produced x 100 Raw Materials
(728.94/4049.8) x 100
18%
Nett of Process Waste Minimisation Index (Nett of P rocess WaMI)
Nett of Process: WaMI Waste Produced – Amount Recovered x 100 Raw Materials
((728.94-468.88) /4049.8)) x 100
6.42%
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2.4.3 National Waste Database Data Report Sheet
Table 2.10: National Waste Database Data Report Sheet
NACE Code
(two letters and max. four numbers)
2561
Reporting Period
January to December 2010
Number of Employees
(for reporting period)
300
Total Tonnage of Waste Pro duced
Hazardous
Non Hazardous
728.94
47.79
681.15
Total Tonnage of Waste Recovered
Hazardous
Non Hazardous
468.88
47.79
421.09
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2.5 Noise
Condition 6.10 of Molex’s IPPC Licence requires that a noise survey of the site operations be carried out every three years and a summary of the results submitted as part of the AER. An external consultant carried out a noise survey of the site during May 2008. The report was submitted to the EPA as part of the 2008 AER.
Schedule B.4 of the IPPC licence sets a daytime noise limit of 55 dB(A) LAeq, and a night-time noise limit of 45 dB(A) LAeq at noise sensitive locations.
The measured underlying noise levels (LA90) at the nearest noise sensitive location, i.e. Tullyglass Hill, were 52 dB(A) and 41dB(A) daytime and night-time respectively. The noise level attributable to Molex at this location is considerably less than this measured level.
There was no clearly audible tonal component or impulsive component in the noise emission from the Molex plant at the noise sensitive location, denoted H1.
It is planned to carry out a noise survey again in 2011 in accordance with IPPC Licence requirements.
.
Molex Ireland Limited Annual Environmental Report 2010
25
2.6 Energy and Water Consumption Energy (electricity and oil) and water usage for the site for the period January to December 2010 are given in the following table.
Table 2.11: Resource Consumption 2010
Oil (m 3) Mains Water (m3)
Electricity (kW)
Daytime
Electricity (kW)
Night time
Gas Usage (m3)
30.01 29,356 7,019,868
4,694,326 2,970
Table 2.12 below compares the resource consumption levels during 2008, 2009 with those from 2010.
Table 2.12: Trend in Resource Consumption
2008 2009 2010
Oil (m 3) 35.0 25.032 30.01
Mains Water (m 3) 11,114 38,741 29,356
Gas (m 3) 6,393 3,951 2,970
Electricity (kW) - Daytime 8,218,057 6,000,707 7,019,868
Electricity (kW) - Night time 5,634,296 3,642,321 4,694,326
No. of Plated Terminals Produced
1,729 x 106 779,000,000 1,003,529,487
Energy Audit
As per Condition 7.1 of the IPPC Licence, Molex engaged a consultancy firm to carry out an Energy Audit in January 2006. This Audit Report was attached as Appendix H in the 2006 AER.
Molex Ireland Limited Annual Environmental Report 2010
26
2.7 Agency Monitoring and Enforcement
2.7.1 Aqueous Emissions Sampling and Analysis The EPA took two samples of sewer emission from the Molex site on 20/04/2010 and 07/10/2010
Table 2.13 provides a comparison of the EPA results with results from Molex’s monitoring programme taken on or close to the date of the EPA monitoring programme.
Table 2.13: Emissions to Sewer – Discharged from Reference Point SE1
Parameter mg/l Emission Limits mg/l
EPA Results Molex Results
(on dates close to EPA monitoring dates)
Date
20/04/10 07/10/10 Q2 composite Q 4 composite
Sample type Composite Composite Composite Composite
Flow / day 150m3 44 49
pH 6-9 7.53 7.71 - -
Temperature 43° C max - -
BOD 300 >7 >24 10 48
COD 600 13 46 11 58
Suspended Solids 300 3 4 3 31
Nitrates 30 0.316 0.189 <0.27 0.35
Chlorides 500 132 614 273 256
Sulphates (as SO 4) 1000 646 514 580 560
Nickel 0.5 0.019 0.023 0.08 0.0096
Cobalt 0.5 0.007 <0.005 0.005 0.0037
Copper 0.5 <0.005 <0.005 0.0006 0.0021
Zinc 0.5 0.007 0.144 0.011 0.0078
Arsenic 0.5 <0.001 0.001 ND 0.0003
Cadmium 0.1 <0.0001 0.0004 ND 0.00005
Lead 0.5 <0.001 0.009 0.0002 0.001
Tin 2.0 0.006 0.033 0.008 0.0029
VOC Screen µg/l - 3.8 8 1.417
Molex Ireland Limited Annual Environmental Report 2010
27
Table 2.14: Surface Water Sampling Point results.
Parameter
Sample taken on 7/10/2010
Units SWSP1 SWSP2
Conductivity @ 25 C uS/cm 4140 289
Chemical Oxygen Demand mg/l O2 145 47
Iron mg/l 0.334 0.482
Manganese mg/l 0.012 0.009
Cadmium mg/l <0.0001 <0.0001
Chromium mg/l 0.005 0.007
Copper mg/l 0.438 0.052
Nickel mg/l 0.127 0.030
Lead mg/l 0.005 0.005
Zinc mg/l 0.044 0.084
Total Heavy Metals mg/l 0.619 0.177
There was no split samples taken when the Agency visited, going forward the process is in place to ensure that split samples are taken. Therefore it is not possible to make a valid comparison between the EPA reported results and Molex’s results.
The Agency recorded a chloride level of 614 mg/l for a daily composite sample while the Molex weekly composite level was 256 mg/l. Without the split samples it was not possible to investigate this in more depth.
High levels of conductivity was detected in Surface Water Sampling Point 1, this is attributed to the fact that the catchment area falls within the range of the chillier farm which uses free water chillier units to control water temperature used in Stamping and Moulding. Sodium chloride was being used to soften the hard water and given that a fine spray being emitted from these units resulted in a high conductivity being recorded in water runoff from this area. Action has been taken and now reverse osmosis (RO) water is now being used in this chillier system.
2.7.2 Atmospheric Emission Sampling and Analysis
No Air Emission sampling was conducted by the Agency during 2010
2.7.3 Site Inspection undertaken by an EPA Inspecto r.
No site Audit or Inspection was conducted by the Agency during 2010
Molex Ireland Limited Annual Environmental Report 2010
28
2.8 Environmental Incidents and Complaints
Environmental Incidents In the period January to December 2010, Molex reported one incident with respect to the IPPC licence.
Environmental Complaints Molex Ireland Limited received no complaints during the period from January to December 2010.
2.9 AER 2010 Returns Excel Worksheets
Please refer to Appendix D for a copy of the AER 2010 Returns Excel Worksheets.
Molex Ireland Limited Annual Environmental Report 2010
29
3.0 Environmental Management of the activity
3.1 Environmental Management System – ISO 14001 Condition 2.2 of Molex Ireland’s IPPC Licence requires the licensee to establish and maintain an Environmental Management System (EMS). In January 2000, Molex Ireland began to modify the EMS which was in place as required by the IPPC Licence in order to meet with the requirements set out by the ISO 14001 Environmental Management System Standard.
The company was awarded accreditation to the Standard in September 2000. (Molex received revised 2004 ISO-14001 certification in Sep 2005). Molex Ireland carries out regular internal audits to assess the EMS for continued compliance. An annual audit is scheduled by the ISO 14001 Certification Body to ensure Molex are compliant with ISO 14001 standards.
During the implementation phase of the Environmental Management System, all employees received training on general environmental awareness. In addition, this training programme has been included in the induction programme for new employees. The Environmental Health and Safety Manager delivers this training in conjunction with the Training Manager.
A number of quality auditors have been trained in internal environmental auditing. Physical site audits and audits of the EMS are carried out on a regular basis by them in accordance with the audit schedule.
3.2 EMP 2010 Report and Schedule of Objectives and Targ ets 2011 A revised Schedule of Objectives and Targets for 2010, as per Condition 2.2.2.2 of the IPPC Licence has been incorporated into the Environmental Management System. Table 3.1 outlines Molex’s Objectives and Targets for 2011.
Due to the continuation and crossover of all of the Objectives and Targets from the 2010 Schedule, the following table is both a report on the 2010 Objectives and Targets (EMP Report) and a schedule of Objectives and Targets for 2011 onwards.
Molex Ireland Limited Annual Environmental Report 2010
30
Table 3.1 Schedule of Objectives and Targets 2011 (includes EMP Report for 2010)
Objectives 2010 Targets Time Frame Respo nsibility
1. Energy & Resource Efficiency Carry out an Energy audit (completed in 2006) review findings and implement its findings over the next 5 years.
Continue to track energy usage in the plant both at local and at departmental level, also purchased energy tracking meters
Institute Energy awareness campaigns
Ongoing
Ongoing
2011
EHS/Facilities and Greenbelt Team
E-Greenbelt team
2. Introduce Cleaner Technology Introduce cleaner technologies as they become commercially available.
Ensure all new projects are RoHS compliant
Uploading Bill of Substances (BoS) for components on SAP system
Lead & ammonia were removed from all plating processes in June 06 & Feb 06 respectively.
Molex will continue to monitor cleaner technologies.
Comply with the Requirements of the REACH Directive.
Ensure that all refrigeration equipment on-site is on the register and the coolant is identified and managed in accordance with Best Practice, per EPA Notifications on 17th July 2009
Create Register of all RAC equipment for site 2010
Ongoing
Ongoing
Ongoing
Complete
Ongoing
Complete
EHS
Facilities
3. Reduction & Minimization of waste
Molex will continue to monitor for further recycling streams. (5 yr plan).
Review monthly waste figures going to landfill and various recycling facilities. Investigate any discrepancies or unaccountable peaks in the waste figures
Remove canteen biodegradable waste from the landfill components
Investigate the possibility of recycling/reuse of plastic resin stream
Ongoing
Ongoing
2010
2011
EHS/Facilities/ Canteen staff
Facilities
4. Develop more stringent control measures/mechanisms in the effluent treatment plant. (Cleaner Technology)
Investigate ways to minimise loading on the effluent treatment plant to ensure compliant discharges to sewer.
Ceased disposal of waste nickel plating solutions in WWTP in 2007. NI based chemistries now sent off site for disposal
Install an online Turbidity Meter Q1 2008
Ongoing
Complete
Complete
Complete
EHS
Molex Ireland Limited Annual Environmental Report 2010
31
Replace cross flow filtration membranes – Q2 2008, completed.
Use RO water (soft water) in plant water chillers system
2011
Facilities
5. As per condition 3.9 of Licence: “The provision of a catchment system to collect any leaks from flanges and valves of all over ground pipes used to transport material other than water shall be examined.”
To ensure that pipe work and its contents does not pose a threat to the environment via spills and/or leaks. Continuous monitoring and auditing will facilitate the control and reduction in risk of leaks.
Ongoing EHS
6. As per condition 7.3 of Licence: “The licensee shall identify opportunities for reduction in the quantity of water used on site including recycling and reuse initiatives, wherever possible.”
Through continuous monitoring of water usage through bills issued by the local authority and analysis of where on site water is specifically used, Molex will ensure that water usage is kept to the required minimum.
Ongoing EHS
7. Ensure that the volume flow for emission point A3-4 is not exceeded during operations and is compliant with the licence conditions.
Investigate and fit controlling equipment to ensue that the volume flow stays within the limit as specified in the licence.
Installed an inverter to control flow rate 2010
2010
Complete
EHS/Facilities
8. Investigate hydrocyanic acid emissions levels from the site.
Ensure that emissions to atmosphere are in compliance with Licence conditions. 2011 Plating +EH&S
Molex Ireland Limited Annual Environmental Report 2010
32
3.3 Pollution Emission Register (PER)
In accordance with Condition 6.11.1 of the IPPC Licence and as agreed with the EPA, Molex completed a mass balance for the following substances:
• Nickel
• Tin
A copy of the PER Report for the period January to December 2010 is included in Appendix C.
Molex introduced ammonia free and lead free electroplating chemistries, which eliminated the use of ammonia and lead in the facility, since January & June 2006 respectively.
As a result and as agreed with the EPA, Molex will did not calculate a mass balance for either ammonia or lead in the PER 2007 and will not include these parameters in future PERs.
Molex Ireland as a result of the economic downturn and company restructuring has discontinued Copper plating and pure Tin plating at the end of 2009. Therefore it is not feasible to continue with copper in the per as stocks are now reduced to zero (March 2010)
Molex proposes to include Nickel and tin in PER 2010
Molex Ireland Limited Annual Environmental Report 2010
4.0 OTHER REPORTS
4.1 Bund Integrity Assessment In accordance with Condition 3.5.5 of IPPC Licence P0288-02, Molex Ireland is required to undertake a Bund Integrity Assessment by external consultants on a three year cycle.
During 2008 the fuel bund was sealed and fitted with a pump for the management of rain water. Also a monitoring program was instituted at the request of the Agency.
An assessment of the bunds on site was undertaken during 2010 and the report is attached in Appendix E.
4.2 Firewater Retention Study. Molex (Ireland) Ltd. contracted external consultants to carry out a fire-water retention study on its electrical components manufacturing facility in accordance with Condition 3.7 of its IPPC Licence P0288-02. The purpose of this study was to determine the requirement or otherwise for the provision of dedicated on-site fire-water retention on the basis of an environmental risk assessment.
The full report was attached as Appendix I in the 2006 AER.
A review of the Firewater Retention Capacity will be undertaken during 2010 and a summary report is attached in Appendix F.
Hard Copies will be forwarded to the Agency in April 2011
4.3 Environmental Liabilities In accordance with Condition 12.3.2 of the IPPC Licence, Molex contracted external consultants to perform an Environmental Liabilities Risk Assessment (ELRA).
In accordance with Condition 12.3.2, the ELRA will be reviewed as necessary to reflect any significant change on site or at a minimum every three years and submitted as part of the AER.
A Residuals Management Plan (RMP) was also completed as per condition 10.2.1 of the IPPC Licence.
In Accordance with Condition 10.2.2, Molex have reviewed the RMP and as there have been no significant changes to the processes on-site during 2008 Molex do not propose to amend the content of the RMP with regards the scope for decommissioning the site, as submitted in the 2006 AER.
These reports were included in Appendix J of the 2006 AER.
Molex will conduct a review of the Environmental Liabilities Risk Assessment (ELRA), in light of the changes that occurred during 2010, this review will be conducted during 2011.
4.4 Intrusive Hydrogeological Investigation. External consultants were commissioned during 2006 by Molex Ireland Ltd. to undertake a hydrogeological investigation at the facility in the Shannon Industrial Estate, in compliance with Condition 6.9.1 of the IPPC Licence.
The entire report was included as Appendix K in the 2006 AER.
Molex Ireland Limited Annual Environmental Report 2010
4.5 CCTV Survey
A CCTV Survey of underground pipes was carried out by external consultants in November 2009. The full report was attached in the 2009 AER. The next CCTV study will be carried out in 2012.
5 SOLVENT USAGE Molex Ireland Ltd. does not have manufacturing processes that incorporate solvents. However, a small quantity of propan-2-ol is kept on site for miscellaneous cleaning purpose
Molex Ireland Limited Annual Environmental Report 2010
APPENDIX A
ENVIRONMENTAL POLICY
Molex Ireland Ltd. AEP Division
Number: ENVMAN4.2 Effective Date: June 8th 2009
Revision: 11
Subject: Environmental Policy Page 1 of 1
Uncontrolled document, Valid only on day of printing, Master Copy on Intranet. Printed on 30/03/2011
Molex Ireland Limited Annual Environmental Report 2010
APPENDIX B
REPORTS ON EMISSIONS TO ATMOSPHERE 2010
Email: [email protected] www.enviro-consult.com Registered Office as above. Registered Number 243 412
Tel: 01 276 1428
Directors: Noel J. McGrath Robert B. Sutcliffe
Environmental Services for Industry Including – ► Air, Noise & Water Monitoring ► Energy & Water use reduction ► Bund Testing ► IPPC/Waste Licence Compliance ► Environmental Management Systems to ISO 14001 ► EIS & Planning Affiliations & Accreditations
► MCERTS Accredited personnel for stack testing ► Member of Source Testing Association ► Member Water Monitoring Association, Membership No WMA 0041
Stack Emission Monitoring Report
Bi-annual 1 of 2010
Molex (Ireland) Ltd.
IPPC Licence No: Licence P0288-02
Environmental Efficiency Document Number 1247-01 v2.01
Environmental Efficiency Consultants Document 1247-01 v2.01
Air Emissions Monitoring Report for B1/2010
Licence No P0288-02 Molex (Ireland) Ltd. Report 1 of 2010
Page 2 of 25
1. Part 1: Executive Summary
1.1 Cover Sheet
Document Title
Air Emissions Monitoring Report – 2010: Bi-annual 1
Licence Register
No.
P0288-02
Licence holder and
Installation name Molex (Ireland) Ltd.
Date(s) of the
monitoring visit 26/05/2010
Name and address
of client
organisation
Molex (Ireland) Ltd.
Shannon Industrial Estate, Shannon, Co. Clare.
Name and address
of monitoring
Organisation
Environmental Efficiency, Parnell House, 19 Quinsboro Road, Bray,
Co. Wicklow
Date of report
24/06/2010
Monitoring team
and qualifications
Richard McElroy, B.Eng (Hons) Environmental Engineering, MCerts
Level 1 (MM08916)
Report Author and
qualifications
Róisín Ní Dhubhda BSc, MSc., AIEMA
Name and function
of person approving
report
Bob Sutcliffe, CEng, MIMechE, CMIWM, Technical Director
Internal document
number
1247-01 v2.01
Report Format LQS SR03 Air Monitoring EPA-AG2 Template v1.7
Environmental Efficiency report status and approvals
Signed for and on behalf of Issue Status Date Author Environmental
Efficiency Client
1.00
2.01 Approved 23/03/2011 RND
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.
Environmental Efficiency Consultants Document 1247-01 v2.01
Air Emissions Monitoring Report for B1/2010
Licence No P0288-02 Molex (Ireland) Ltd. Report 1 of 2010
Page 3 of 25
1. PART 1: EXECUTIVE SUMMARY...........................................................................................2
1.1 COVER SHEET.........................................................................................................................2 1.2 MONITORING OBJECTIVES ......................................................................................................4 1.3 MONITORING RESULTS ............................................................................................................4
1.3.1 Emission point A3-3 ..........................................................................................................5 1.3.2 Emission Point A3-4..........................................................................................................7
2. PART 2: SUPPORTING INFORMATION ................................................................................9
2.1 COVER SHEET.........................................................................................................................9 2.2 ANNEX 1...............................................................................................................................10
2.2.1 Names, functions and qualifications of monitoring staff.................................................10 2.2.2 Substances monitored, methods used and operating procedure .....................................10
2.3 UNCERTAINTY CALCULATIONS .............................................................................................11
APPENDIX 1 EMISSION POINT A3-3..........................................................................................................12 APPENDIX 2 EMISSION POINT A3-4..........................................................................................................19
Environmental Efficiency Consultants Document 1247-01 v2.01
Air Emissions Monitoring Report for B1/2010
Licence No P0288-02 Molex (Ireland) Ltd. Report 1 of 2010
Page 4 of 25
1.2 Monitoring Objectives
The objective of the monitoring is to determine compliance with the Emission Limit
Values stated in the client’s licence. Such monitoring is required for the following
emission points, parameters and at the frequency indicated in the table below.
Emission
Point Parameter
Frequency of
monitoring
Reported in
this report
Comment
A3-3
TA Luft Inorganic
Particulate Matter
Class II
Biannually Yes No comment
A3-3 TA Luft Inorganic
Particulate Matter
Class III
Biannually
Yes No comment
A3-3 TA Luft Inorganics
Class II
Biannually Yes
No comment
A3-3 TA Luft Inorganics
Class III
Biannually Yes
No comment
A3-4 TA Luft Inorganic
Particulate Matter
Class II
Biannually Yes No comment
A3-4 TA Luft Inorganic
Particulate Matter
Class III
Biannually Yes No comment
A3-4 TA Luft Inorganics
Class II
Biannually Yes No comment
A3-4 TA Luft Inorganics
Class III
Biannually Yes No comment
1.3 Monitoring results
The results of the monitoring reported in this document are tabulated below. The
methods used are defined by Standard Operating Procedures (SOP), each SOP having
a unique number. The relevant detail regarding each SOP is given in Section 2.
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Ino
rgan
ic
Par
ticu
late
Mat
ter
Cla
ss I
II
1.0
0
.45
6
+/-
1.4
mg/N
m3
26
/06
/20
10
11
.00
–
11
.30
Yes
N
o c
om
men
t
10
.23
T
A L
uft
Ino
rgan
ic
Cla
ss I
I 3
.0
5.5
4
+/-
3.1
m
g/N
m3
2
6/0
6/2
01
0
11
.00
–
11
.30
See
co
mm
ent
See
No
te 1
10
.98
T
A L
uft
Ino
rgan
ic
Cla
ss I
II
30
.0
<0
.04
1
+/-
16
.66
m
g/N
m3
2
6/0
6/2
01
0
11
.00
–
11
.30
Yes
N
o c
om
men
t
00
.00
V
olu
me
Flo
w
10
,00
0
8,3
41
.0
+/-
31
0.5
N
m3/h
r 2
6/0
6/2
01
0
11
.00
–
11
.30
Y
es
No
co
mm
ent
1.
No
te 1
: R
esult
ab
ove
EL
V b
ut
no
t w
ith 9
5%
co
nfi
den
ce a
s th
e U
OM
is
+/-
3.1
.
The
indiv
idual
subst
ance
s det
ecte
d d
uri
ng t
he
monit
ori
ng t
hat
mak
e up t
he
par
amet
er r
eport
ed a
re l
iste
d i
n P
art
2, S
upport
ing I
nfo
rmat
ion.
The
Ref
eren
ce C
ondit
ions
(tem
per
ature
, pre
ssure
, ox
ygen
and m
ois
ture
) fo
r co
nce
ntr
atio
n a
nd v
olu
me
flow
s fo
r th
e ab
ove
emis
sion p
oin
t ar
e as
foll
ow
s.
Ref
eren
ce C
on
dit
ion
s
Tem
per
atu
re, K
P
ress
ure
, h
Pa
Oxygen
, %
M
ois
ture
273.1
5
1,0
14
N/A
N
/A
En
vir
on
men
tal
Eff
icie
ncy
Con
sult
an
ts
Docu
men
t 1247-0
1 v
2.0
1
Air
Em
issi
on
s M
on
itori
ng R
eport
for
B1/2
010
Lic
ence
No P
0288-0
2 M
ole
x (
Irel
an
d)
Ltd
. R
eport
1 o
f 2010
Page
8 o
f 25
1.3
.2.1
M
eth
ods
Sit
e S
pec
ific
Pro
toco
l re
fere
nce
num
ber
for
emis
sion p
oin
t 1247-0
1 v
1.0
4
Org
anis
atio
n c
arry
ing o
ut
monit
ori
ng
Envir
onm
enta
l E
ffic
iency
1.3
.2.2
O
per
ati
ng i
nfo
rmati
on
Pro
cess
sta
tus
Ele
ctro
-pla
ting
Conti
nuous
or
bat
ch p
roce
ss
Conti
nuous
If b
atch
, det
ails
of
par
t of
bat
ch s
ample
d
Not
appli
cable
Fee
dst
ock
use
d
Norm
al
Fuel
E
lect
rici
ty
Norm
al l
oad
, th
roughput
or
conti
nuous
rati
ng o
f
pla
nt
Norm
al l
oad
Type
of
abat
emen
t S
crubber
1.3
.2.3
C
om
pari
son
of
oper
ato
r C
EM
S d
ata
an
d P
erio
dic
Mon
itori
ng R
esu
lts
Ther
e is
no C
EM
S d
ata
for
this
em
issi
on p
oin
t.
1.3
.2.4
C
om
men
ts
Issu
e 2010:
B1
Monit
ori
ng l
oca
tion
A3-4
(P
lati
ng S
hop R
oof)
Dev
iati
ons
from
SS
P a
nd S
OP
s n/a
Environmental Efficiency Consultants Document 1247-01 v2.01
Air Emissions Monitoring Report for B1/2010
Licence No P0288-02 Molex (Ireland) Ltd. Report 1 of 2010
Page 9 of 25
2. Part 2: Supporting Information
EPA AG2 states that the supporting information is an option requirement.
2.1 Cover Sheet
Document Title
Air Emissions Monitoring Report – 2010: Bi-annual 1
Licence Register
No.
P0288-02
Licence holder and
Installation name Molex (Ireland) Ltd.
Date(s) of the
monitoring visit 26/05/2010
Name and address
of client
organisation
Molex (Ireland) Ltd.
Shannon Industrial Estate, Shannon, Co. Clare.
Name and address
of monitoring
Organisation
Environmental Efficiency, Parnell House, 19 Quinsboro Road, Bray,
Co. Wicklow
Date of report
24/06/2010
Monitoring team
and qualifications
Richard McElroy, B.Eng (Hons) Environmental Engineering, MCerts
Level 1 (MM08916)
Report Author and
qualifications
Róisín Ní Dhubhda BSc, MSc., AIEMA
Name and function
of person approving
report
Bob Sutcliffe, CEng, MIMechE, CMIWM, Technical Director
Internal document
number
1247-01 v2.01
Report Format LQS SR03 Air Monitoring EPA-AG2 Template v1.7
Environmental Efficiency Consultants Document 1247-01 v2.01
Air Emissions Monitoring Report for B1/2010
Licence No P0288-02 Molex (Ireland) Ltd. Report 1 of 2010
Page 10 of 25
2.2 Annex 1
2.2.1 Names, functions and qualifications of monitoring staff
Name Function MCERTS Level Qualifications
Richard McElroy Lead Monitoring
Technician Level 1 (MM08916) B.Eng (Env Eng)
Ronan Sutcliffe Assistant Monitoring
Technician Trainee Dip. in
Environmental
Protection
2.2.2 Substances monitored, methods used and operating procedure
The methods used are referenced by SOPs (Standard Operating Procedures) in Part 1
of this report. The descriptions of the methods referenced by these SOPs are listed
below.
SOP Parameter Method Standard Analysis by Accreditation
99.80 TA Luft
Inorganic
Particulate
Matter Class II
Isokinetic
sampling.
Analysis by
SOPs specified
below.
ISO 9096 EEC Not accredited
01.08 Particulates Gravimetric Environmental
Efficiency
None
99.81 TA Luft
Inorganic
Particulate
Matter Class III
Isokinetic
sampling.
Analysis by
SOPs specified
below.
ISO 9096 N/A N/A
01.08 Particulates Gravimetric Environmental
Efficiency
Not UKAS
accredited 01.04 Any gas with use
of appropriate
tube selected by
reference to
manufacturer’s
web site
Sorbent tube RPS Laboratories ISO 17025:2005
98.06 Hydrogen
Bromide
IC SAL Laboratory Not UKAS
accredited 99.95 Hydrogen
Fluoride
IC SAL Laboratory Not UKAS
accredited 98.08 Hydrogen
Sulphide
IC SAL Laboratory Not UKAS
accredited 98.07 Hydrocyanic
Acid (as CN)
Colorimetry SAL Laboratory Not UKAS
accredited 99.94 Chlorine IC SAL Laboratory Not UKAS
accredited 10.98 Ammonia Colorimetry SAL Laboratory Not UKAS
accredited 01.31 Velocity and
volume flow rate
Determination of
velocity using a
Pitot tube and
manometer
ISO 9096/
ISEN
13284
PART 1
Environmental
Efficiency
None
Environmental Efficiency Consultants Document 1247-01 v2.01
Air Emissions Monitoring Report for B1/2010
Licence No P0288-02 Molex (Ireland) Ltd. Report 1 of 2010
Page 11 of 25
The following table summarises the equipment used and the QC checks. The SOP
details the equipment used and QC checks.
SOP Equipment QC Check
01.31 Pitot tube Zero check
01.31 Manometer Zero check
01.19 FID Zero check and Span check with calibration
gas at 500 ppm at start and end of use of FID
01.04 Pump (< 3 litres/minute) Flow rate set in lab prior to use on site
01.08 Isokinetic sampling train Leak Test. Swirl Test. Sample blank.
2.3 Uncertainty Calculations
Uncertainties are calculated for 95% confidence based on available data. The
calculations used are described by SOPs and the actual calculation for each
monitoring result is determined by spreadsheet referenced by the same SOP.
Calculations are not included in this report; however, a copy of the spreadsheet is
available on request.
SOP
Method
96.01
UOM FGA and FID (O2, NOx, SOx, CO, Efficiency, TOC, Volume
Flow)
96.02 UOM Isokinetic Monitoring
96.10 UOM Sorbent Tube
96.11
UOM of concentration by extraction onto self indicating colorimetric
tube
96.12 UOM of velocity measurement using Pitot tube
96.14 UOM Impinger and pump
Environmental Efficiency Consultants Document 1247-01 v2.01
Air Emissions Monitoring Report for B1/2010
Licence No P0288-02 Molex (Ireland) Ltd. Report 1 of 2010
Page 12 of 25
Appendix 1 Emission Point A3-3
A1.1 Diagram of stack
A1.2 Results Calculations
Calculation for flow rate – A3-3
Parameter Value Unit Comment
Velocity 8.07 m/s -
Duct cross section area 0.152 m2 -
Flow rate 4,415.9 m3/hour -
Duct Temperature 22 C -
Ambient pressure 1,022 hPa -
Normalised flow rate 4,122 Nm3/hour +/- 166.2
Sampling plane
Platform
Sampling Plane
Environmental Efficiency Consultants Document 1247-01 v2.01
Air Emissions Monitoring Report for B1/2010
Licence No P0288-02 Molex (Ireland) Ltd. Report 1 of 2010
Page 13 of 25
A1.3 Analysis details where applicable
Environmental Efficiency Consultants Document 1247-01 v2.01
Air Emissions Monitoring Report for B1/2010
Licence No P0288-02 Molex (Ireland) Ltd. Report 1 of 2010
Page 14 of 25
Environmental Efficiency Consultants Document 1247-01 v2.01
Air Emissions Monitoring Report for B1/2010
Licence No P0288-02 Molex (Ireland) Ltd. Report 1 of 2010
Page 15 of 25
Environmental Efficiency Consultants Document 1247-01 v2.01
Air Emissions Monitoring Report for B1/2010
Licence No P0288-02 Molex (Ireland) Ltd. Report 1 of 2010
Page 16 of 25
Environmental Efficiency Consultants Document 1247-01 v2.01
Air Emissions Monitoring Report for B1/2010
Licence No P0288-02 Molex (Ireland) Ltd. Report 1 of 2010
Page 17 of 25
Environmental Efficiency Consultants Document 1247-01 v2.01
Air Emissions Monitoring Report for B1/2010
Licence No P0288-02 Molex (Ireland) Ltd. Report 1 of 2010
Page 18 of 25
A1.4 Derivation of total or class parameters
The general method for determining the results for ‘class parameters’, e.g. TA Luft
Class II is to speciated the sample and for each substance found determine whether it
is a member of the class of interest. The tables below show the substances found that
belong to each class of interest. The concentrations are detailed on the following
Certificate of Analysis.
TA Luft Inorganic Particulates Class II SOP Parameter Mass, µg
99.80 Lead <100
99.80 Cobalt <100 99.80 Nickel <100 99.80 Selenium <100 99.80 Tellurium <100 Total <250
TA Luft Inorganic Particulates Class III SOP Parameter Mass, µg
99.81 Antimony <100 99.81 Chromium <100 99.81 Easily soluble cyanides <100 99.81 Easily soluble fluorides <100 99.81 Copper <100 99.81 Manganese <100 99.81 Vanadium <100 99.81 Tin <100 Total <400
TA Luft Inorganics Class II SOP Parameter Mass, µg
99.80 Hydrogen Bromide <2
99.81 Hydrogen Fluoride <5
99.80 Hydrogen Sulphide <5
99.80 Hydrocyanic Acid (as CN) 2
99.80 Chlorine 1
Total <9
TA Luft Inorganics Class III SOP Parameter Mass, µg
99.81 Ammonia <0.2
Total <0.1
Environmental Efficiency Consultants Document 1247-01 v2.01
Air Emissions Monitoring Report for B1/2010
Licence No P0288-02 Molex (Ireland) Ltd. Report 1 of 2010
Page 19 of 25
Appendix 2 Emission Point A3-4
A2.1 Diagram of stack
A2.2 Results Calculations
Calculation for flow rate – A3-4
Parameter Value Unit Comment
Velocity 7.61 m/s -
Duct cross section area 0.369 m2 -
Flow rate 10,109.1 m3/hour -
Duct Temperature 22 C -
Ambient pressure 1,022 hPa -
Normalised flow rate 9,436 Nm3/hour +/- 380.4
Sampling plane
Platform
Sampling Plane
Environmental Efficiency Consultants Document 1247-01 v2.01
Air Emissions Monitoring Report for B1/2010
Licence No P0288-02 Molex (Ireland) Ltd. Report 1 of 2010
Page 20 of 25
A2.3 Analysis details where applicable
Environmental Efficiency Consultants Document 1247-01 v2.01
Air Emissions Monitoring Report for B1/2010
Licence No P0288-02 Molex (Ireland) Ltd. Report 1 of 2010
Page 21 of 25
Environmental Efficiency Consultants Document 1247-01 v2.01
Air Emissions Monitoring Report for B1/2010
Licence No P0288-02 Molex (Ireland) Ltd. Report 1 of 2010
Page 22 of 25
Environmental Efficiency Consultants Document 1247-01 v2.01
Air Emissions Monitoring Report for B1/2010
Licence No P0288-02 Molex (Ireland) Ltd. Report 1 of 2010
Page 23 of 25
Environmental Efficiency Consultants Document 1247-01 v2.01
Air Emissions Monitoring Report for B1/2010
Licence No P0288-02 Molex (Ireland) Ltd. Report 1 of 2010
Page 24 of 25
Environmental Efficiency Consultants Document 1247-01 v2.01
Air Emissions Monitoring Report for B1/2010
Licence No P0288-02 Molex (Ireland) Ltd. Report 1 of 2010
Page 25 of 25
A2.4 Derivation of total or class parameters
The general method for determining the results for ‘class parameters’, e.g. TA Luft
Class II is to speciated the sample and for each substance found determine whether it
is a member of the class of interest. The tables below show the substances found that
belong to each class of interest. The concentrations are detailed on the following
Certificate of Analysis.
TA Luft Inorganic Particulates Class II SOP Parameter Mass, µg
99.80 Lead <100
99.80 Cobalt <100 99.80 Nickel <100 99.80 Selenium <100 99.80 Tellurium <100 Total <250
TA Luft Inorganic Particulates Class III SOP Parameter Mass, µg
99.81 Antimony <100 99.81 Chromium <100 99.81 Easily soluble cyanides <100 99.81 Easily soluble fluorides <100 99.81 Copper <100 99.81 Manganese <100 99.81 Vanadium <100 99.81 Tin <100 Total <400
TA Luft Inorganics Class II SOP Parameter Mass, µg
99.80 Hydrogen Bromide <2
99.81 Hydrogen Fluoride <5
99.80 Hydrogen Sulphide <5
99.80 Hydrocyanic Acid (as CN) 13
99.80 Chlorine 1
Total <20
TA Luft Inorganics Class III SOP Parameter Mass, µg
99.81 Ammonia <0.2
Total <0.1
Tel: + 353 (0)1 276 1428 Fax: + 353 (0)1 276 1561 Email:[email protected] www.enviro-consult.com
Registered Office as above. Registered Number 243 412
Directors: Noel J. McGrath, Robert B. Sutcliffe
Stack Emission Monitoring Report
2010: Bi-annual 2
Molex (Ireland) Ltd.
IPPC Licence No: Licence No P0288-02
(Environmental Efficiency Document Number 1247-02 v2.01
Environmental Efficiency Consultants Document 1247-02 v2.01
Emissions Monitoring Report for B2/2010
IPPC Licence No. P0288-02 Molex (Ireland) Ltd. Report 2 of 2010 Version 2.01
Page 2 of 32
1. Part 1: Executive Summary
1.1 Cover Sheet
Document Title
Air Emissions Monitoring Report – 2010: Bi-annual 2
Licence Register No.
P0288-02
Licence holder and
Installation name
Molex (Ireland) Ltd.
Date(s) of the
monitoring visit
12/10/2010
Name and address of
client organisation
Molex (Ireland) Ltd.
Shannon Industrial Estate, Shannon, Co. Clare.
Name and address of
monitoring Organisation
Environmental Efficiency, Parnell House, 19 Quinsboro Road, Bray,
Co. Wicklow
Date of report
23/02/2011
Monitoring team and
qualifications Richard McElroy, B.Eng (Hons) Environmental Engineering, MCerts
Level 1 (MM08916)
Report Author and
qualifications
Róisín Ní Dhubhda BSc, MSc., AIEMA
Name and function of
person approving report
Bob Sutcliffe, CEng, MIMechE, CMIWM, Technical Director
Internal document number 1247-02 v2.01
Report Format LQS SR03 Air Monitoring EPA-AG2 Template v1.3
Environmental Efficiency report status and approvals
Signed for and on behalf of Issue Status Date Author Environmental
Efficiency Client
1.00 Draft RND
2.01 Approved 24/02/2011
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.
Environmental Efficiency Consultants Document 1247-02 v2.01
Emissions Monitoring Report for B2/2010
IPPC Licence No. P0288-02 Molex (Ireland) Ltd. Report 2 of 2010 Version 2.01
Page 3 of 32
1. PART 1: EXECUTIVE SUMMARY...........................................................................................2
1.1 COVER SHEET.........................................................................................................................2 1.2 MONITORING OBJECTIVES ......................................................................................................4 1.3 MONITORING RESULTS ............................................................................................................4
1.3.1 Emission point A3-3 ..........................................................................................................5 1.3.2 Emission point A3-4 ..........................................................................................................9
2. PART 2: SUPPORTING INFORMATION ..............................................................................13
2.1 COVER SHEET.......................................................................................................................13 2.2 ANNEX 1...............................................................................................................................14
2.2.1 Names, functions and qualifications of monitoring staff.................................................14 2.2.2 Substances monitored, methods used and operating procedure .....................................14
2.3 UNCERTAINTY CALCULATIONS .............................................................................................16
APPENDIX 1 EMISSION POINTS A3-3 ........................................................................................................17 APPENDIX 2 EMISSION POINT A3-4 ..........................................................................................................25
Environmental Efficiency Consultants Document 1247-02 v2.01
Emissions Monitoring Report for B2/2010
IPPC Licence No. P0288-02 Molex (Ireland) Ltd. Report 2 of 2010 Version 2.01
Page 4 of 32
1.2 Monitoring Objectives
The objective of the monitoring is to determine compliance with the Emission Limit
Values stated in the client’s licence. Such monitoring is required for the following
emission points, parameters and at the frequency indicated in the table below.
Emission
Point
Parameter Frequency of
monitoring
Reported in
this report
Comment
A3-3
TA Luft
Inorganic
Particulate
Matter Class II
Biannually Yes -
A3-3 TA Luft
Inorganic
Particulate
Matter Class III
Biannually
Yes -
A3-3 TA Luft
Inorganics
Class II
Biannually Yes -
A3-3 TA Luft
Inorganics
Class III
Biannually Yes -
A3-4 TA Luft
Inorganic
Particulate
Matter Class II
Biannually Yes
-
A3-4 TA Luft
Inorganic
Particulate
Matter Class III
Biannually Yes
-
A3-4 TA Luft
Inorganics
Class II
Biannually Yes -
A3-4 TA Luft
Inorganics
Class III
Biannually Yes -
1.3 Monitoring results
The results of the monitoring reported in this document are tabulated below. The
methods used are defined by Standard Operating Procedures (SOP), each SOP having
a unique number. The relevant detail regarding each SOP is given in Section 2.
Envir
onm
enta
l E
ffic
iency
Consu
ltan
ts
Docu
men
t 1247-0
2 v
2.0
1
E
mis
sions
Monit
ori
ng R
eport
for
B2/2
010
IPP
C L
icen
ce N
o. P
0288-0
2
Mole
x (I
rela
nd)
Ltd
.
Rep
ort
2 o
f 2010 V
ersi
on 2
.01
P
age
5 o
f 32
1.3
.1
Em
issi
on
poin
t A
3-3
1.3
.1.1
R
esu
lts
TA
Lu
ft I
norg
an
ics
Part
icu
late
Matt
er
Ref
eren
ce
Co
nd
itio
ns
SO
P
Pa
ram
eter
E
LV
R
esu
lt
Un
cert
ain
ty
at
95
%
con
fid
ence
Un
its
Da
te
Sta
rt/
En
d
Tim
e
Co
mp
lia
nce
T
P
O2
M
Fu
el
Co
mm
ent
99
.80
TA
Luft
Ino
rgan
ic
Par
ticu
late
Mat
ter
Cla
ss
II
0.5
<
0.0
59
+
/- 0
.4
mg/N
m3
12
/10
/20
10
12
.11
-
12
.41
Yes
Y
Y
N
N
N
/A
-
99
.81
TA
Luft
Ino
rgan
ic
Par
ticu
late
Mat
ter
Cla
ss
III
1.0
<
0.1
07
+
/- 0
.4
mg/N
m3
12
/10
/20
10
12
.11
-
12
.41
Yes
Y
Y
N
N
N
/A
-
Envir
onm
enta
l E
ffic
iency
Consu
ltan
ts
Docu
men
t 1247-0
2 v
2.0
1
E
mis
sions
Monit
ori
ng R
eport
for
B2/2
010
IPP
C L
icen
ce N
o. P
0288-0
2
Mole
x (I
rela
nd)
Ltd
.
Rep
ort
2 o
f 2010 V
ersi
on 2
.01
P
age
6 o
f 32
TA
Lu
ft I
norg
an
ics
Cla
ss I
I R
efer
ence
Co
nd
itio
ns
SO
P
Pa
ram
eter
E
LV
R
esu
lt
Un
cert
ain
ty
at
95
%
con
fid
ence
Un
its
Da
te
Sta
rt/
En
d
Tim
e
Co
mp
lia
nce
T
P
O2
M
Fu
el
Co
mm
ent
98
.06
H
yd
rogen
Bro
mid
e
No
t
spec
ifie
d
<0
.06
8
+/-
0.6
67
m
g/N
m3
12
/10
/20
10
11
.15
-
11
.45
Yes
Y
Y
N
N
N
/A
-
99
.95
H
yd
rogen
Flu
ori
de
No
t
spec
ifie
d
<0
.06
8
+/-
0.6
67
m
g/N
m3
12
/10
/20
10
11
.15
-
11
.45
Yes
Y
Y
N
N
N
/A
-
98
.08
H
yd
rogen
Sulp
hid
e
No
t
spec
ifie
d
0.3
23
+
/- 0
.02
7
mg/N
m3
12
/10
/20
10
11
.15
-
11
.45
Yes
Y
Y
N
N
N
/A
-
98
.07
H
yd
rocy
anic
Aci
d (
as C
N)
No
t
spec
ifie
d
<0
.17
1
+/-
0.6
67
m
g/N
m3
12
/10
/20
10
11
.15
-
11
.45
Yes
Y
Y
N
N
N
/A
-
99
.94
C
hlo
rine
No
t
spec
ifie
d
0.0
81
+
/- 0
.16
7
mg/N
m3
12
/10
/20
10
11
.15
-
11
.45
Yes
Y
Y
N
N
N
/A
-
-
TA
Lu
ft
Ino
rga
nic
s
Cla
ss I
I
3.0
<
0.7
11
+
/- 1
.16
7
mg/N
m3
12
/10
/20
10
1
1.1
5
-
11
.45
Yes
Y
Y
N
N
N
/A
To
tal
TA
Lu
ft I
norg
an
ics
Cla
ss I
II
Ref
eren
ce
Co
nd
itio
ns
SO
P
Pa
ram
eter
E
LV
R
esu
lt
Un
cert
ain
ty
at
95
%
con
fid
ence
Un
its
Da
te
Sta
rt/
En
d
Tim
e
Co
mp
lia
nce
T
P
O2
M
Fu
el
Co
mm
ent
10
.98
A
mm
onia
3
0.0
0
.17
5
+/-
0.6
67
m
g/N
m3
12
/10
/20
10
11
.15
-
11
.45
Yes
Y
Y
N
N
N
/A
To
tal
Envir
onm
enta
l E
ffic
iency
Consu
ltan
ts
Docu
men
t 1247-0
2 v
2.0
1
E
mis
sions
Monit
ori
ng R
eport
for
B2/2
010
IPP
C L
icen
ce N
o. P
0288-0
2
Mole
x (I
rela
nd)
Ltd
.
Rep
ort
2 o
f 2010 V
ersi
on 2
.01
P
age
7 o
f 32
Volu
me
Flo
w
Ref
eren
ce
Co
nd
itio
ns
SO
P
Pa
ram
eter
E
LV
R
esu
lt
Un
cert
ain
ty
at
95
%
con
fid
ence
Un
its
Da
te
Sta
rt/
En
d
Tim
e
Co
mp
lia
nce
T
P
O2
M
Fu
el
Co
mm
ent
00
.00
V
olu
me
Flo
w
5,5
00
.00
4
,12
2.0
+
/-1
66
.2
Nm
3/h
r
12
/10
/20
10
11
.15
-
11
.45
Yes
Y
Y
N
N
N
/A
-
The
appli
cati
on o
f ea
ch o
f th
e fo
ur
poss
ible
Ref
eren
ce C
ondit
ions
(tem
per
ature
, pre
ssure
, ox
ygen
and m
ois
ture
) fo
r ea
ch p
aram
eter
in t
he
above
table
is
indic
ated
by ‘
Y’
(Yes
) under
the
resp
ecti
ve
read
ing (
T, P
, O
2 o
r M
). If
‘N
’ (N
o)
is i
ndic
ated
, th
en t
he
refe
rence
condit
ion i
s not
appli
ed.
Ref
eren
ce C
ondit
ions
Tem
per
ature
, K
P
ress
ure
, hP
a O
xygen
, %
M
ois
ture
273.1
5
1,0
13.2
5
N/A
N
/A
1.3
.1.2
M
eth
ods
Sit
e S
pec
ific
Pro
toco
l re
fere
nce
num
ber
for
emis
sion p
oin
t M
S 1
247-0
1
MS
1247-0
2
Org
anis
atio
n c
arry
ing o
ut
monit
ori
ng
Envir
onm
enta
l E
ffic
iency
Consu
ltan
ts
1.3
.1.3
O
per
ati
ng i
nfo
rmati
on
Pro
cess
sta
tus
Ele
ctro
-pla
ting
Conti
nuous
or
bat
ch p
roce
ss
Conti
nuous
If b
atch
, det
ails
of
par
t of
bat
ch s
ample
d
Not
appli
cable
Fee
dst
ock
use
d
Ele
ctri
city
Norm
al l
oad
, th
roughput
or
conti
nuous
rati
ng o
f pla
nt
Norm
al l
oad
Type
of
abat
emen
t S
crubber
1.3
.1.4
C
om
pari
son
of
oper
ato
r C
EM
S d
ata
an
d P
erio
dic
Mon
itori
ng R
esu
lts
Ther
e is
no C
EM
S d
ata
for
this
em
issi
on p
oin
t
Envir
onm
enta
l E
ffic
iency
Consu
ltan
ts
Docu
men
t 1247-0
2 v
2.0
1
E
mis
sions
Monit
ori
ng R
eport
for
B2/2
010
IPP
C L
icen
ce N
o. P
0288-0
2
Mole
x (I
rela
nd)
Ltd
.
Rep
ort
2 o
f 2010 V
ersi
on 2
.01
P
age
8 o
f 32
1.3
.1.5
C
om
men
ts
Issu
e 2010:
B2
Monit
ori
ng l
oca
tion
A3-3
(P
lati
ng S
hop R
oof)
A3-4
(P
lati
ng S
hop R
oof)
Dev
iati
ons
from
SS
P a
nd S
OP
s n/a
Envir
onm
enta
l E
ffic
iency
Consu
ltan
ts
Docu
men
t 1247-0
2 v
2.0
1
E
mis
sions
Monit
ori
ng R
eport
for
B2/2
010
IPP
C L
icen
ce N
o. P
0288-0
2
Mole
x (I
rela
nd)
Ltd
.
Rep
ort
2 o
f 2010 V
ersi
on 2
.01
P
age
9 o
f 32
1.3
.2
Em
issi
on
poin
t A
3-4
1.3
.2.1
R
esu
lts
TA
Lu
ft I
norg
an
ic P
art
icu
late
Matt
er
Ref
eren
ce
Co
nd
itio
ns
SO
P
Pa
ram
eter
E
LV
R
esu
lt
Un
cert
ain
ty
at
95
%
con
fid
ence
Un
its
Da
te
Sta
rt/
En
d
Tim
e
Co
mp
lia
nce
T
P
O2
M
Fu
el
Co
mm
ent
99
.80
TA
Luft
Ino
rgan
ic
Par
ticu
late
Mat
ter
Cla
ss I
I
0.5
<
0.0
31
+
/- 0
.51
m
g/N
m3
12
/10
/20
10
1
1.3
5
Yes
Y
Y
N
N
N
/A
-
99
.81
TA
Luft
Ino
rgan
ic
Par
ticu
late
Mat
ter
Cla
ss
III
1.0
0
.87
7
+/-
0.5
1
mg/N
m3
12
/10
/20
10
1
1.3
5
Yes
Y
Y
N
N
N
/A
-
Envir
onm
enta
l E
ffic
iency
Consu
ltan
ts
Docu
men
t 1247-0
2 v
2.0
1
E
mis
sions
Monit
ori
ng R
eport
for
B2/2
010
IPP
C L
icen
ce N
o. P
0288-0
2
Mole
x (I
rela
nd)
Ltd
.
Rep
ort
2 o
f 2010 V
ersi
on 2
.01
P
age
10 o
f 32
TA
Lu
ft I
norg
an
ics
Cla
ss I
I
Ref
eren
ce
Co
nd
itio
ns
SO
P
Pa
ram
eter
E
LV
R
esu
lt
Un
cert
ain
ty
at
95
%
con
fid
ence
Un
its
Da
te
Sta
rt/
En
d
Tim
e
Co
mp
lia
nce
T
P
O2
M
Fu
el
Co
mm
ent
98
.06
H
yd
rogen
Bro
mid
e
No
t
spec
ifie
d
<0
.06
1
+/-
0.0
27
m
g/N
m3
12
/10
/20
10
1
2.0
7
Yes
Y
Y
N
N
N
/A
-
99
.95
H
yd
rogen
Flo
uri
de
No
t
spec
ifie
d
<0
.06
1
+/-
0.0
27
m
g/N
m3
12
/10
/20
10
12
.07
Yes
Y
Y
N
N
N
/A
-
98
.08
H
yd
rogen
Sulp
hid
e
No
t
spec
ifie
d
<0
.29
3
+/-
0.0
27
m
g/N
m3
12
/10
/20
10
12
.07
Yes
Y
Y
N
N
N
/A
-
98
.07
H
yd
rocy
anic
Aci
d (
as C
N)
No
t
spec
ifie
d
15
.4
+/-
0.0
01
m
g/N
m3
12
/10
/20
10
12
.07
No
Y
Y
N
N
N
/A
-
99
.94
C
hlo
rine
No
t
spec
ifie
d
0.0
74
+
/- 0
.16
7
mg/N
m3
12
/10
/20
10
12
.07
Y
es
Y
Y
N
N
N/A
-
TA
L
uft
Ino
rga
nic
s
Cla
ss I
I
3.0
1
5.8
89
+
/- 0
.17
3
mg/N
m3
12
/10
/20
10
1
2.0
7
No
Y
Y
N
N
N
/A
To
tal
TA
Lu
ft I
norg
an
ics
Cla
ss I
II
Ref
eren
ce
Co
nd
itio
ns
SO
P
Pa
ram
eter
E
LV
R
esu
lt
Un
cert
ain
ty
at
95
%
con
fid
ence
Un
its
Da
te
Sta
rt/
En
d
Tim
e
Co
mp
lia
nce
T
P
O2
M
Fu
el
Co
mm
ent
10
.98
A
mm
onia
3
0.0
<
0.4
76
+
/- 0
.07
4
mg/N
m3
12
/10
/20
10
12
.07
Yes
Y
Y
N
N
N
/A
To
tal
Volu
me
Flo
w
Ref
eren
ce
Co
nd
itio
ns
SO
P
Pa
ram
eter
E
LV
R
esu
lt
Un
cert
ain
ty
at
95
%
con
fid
ence
Un
its
Da
te
Sta
rt/
En
d
Tim
e
Co
mp
lia
nce
T
P
O2
M
Fu
el
Co
mm
ent
00
.00
V
olu
me
Flo
w
10
,00
0
9,4
36
+
/- 3
80
.4
Nm
3/h
r 1
2/1
0/2
01
0
12
.07
Y
es
Y
Y
N
N
N/A
-
Envir
onm
enta
l E
ffic
iency
Consu
ltan
ts
Docu
men
t 1247-0
2 v
2.0
1
E
mis
sions
Monit
ori
ng R
eport
for
B2/2
010
IPP
C L
icen
ce N
o. P
0288-0
2
Mole
x (I
rela
nd)
Ltd
.
Rep
ort
2 o
f 2010 V
ersi
on 2
.01
P
age
11 o
f 32
The
appli
cati
on o
f ea
ch o
f th
e fo
ur
poss
ible
Ref
eren
ce C
ondit
ions
(tem
per
ature
, pre
ssure
, ox
ygen
and m
ois
ture
) fo
r ea
ch p
aram
eter
in t
he
above
table
is
indic
ated
by ‘
Y’
(Yes
) under
the
resp
ecti
ve
read
ing (
T, P
, O
2 o
r M
). If
‘N
’ (N
o)
is i
ndic
ated
, th
en t
he
refe
rence
condit
ion i
s not
appli
ed.
Ref
eren
ce C
ondit
ions
Tem
per
ature
, K
P
ress
ure
, hP
a O
xygen
, %
M
ois
ture
273.1
5
1,0
13
N/A
N
/A
1.3
.2.2
M
eth
ods
Sit
e S
pec
ific
Pro
toco
l re
fere
nce
num
ber
for
emis
sion p
oin
t M
S 1
247-0
1
MS
1247-0
2
Org
anis
atio
n c
arry
ing o
ut
monit
ori
ng
Envir
onm
enta
l E
ffic
iency
Consu
ltan
ts
1.3
.2.3
O
per
ati
ng i
nfo
rmati
on
Pro
cess
sta
tus
Ele
ctro
-pla
ting
Conti
nuous
or
bat
ch p
roce
ss
Conti
nuous
If b
atch
, det
ails
of
par
t of
bat
ch s
ample
d
Not
appli
cable
Fuel
use
d
Ele
ctri
city
Fee
dst
ock
use
d
Norm
al l
oad
Norm
al l
oad
, th
roughput
or
conti
nuous
rati
ng o
f
pla
nt
Norm
al l
oad
Type
of
abat
emen
t S
crubber
1.3
.2.4
C
om
pari
son
of
oper
ato
r C
EM
S d
ata
an
d P
erio
dic
Mon
itori
ng R
esu
lts
Ther
e is
no C
EM
S d
ata
for
this
em
issi
on p
oin
t
1.3
.2.5
C
om
men
ts
Issu
e 2010:
B2
Envir
onm
enta
l E
ffic
iency
Consu
ltan
ts
Docu
men
t 1247-0
2 v
2.0
1
E
mis
sions
Monit
ori
ng R
eport
for
B2/2
010
IPP
C L
icen
ce N
o. P
0288-0
2
Mole
x (I
rela
nd)
Ltd
.
Rep
ort
2 o
f 2010 V
ersi
on 2
.01
P
age
12 o
f 32
Monit
ori
ng l
oca
tion
A3-3
(P
lati
ng S
hop R
oof)
A3-4
(P
lati
ng S
hop R
oof)
Dev
iati
ons
from
SS
P a
nd S
OP
s n/a
Environmental Efficiency Consultants Document 1247-02 v2.01
Emissions Monitoring Report for B2/2010
IPPC Licence No. P0288-02 Molex (Ireland) Ltd. Report 2 of 2010 Version 2.01
Page 13 of 32
2. Part 2: Supporting Information
2.1 Cover Sheet
Document Title
Air Emissions Monitoring Report – 2010: Bi-annual 2
Licence Register No.
P0288-02
Licence holder and
Installation name
Molex (Ireland) Ltd.
Date(s) of the
monitoring visit
12/10/2010
Name and address of
client organisation
Molex (Ireland) Ltd.
Shannon Industrial Estate, Shannon, Co. Clare.
Name and address of
monitoring Organisation
Environmental Efficiency, Parnell House, 19 Quinsboro Road, Bray,
Co. Wicklow
Date of report
23/02/2011
Monitoring team and
qualifications Richard McElroy, B.Eng (Hons) Environmental Engineering, MCerts
Level 1 (MM08916)
Report Author and
qualifications
Róisín Ní Dhubhda BSc, MSc., AIEMA
Name and function of
person approving report
Bob Sutcliffe, CEng, MIMechE, CMIWM, Technical Director
Internal document number 1247-02 v2.00
Report Format LQS SR03 Air Monitoring EPA-AG2 Template v1.3
Environmental Efficiency Consultants Document 1247-02 v2.01
Emissions Monitoring Report for B2/2010
IPPC Licence No. P0288-02 Molex (Ireland) Ltd. Report 2 of 2010 Version 2.01
Page 14 of 32
2.2 Annex 1
2.2.1 Names, functions and qualifications of monitoring staff
Name Function MCERTS Level Qualifications
Richard McElroy Lead Monitoring
Technician Level 1 (MM08916) B.Eng (Env Eng)
Ronan Sutcliffe Assistant Monitoring
Technician Trainee Dip. in Environmental
Protection
2.2.2 Substances monitored, methods used and operating procedure
The methods used are referenced by SOPs (Standard Operating Procedures) in Part 1
of this report. The descriptions of the methods referenced by these SOPs are listed
below.
TA Luft Inorganic Particulate Matter Class II SOP SOP type Parameter Method Standard Analysis by Accreditation
of Analysis
method
99.80 Sample
collection
TA Luft
Inorganic
Particulate
Matter Class
II
Isokinetic
sampling.
Analysis by
SOPs
specified
below.
ISO
9096
N/A N/A
99.29 Analysis Lead dust ICP/OES SAL
Laboratory
UKAS
accredited
98.09 Analysis Cobalt dust ICP/OES SAL
Laboratory
UKAS
accredited 99.28 Analysis Nickel dust ICP/OES SAL
Laboratory
UKAS
accredited 98.02 Analysis Selenium
dust
ICP/OES SAL
Laboratory
UKAS
accredited 98.03 Analysis Tellurium
dust
ICP/OES SAL
Laboratory
Not UKAS
accredited 01.08 Analysis Particulates Gravimetric Environmental
Efficiency
Not UKAS
accredited
TA Luft Inorganic Particulate Matter Class III SOP SOP type Parameter Method Standard Analysis by Accreditation
of Analysis
method
99.81 Sample
collection
TA Luft
Inorganic
Particulate
Matter Class
III
Isokinetic
sampling.
Analysis by
SOPs
specified
below.
ISO
9096
N/A N/A
99.25 Analysis Antimony
Dust
ICP/OES SAL
Laboratory
UKAS
accredited 99.25 Analysis Chromium
dust
ICP/OES SAL
Laboratory
UKAS
accredited
Environmental Efficiency Consultants Document 1247-02 v2.01
Emissions Monitoring Report for B2/2010
IPPC Licence No. P0288-02 Molex (Ireland) Ltd. Report 2 of 2010 Version 2.01
Page 15 of 32
SOP SOP type Parameter Method Standard Analysis by Accreditation
of Analysis
method
98.04 Analysis Easily
Soluble
Cyanides
Colorimetry SAL
Laboratory
Not UKAS
accredited
98.05 Analysis Easily
Soluble
Fluorides
IC SAL
Laboratory
Not UKAS
accredited
99.26 Analysis Copper dust ICP/OES SAL
Laboratory
UKAS
accredited 99.27 Analysis Manganese
dust
ICP/OES SAL
Laboratory
UKAS
accredited 10.56 Analysis Vanadium
dust
ICP/OES SAL
Laboratory
UKAS
accredited 10.54 Analysis Tin dust ICP/OES SAL
Laboratory
UKAS
accredited 01.08 Analysis Particulates Gravimetric Environmental
Efficiency
Not UKAS
accredited
TA Luft Inorganic Class II SOP SOP type Parameter Method Standard Analysis by Accreditation
of Analysis
method
01.04 Sample
collection
Any gas with
use of
appropriate
tube selected
by reference to
manufacturer’s
web site
Sorbent tube N/A N/A
98.06 Analysis Hydrogen
Bromide
IC SAL
Laboratory
Not UKAS
accredited 99.95 Analysis Hydrogen
Fluoride
IC SAL
Laboratory
Not UKAS
accredited 98.08 Analysis Hydrogen
Sulphide
IC SAL
Laboratory
Not UKAS
accredited 98.07 Analysis Hydrocyanic
Acid (as CN)
Colorimetry SAL
Laboratory
Not UKAS
accredited 99.94 Analysis Chlorine IC SAL
Laboratory
Not UKAS
accredited
TA Luft Inorganics Class III SOP SOP type Parameter Method Standard Analysis by Accreditation
of Analysis
method
01.04 Sample
collection
Any gas with
use of
appropriate
tube selected
by reference to
manufacturer’s
web site
Sorbent tube N/A N/A
10.98 Analysis Ammonia Colorimetry SAL
Laboratory
Not UKAS
accredited
Environmental Efficiency Consultants Document 1247-02 v2.01
Emissions Monitoring Report for B2/2010
IPPC Licence No. P0288-02 Molex (Ireland) Ltd. Report 2 of 2010 Version 2.01
Page 16 of 32
Volume flow SOP SOP type Parameter Method Standard Analysis by Accreditation
of Analysis
method
01.31 Sample
collection
Velocity and
volume flow
rate
Determination
of velocity
using a Pitot
tube and
manometer
ISO
9096/
ISEN
13284
PART 1
Environmental
Efficiency
None
The following table summarises the equipment used and the QC checks. The SOP
details the equipment used and QC checks.
SOP Equipment QC Check
01.31 Pitot tube Zero check
01.31 Manometer Zero check
01.19 FID Zero check and Span check with calibration
gas at 500 ppm at start and end of use of FID
01.04 Pump (< 3 litres/minute) Flow rate set in lab prior to use on site
01.08 Isokinetic sampling train Leak Test. Swirl Test. Sample blank.
2.3 Uncertainty Calculations
Uncertainties are calculated for 95% confidence based on available data. The
calculations used are described by SOPs and the actual calculation for each
monitoring result is determined by spreadsheet referenced by the same SOP.
SOP
Method
96.01 UOM FGA and FID
96.02 UOM Isokinetic Monitoring
96.03 UOM of Oxygen determination by FGA
96.04 UOM of NOx determination by FGA
96.05 UOM of SOx determination by FGA
96.06 UOM of CO determination by FGA
96.07 UOM of CO2 determination by FGA
96.08 UOM of temperature determination by FGA
96.09 UOM of Boiler Efficiency determination by FGA
96.10 UOM Sorbent Tube
96.11
UOM of concentration by extraction onto self indicating colorimetric
tube
96.12 UOM of velocity measurement using Pitot tube
96.13 UOM of volume flow rate
96.14 UOM Impinger and pump
Environmental Efficiency Consultants Document 1247-02 v2.01
Emissions Monitoring Report for B2/2010
IPPC Licence No. P0288-02 Molex (Ireland) Ltd. Report 2 of 2010 Version 2.01
Page 17 of 32
Appendix 1 Emission Points A3-3
A1.1 Diagram of stack
A1.2 Data re the monitoring conditions are as below
Emission Point A3-3
Parameter Value Units
Date of test 12/10/2010 dd/mm/yyyy
Time of test 11.15 hour
Run time 30 minutes
Stack velocity 8.07 m/s
Stack Temperature 22.0 Celsius
Ambient Pressure 1,022 hPa
Oxygen % 20.9 %
Sampling plane
Platform
Sampling Plane
Environmental Efficiency Consultants Document 1247-02 v2.01
Emissions Monitoring Report for B2/2010
IPPC Licence No. P0288-02 Molex (Ireland) Ltd. Report 2 of 2010 Version 2.01
Page 18 of 32
A1.3 Analysis details where applicable
Environmental Efficiency Consultants Document 1247-02 v2.01
Emissions Monitoring Report for B2/2010
IPPC Licence No. P0288-02 Molex (Ireland) Ltd. Report 2 of 2010 Version 2.01
Page 19 of 32
Environmental Efficiency Consultants Document 1247-02 v2.01
Emissions Monitoring Report for B2/2010
IPPC Licence No. P0288-02 Molex (Ireland) Ltd. Report 2 of 2010 Version 2.01
Page 20 of 32
Environmental Efficiency Consultants Document 1247-02 v2.01
Emissions Monitoring Report for B2/2010
IPPC Licence No. P0288-02 Molex (Ireland) Ltd. Report 2 of 2010 Version 2.01
Page 21 of 32
Environmental Efficiency Consultants Document 1247-02 v2.01
Emissions Monitoring Report for B2/2010
IPPC Licence No. P0288-02 Molex (Ireland) Ltd. Report 2 of 2010 Version 2.01
Page 22 of 32
Environmental Efficiency Consultants Document 1247-02 v2.01
Emissions Monitoring Report for B2/2010
IPPC Licence No. P0288-02 Molex (Ireland) Ltd. Report 2 of 2010 Version 2.01
Page 23 of 32
Environmental Efficiency Consultants Document 1247-02 v2.01
Emissions Monitoring Report for B2/2010
IPPC Licence No. P0288-02 Molex (Ireland) Ltd. Report 2 of 2010 Version 2.01
Page 24 of 32
A1.4 Results Calculations
Calculation for flow rate – A3-3
Parameter Value Unit Comment
Velocity 8.07 m/s -
Duct cross section area 0.152 m2 -
Flow rate 4,415.9 m3/hour -
Duct Temperature 22 C -
Ambient pressure 1,022 hPa -
Normalised flow rate 4,122 Nm3/hour +/- 166.2
Environmental Efficiency Consultants Document 1247-02 v2.01
Emissions Monitoring Report for B2/2010
IPPC Licence No. P0288-02 Molex (Ireland) Ltd. Report 2 of 2010 Version 2.01
Page 25 of 32
Appendix 2 Emission point A3-4
A1.1 Diagram of stack
A1.2 Data re the monitoring conditions are as below
Emission Point A3-4
Parameter Value Units
Date of test 12/10/2010 dd/mm/yyyy
Time of test 11.35 hour
Run time 30 minutes
Duct velocity 7.61 m/s
Duct Temperature 22.0 Celsius
Ambient Pressure 1,022 hPa
Oxygen % 20.9 %
Sampling plane
Platform
Sampling Plane
Environmental Efficiency Consultants Document 1247-02 v2.01
Emissions Monitoring Report for B2/2010
IPPC Licence No. P0288-02 Molex (Ireland) Ltd. Report 2 of 2010 Version 2.01
Page 26 of 32
A1.3 Analysis details where applicable
Environmental Efficiency Consultants Document 1247-02 v2.01
Emissions Monitoring Report for B2/2010
IPPC Licence No. P0288-02 Molex (Ireland) Ltd. Report 2 of 2010 Version 2.01
Page 27 of 32
Environmental Efficiency Consultants Document 1247-02 v2.01
Emissions Monitoring Report for B2/2010
IPPC Licence No. P0288-02 Molex (Ireland) Ltd. Report 2 of 2010 Version 2.01
Page 28 of 32
Environmental Efficiency Consultants Document 1247-02 v2.01
Emissions Monitoring Report for B2/2010
IPPC Licence No. P0288-02 Molex (Ireland) Ltd. Report 2 of 2010 Version 2.01
Page 29 of 32
Environmental Efficiency Consultants Document 1247-02 v2.01
Emissions Monitoring Report for B2/2010
IPPC Licence No. P0288-02 Molex (Ireland) Ltd. Report 2 of 2010 Version 2.01
Page 30 of 32
Environmental Efficiency Consultants Document 1247-02 v2.01
Emissions Monitoring Report for B2/2010
IPPC Licence No. P0288-02 Molex (Ireland) Ltd. Report 2 of 2010 Version 2.01
Page 31 of 32
Environmental Efficiency Consultants Document 1247-02 v2.01
Emissions Monitoring Report for B2/2010
IPPC Licence No. P0288-02 Molex (Ireland) Ltd. Report 2 of 2010 Version 2.01
Page 32 of 32
A1.4 Results Calculations
Calculation for flow rate – A3-4
Parameter Value Unit Comment
Velocity 7.61 m/s -
Duct cross section area 0.369 m2 -
Flow rate 10,109.1 m3/hour -
Duct Temperature 22 C -
Ambient pressure 1,022 hPa -
Normalised flow rate 9,436 Nm3/hour +/- 380.4
Molex Ireland Limited Annual Environmental Report 2010
APPENDIX C
POLLUTION EMISSION REGISTER REPORT 2010
Molex Ireland Limited Pollution Emissions Register 2010
POLLUTION EMISSIONS REGISTER - 2010
Molex Ireland Limited Pollution Emissions Register 2010
1
CONTENTS
1. INTRODUCTION 2
2. USES AND METHOD OF MEASUREMENT OF MATERIALS 2
2.1 Nickel 2
2.2 Tin 4
3. PER RESULTS 5
3.1 Nickel 5
3.2 Tin 6
3.4 Pollution Emission Register 2010 7
Molex Ireland Limited Pollution Emissions Register 2010
2
1. INTRODUCTION Condition 6.11 of Molex’s IPPC Licence requires the company to prepare a Pollution Emissions Register (PER) on substances agreed with the EPA and to submit this as part of the company’s Annual Environmental Report (AER).
Molex submitted a proposal to the Agency in June 2002 stating that it would complete a mass balance PER on the following substances:
• Nickel • Copper
• Ammonia • Lead
• Tin
During the year 2006 Molex went lead free and ammonia free and advised the Agency in the 2006 AER of these developments and as such advised the Agency that lead and ammonia will be removed from the 2007 PER and subsequent PERs as there is no grounds to conduct a mass analysis on these agents and this continues to be the case.
During 2009 Molex ceased plating copper in Shannon and advised the Agency in the 2009 AER that copper plating had been discontinued.
Molex proposes to undertake a PER on nickel and tin for year 2011.
2. USES AND METHOD OF MEASUREMENT OF MATERIALS
2.1 Nickel
2.1.1 Uses of Nickel Nickel is used in the nickel plating solution and nickel anodes. The purpose of nickel plating is to prevent the migration of zinc into tin and copper into gold. It is the standard finish in connector manufacture. Also, nickel is used as an alloying element in palladium-nickel, where it possesses properties suitable for electronic applications.
Nickel is also used as a brightening and hardening agent in one gold plating bath.
The primary source of nickel is the metal anode. However a range of support chemistries containing nickel are required to replenish loss due to drag-out and plating inefficiencies.
In the case of palladium-nickel plating the chemistry is added as a soluble salt.
2.1.2 Measurement of Nickel The quantities of both the nickel going either to sewer or to the sludge were determined as follows:
Independently of the above, the nickel content of the sludge was determined by the waste contractors, World Resources.
The emissions to atmosphere from the plating department and the fugitive emissions were determined by external consultants.
Molex Ireland Limited Pollution Emissions Register 2010
3
Supplier records of weight of anode purchased indicated the amount of nickel plated onto parts and coupled with supplier information on nickel chemistries provided sufficient information for a mass balance on nickel.
It was assumed that the concentration of nickel chemistry in each of the plating baths is constant. This was a reasonable assumption since there is SPC control on the density of all plating baths.
As Molex Ireland do not have a direct method of measuring the amount of nickel plated onto the parts, it is reasonable to assume that accounting for the losses from the system via air extraction (measured), drag-out captured in effluent and sludge analysis, all the remaining nickel is plated onto the connectors.
Opening stock of nickel
(stock take)
=
Discharge to sewer
(analysis of discharge)
+ +
Change in inventory of nickel
(Supplier information)
Plating onto parts
(extrapolation)
+
Discharge to sludge
(analysis)
+
Emissions to atmosphere
(analysis)
+
Closing stock of nickel
(stock take)
+
Unaccounted losses
Molex Ireland Limited Pollution Emissions Register 2010
4
2.2 Tin
2.2.1 Uses of Tin Tin is plated on electronic connectors to afford them properties that allow ease of application, be it solderable joint or a friction contact surface.
There is one type of tin plating used in Molex Ireland during 2010.
. Pure tin, based on methyl sulphonic acid, currently there are six baths in operation.
Tin replenishment is both in soluble anode format and also as liquid chemistry.
2.2.2 Measurement of Tin The tin content of the waste sludge was determined by the waste contractors, World Resources. The emissions to atmosphere from the plating department and the fugitive emissions were determined by external consultants.
Supplier records of weight of anode purchased indicated the amount of tin plated onto parts and coupled with supplier information on tin chemistries provided sufficient information for a mass balance on tin.
It was assumed that the concentration of tin chemistry in each of the plating baths is constant. This was a reasonable assumption since there is close control on the exercised on the chemistries
Molex Ireland does not have a direct method of measuring the tin plated onto the parts, it is reasonable to assume that accounting for the losses from the system, via air extraction (measured), drag-out captured in effluent and sludge analysis, all the remaining tin is plated onto the connectors.
Opening stock of tin (stock take)
=
Discharge to sewer (analysis of discharge)
+ +
Change in inventory
(supplier information)
Discharge to sludge (analysis)
+
Emissions to Atmosphere (analysis)
+
Plating onto products
+
Closing stock
(stock take)
+
Unaccounted losses
Molex Ireland Limited Pollution Emissions Register 2010
5
3. PER RESULTS
3.1 Nickel
3.1.1 Mass Balance The mass balance was carried out over the period January to December 2010. The difference between inputs and outputs is known as the unaccounted losses.
The mass balance equation is as follows:
On– Cn + In = Dn + Pn + Dd + Ea + U
Table 3.1: Result of Mass Balance for Nickel
Initial Inputs Ref. Kg Final Outputs Ref. Kg
Opening Stock of Nickel
On 322.55 Discharge to Sewer
Dn 1.710
Change in Inventory of Nickel
In 2062.60 Plating onto Parts
Pn 1946.02
Closing Stock of Nickel Cn 346.6 Discharge to Sludge
Dd 90.82
Emissions to Atmosphere
Ea 0.0
Unaccounted Losses
U 0.0
3.1.2 Gross and Net Eco-Efficiencies
Index of Gross Eco Efficiency (IGEE)
IGEE = (Gross Process Waste / Gross Usage) x 100
= ((Dn + Dd +Ea + U) / (On– Cn + In) x 100
= ((1.71 + 90.82 + 0 + 0)/(322.55– 346.6+ 2062.60)) x 100
= 4.54
Index of Nett Eco-Efficiency (INEE)
INEE = ((Gross Process Waste–Material Recovered) / Gross Usage)) x 100
= (Dn + Dd + Ea – Dd + U) / (On– Cn + In) x 100
= ((1.71+ 90.82+ 0 – 90.82 + 0) / (322.55– 346.6 + 2062.6)) x 100
= 0.084
Molex Ireland Limited Pollution Emissions Register 2010
6
3.2 Tin
3.2.1 Mass Balance The mass balance was carried out over the period January to December 2010. The difference between inputs and outputs is known as the unaccounted losses.
The mass balance equation is as follows:
Ot – Ct + It = Dt + Dd + Ea + Pt + U
Table 3.3: Result of the Mass Balance for Tin
Initial Inputs Ref. Kg Final Outputs Ref. Kg
Opening Stock of Tin
Ot 206.1 Discharge to Sewer Dt 0.975
Closing Stock of Tin Ct 145.05 Discharge to Sludge Dd 513.77
Change in Inventory It 3,249.00 Emissions to Atmosphere
Ea 0.00
Plating onto product Pt 2795.31
Unaccounted Losses
U 0.00
3.2.2 Gross and Nett Eco-Efficiencies
Index of Gross Eco Efficiency (IGEE)
IGEE = (Gross Process Waste / Gross Usage) x 100
= ((Dt+ Dd + Ea + U) / (Ot – Ct + It)) x 100
= ((0.975 + 513.77 + 0 + 0) / (206.1 – 145.05 + 3249)) x 100
= 15.55
Index of Nett Eco-Efficiency (INEE)
INEE = ((Gross Process Waste–Material Recovered) / Gross Usage)) x 100
= (Dt + Dd + Ea – Dd + U) / (Ot– Ct + It ) x 100
= ((0.975 + 513.77 + 0 – 513.77 + 0) / (206.1– 145.05 + 3,249.00)) x 100
= 0.0294
Molex Ireland Limited Pollution Emissions Register 2010
7
3.3 Pollution Emission Register 2010
FACILITY IDENTIFICATION
Facility Name Molex Ireland Limited
Register No. 288-02
National Grid Reference E1397 N1622
Reporting Period
(mm-yy to mm-yy)
January 2010 to December 2010
Production units / amount Connectors plated 1,003,529,487
Employee No. 300
POLLUTANTS SUMMARY
Pollutant Name
CAS No. Input (kg)
Gross Usage
(kg)
Outputs
(kg)
Eco-Productivity
Indices
Air MoM
Liq. Eff. MoM
Waste MoM
Prod MoM Recovery
(kg)
Treated
(kg)
Unaccounted (kg)
IGEE INEE
Nickel 7440-02-0 2,038.55 2,038.55 0 M 1.71 M 90.82 B 1946.02 E 90.82 0 0 4.54 0.084
Tin 7440-31-5 3310.05 3310.05 0 M 0.975 M 513.77 B 2795.31 E 513.77 0 0 15.55 0.0294
Molex Ireland Limited Annual Environmental Report 2010
APPENDIX D
PRTR 2010 RETURNS EXCEL WORKSHEETS
| PRTR# : P0288 | Facility Name : Molex Ireland Limited | Filename : Heating Oil Consumption .xlsx | Return Year : 2010 | 2390 30/03/2011 09:06
Guidance to completing the PRTR workbook
Version 1.1.11
REFERENCE YEAR 2010
1. FACILITY IDENTIFICATIONParent Company Name Molex Ireland Limited
Facility Name Molex Ireland LimitedPRTR Identification Number P0288
Licence Number P0288-02
Waste or IPPC Classes of ActivityNo. class_name
12.3
The surface treatment of metals and plastic materials using an electrolytic or chemical process where the volume of the treatment vats exceeds 30 m3.
Address 1 Shannon Industrial EstateAddress 2 ShannonAddress 3 Co. ClareAddress 4
Country IrelandCoordinates of Location -8.89104 52.7086
River Basin District IEGBNISHNACE Code 2561
Main Economic Activity Treatment and coating of metalsAER Returns Contact Name Donal Horgan
AER Returns Contact Email Address [email protected] Returns Contact Position Environmental Health and Safety Manager
AER Returns Contact Telephone Number 061-702400AER Returns Contact Mobile Phone Number
AER Returns Workbook
AER Returns Contact Mobile Phone NumberAER Returns Contact Fax Number 061-702700
Production Volume 1003529487.0Production Volume Units pcs
Number of Installations 1Number of Operating Hours in Year 3840
Number of Employees 300User Feedback/Comments
Web Address www//molex.com
2. PRTR CLASS ACTIVITIESActivity Number Activity Name
2(f)Installations for surface treatment of metals and plastic materials using an electrolytic or chemical process
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 ?
4.1 RELEASES TO AIR Link to previous years emissions data | PRTR# : P0288 | Facility Name : Molex Ireland Limited | Filename : Heating Oil Consumption .xlsx | Return Year : 2010 | 30/03/2011 09:06
8 10 18 18 26 27 6 7 6 6 6 7 9SECTION A : SECTOR SPECIFIC PRTR POLLUTANTS
Please enter all quantities in this section in KGsQUANTITY
No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 Emission Point 2 T (Total) KG/YearA (Accidental) KG/Year
F (Fugitive) KG/Year
06 Ammonia (NH3) M CRM NIOSH 6015 1.44 0.0 1.44 0.0 0.080 Chlorine and inorganic compounds (as HCl) M CRM NIOSH 6011 0.8 1.55 2.35 0.0 0.085 Hydrogen cyanide (HCN) M CRM NIOSH 6010 3.33 156.67 160.0 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 POLLUTANTSPlease enter all quantities in this section in KGs
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/Year0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
SECTION C : REMAINING POLLUTANT EMISSIONS (As required in your Licence)Please enter all quantities in this section in KGs
QUANTITY
Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 Emission Point 2 T (Total) KG/YearA (Accidental) KG/Year
F (Fugitive) KG/Year
228 TA Luft inorganic dust particles class 2 M ALT ISO 9096/ISEN 13284-1 1.8 3.9 5.7 0.0 0.0229 TA Luft inorganic dust particles class 3 M ALT ISO 9096/ISEN 13284-1 2.0 18.6 20.6 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
Additional Data Requested from Landfill operators
Landfill: Molex Ireland LimitedPlease enter summary data on the quantities of methane flared and / or utilised
additional_pollutant_no T (Total) kg/Year M/C/E Method CodeDesignation or
DescriptionFacility Total Capacity m3
per hourTotal estimated methane generation (as per
site model) 0.0 N/AMethane 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
RELEASES TO AIRPOLLUTANT METHOD
Method Used
POLLUTANT
RELEASES TO AIR
RELEASES TO AIRMETHOD
POLLUTANT METHODMethod 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
Sheet : Releases to Waters AER Returns Workbook 25/3/2011 12:45
4.2 RELEASES TO WATERS Link to previous years emissions data | PRTR# : P0288 | Facility Name : Molex Ireland Limited | Filename : Heating Oil Consumption .xlsx | Return Year : 2010 | 30/03/2011 09:06
8 9 17 17 25 25 6 6 6 6 6 6SECTION 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
Please enter all quantities in this section in KGsQUANTITY
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/Year0.0 0.0 0.0 0.00.0 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 POLLUTANTSPlease enter all quantities in this section in KGs
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/Year0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
SECTION C : REMAINING POLLUTANT EMISSIONS (as required in your Licence)Please enter all quantities in this section in KGs
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/Year0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
RELEASES TO WATERS
Method Used
RELEASES TO WATERS
RELEASES TO WATERS
Method Used
POLLUTANTMethod Used
POLLUTANT
POLLUTANT
| PRTR# : P0288 | Facility Name : Molex Ireland Limited | Filename : P0288_2010_01 Eddeted.xls | Return Year : 2010 | Page 1 of 2
Sheet : Releases to Wastewater or Sewer AER Returns Workbook 25/3/2011 12:4
4.3 RELEASES TO WASTEWATER OR SEWER Link to previous years emissions data | PRTR# : P0288 | Facility Name : Molex Ireland Limited | Filename : Heating Oil Consumption .xlsx | Return Year : 2010 |30/03/2011 09:06
8 15 23 35 6 6 6 6 35SECTION A : PRTR POLLUTANTS
Please enter all quantities in this section in KGsQUANTITY
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
79 Chlorides (as Cl) M CRMProcedure based on EPA Standard Method 325.1 1950.0 1950.0 0.0 0.0
20 Copper and compounds (as Cu) M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 210.279 0.279 0.0 0.0
22 Nickel and compounds (as Ni) M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 211.71 1.71 0.0 0.0
12 Total nitrogen M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 2162.0 62.0 0.0 0.0
13 Total phosphorus M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 210.495 0.495 0.0 0.0
24 Zinc and compounds (as Zn) M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 210.044 0.044 0.0 0.0
17 Arsenic and compounds (as As) M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 210.011 0.011 0.0 0.0
23 Lead and compounds (as Pb) M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 210.003 0.003 0.0 0.0* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
SECTION B : REMAINING POLLUTANT EMISSIONS (as required in your Licence)Please enter all quantities in this section in KGs
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
303 BOD M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 21240.3 240.3 0.0 0.0
356 Cobalt M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 210.024 0.024 0.0 0.0
306 COD M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 21279.1 279.1 0.0 0.0
308 Detergents (as MBAS) M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 1998, 201.0 1.0 0.0 0.0
314 Fats, Oils and Greases M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 210.0 0.0 0.0 0.0
357 Iron M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 211.575 1.575 0.0 0.0
327 Nitrate (as N) M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 212.2 2.2 0.0 0.0
343 Sulphate M CRMProcedure based on EPA Standard Method 375.4 5565.0 5565.0 0.0 0.0
353 Sulphides M CRM Procedure based on Standard Methods for the Examination of Water and Wastewater 1998, 200.03 0.03 0.0 0.0
240 Suspended Solids M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 21173.3 173.3 0.0 0.0
358 Tin M CRM Procedure based on Standard Method for the Examination of Water and Wastewater 2005, 210.975 0.975 0.0 0.0331 Organohalogens M CRM Procedure based on EPA Method 8260B 0.0 0.0 0.0 0.0237 Volatile organic compounds (as TOC) M CRM Procedure based on EPA Method 8260B 0.048 0.048 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
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
Link to previous years emissions data Page 1 of 1
Sheet : Releases to Land AER Returns Workbook 25/3/2011 12:47
4.4 RELEASES TO LAND Link to previous years emissions data | PRTR# : P0288 | Facility Name : Molex Ireland Limited | Filename : Heating Oil Consumption .xlsx | Return Year : 2010 | 30/03/2011 09:06
8 8 16 16 6 6 6 6SECTION A : PRTR POLLUTANTS
Please enter all quantities in this section in KGsQUANTITY
No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
SECTION B : REMAINING POLLUTANT EMISSIONS (as required in your Licence)Please enter all quantities in this section in KGs
QUANTITY
Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
POLLUTANT METHODMethod Used
RELEASES TO LAND
RELEASES TO LAND
POLLUTANT METHODMethod Used
| PRTR# : P0288 | Facility Name : Molex Ireland Limited | Filename : P0288_2010_01 Eddeted.xls | Return Year : 2010 | Page 1 of 1
5. ONSITE TREATMENT & OFFSITE TRANSFERS OF WASTE | PRTR# : P0288 | Facility Name : Molex Ireland Limited | Filename : Heating Oil Consumption .xlsx | Return Year : 2010 | 30/03/2011 09:06
5 36 Please enter all quantities on this sheet in Tonnes 23
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 DestinationEuropean 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 Recoverer / Disposer / Broker Address of Recoverer / Disposer / Broker Name and Address of Final Destination i.e. Final Recovery / Disposal Site (HAZARDOUS WASTE ONLY) Licence / Permit No. of Final Destination i.e. Final Recovery / Disposal Site (HAZARDOUS WASTE ONLY)
Within the Country 16 01 17 No 3.025 ferrous metal R4 M Weighed Offsite in Ireland Hegarty Metals,WP05-04
Ballysimon ,Tipperary Road,Limerick,Co. Limerick,Ireland
Within the Country 12 01 03 No 0.484 non-ferrous metal filings and turnings R4 M Weighed Offsite in Ireland Hegarty Metals,WP05-04
Ballysimon ,Tipperary Road,Limerick,Co. Limerick,Ireland
Within the Country 12 01 99 No 22.908 wastes not otherwise specified R4 M Weighed Offsite in Ireland Hegarty Metals,WP05-04
Ballysimon ,Tipperary Road,Limerick,Co. Limerick,Ireland
Within the Country 17 04 01 No 31.611 copper, bronze, brass R4 M Weighed Offsite in Ireland Hegarty Metals,WP05-04
Ballysimon ,Tipperary Road,Limerick,Co. Limerick,Ireland
Within the Country 17 04 05 No 5.02 iron and steel R4 M Weighed Offsite in Ireland Hegarty Metals,WP05-04
Ballysimon ,Tipperary Road,Limerick,Co. Limerick,Ireland
Within the Country 20 01 01 No 92.812 paper and cardboard R3 M Weighed Offsite in Ireland Greenstar/Veolia,W0082-02
Ballykeefe,Dock Road,Limerick,Co. Limerick,Ireland
Within the Country 15 01 06 No 1.0 mixed packaging R3 M Weighed Offsite in Ireland Greenstar/Veolia,W0082-02
Ballykeefe,Dock Road,Limerick,Co. Limerick,Ireland
Within the Country 20 01 38 No 78.2 wood other than that mentioned in 20 01 37 R1 M Weighed Offsite in Ireland Greenstar/Veolia,W0082-02
Ballykeefe,Dock Road,Limerick,Co. Limerick,Ireland
Within the Country 20 02 01 No 2.84 biodegradable waste R3 M Weighed Offsite in Ireland Greenstar/Veolia,W0082-02
Ballykeefe,Dock Road,Limerick,Co. Limerick,Ireland
Within the Country 20 01 39 No 99.9 plastics R3 M Weighed Offsite in Ireland Greenstar/Veolia,W0082-02
Ballykeefe,Dock Road,Limerick,Co. Limerick,IrelandBallykeefe,Dock
Method Used
Within the Country 20 03 01 No 259.16 mixed municipal waste D1 M Weighed Offsite in Ireland Greenstar/Veolia,W0082-02
Ballykeefe,Dock Road,Limerick,Co. Limerick,Ireland
Within the Country 20 02 02 No 20.54 soil and stones R5 M Weighed Offsite in Ireland Greenstar/Veolia,W0082-02
Ballykeefe,Dock Road,Limerick,Co. Limerick,Ireland
Within the Country 17 01 07 No 7.56
mixture of concrete, bricks, tiles and ceramics other than those mentioned in 17 01 06 R5 M Weighed Offsite in Ireland Greenstar/Veolia,W0082-02
Ballykeefe,Dock Road,Limerick,Co. Limerick,Ireland
Within the Country 20 01 25 No 1.16 edible oil and fat R9 M Weighed Offsite in Ireland Frylite,WR-77Kilcolgan, , ,Co. Galway,Ireland
To Other Countries 20 01 40 No 44.93 metals R4 M Weighed AbroadMastermelt Refining Services Ltd,BL 1312
Staden Lane Industrial Estate,Ashbourne Road,Buxton Derbyshire.,SK17 9RZ,United Kingdom
Within the Country 18 01 04 No 0.898
wastes whose collection and disposal is not subject to special requirements in order to prevent infection (for example dressings, plaster casts, linen, disposable clothing, diapers) D1 M Weighed Offsite in Ireland
Cannon (OCS),WFP-LKC-09-001-01
North Richmond St.,Unit 2,Dublin 1,.,Ireland
To Other Countries 16 05 09 No 0.292discarded chemicals other than those mentioned in 16 05 06, 16 05 07 or 16 05 08 R1 M Weighed Abroad ENVA Ireland,WOO41-01
Smithstown Industrial Estate,.,Shannon.,Co. Clare.,Ireland
To Other Countries 15 02 02 Yes 0.759
absorbents, filter materials (including oil filters not otherwise specified), wiping cloths, protective clothing contaminated by dangerous substances R1 M Weighed Abroad ENVA Ireland,W0041/01
Smithstown Industrial Estate,.,Shannon.,Co. Clare.,Ireland
Lindenschmidt KG,47148089,Krombacher Str. 42-46,Kreuztal,Krombach ,Westfalen,Germany
Krombacher Str. 42-46,Kreuztal,Krombach ,Westfalen,Germany
Within the Country 11 02 05 Yes 1.2wastes from copper hydrometallurgical processes containing dangerous substances D9 M Weighed Offsite in Ireland ENVA Ireland,WOO41-01
Smithstown Industrial Estate,.,Shannon.,Co. Clare.,Ireland
Enva Ireland Ltd,W0041-01,Smithstown Industrial Estate,Smithstown ,Shannon,Co. Clare,Ireland
Smithstown Industrial Estate,Smithstown,Shannon,Co. Clare,Ireland
Within the Country 06 04 05 Yes 2.2 wastes containing other heavy metals D9 M Weighed Offsite in Ireland ENVA Ireland,W0041/01
Smithstown Industrial Estate,.,Shannon.,Co. Clare.,Ireland
Enva Ireland Ltd,W0041-01,Smithstown Industrial Estate,Smithstown ,Shannon,Co. Clare,Ireland
Smithstown Industrial Estate,Smithstown,Shannon,Co. Clare,Ireland
To Other Countries 11 01 98 Yes 3.446other wastes containing dangerous substances R1 M Weighed Abroad ENVA Ireland,W0041/01
Smithstown Industrial Estate,.,Shannon.,Co. Clare.,Ireland
Lindenschmidt KG,47148089,Krombacher Str. 42-46,Kreuztal,Krombach ,Westfalen,Germany
Krombacher Str. 42-46,Kreuztal,Krombach ,Westfalen,GermanyTo Other Countries 11 01 98 Yes 3.446 substances R1 M Weighed Abroad ENVA Ireland,W0041/01 Clare.,Ireland ,Westfalen,Germany ,Westfalen,Germany
To Other Countries 06 04 05 Yes 0.412 wastes containing other heavy metals R4 M Weighed Abroad ENVA Ireland,W0041/01
Smithstown Industrial Estate,.,Shannon.,Co. Clare.,Ireland
Linderschmidt KG,47148089,Krombacher Str. 42-46,Kreuztal,Krombach ,Westfalen,Germany
Krombacher Str. 42-46,Kreuztal,Krombach ,Westfalen,Germany
To Other Countries 16 05 08 Yes 0.069discarded organic chemicals consisting of or containing dangerous substances R1 M Weighed Abroad ENVA Ireland,W0041/01
Smithstown Industrial Estate,.,Shannon.,Co. Clare.,Ireland
Lindenschmidt KG,47148089,Krombacher Str. 42-46,Kreuztal,Krombach ,Westfalen,Germany
Krombacher Str. 42-46,Kreuztal,Krombach ,Westfalen,Germany
Within the Country 20 01 21 Yes 0.145fluorescent tubes and other mercury-containing waste R4 M Weighed Offsite in Ireland
Irish Lamp Recycling Co.,WFP-KE-08-348-01
Kilkenny Road,Athy,Co. Kildare,.,Ireland
Irish Lamp Recycling Co.,WFP-KE-08-348-01,Kilkenny Road,.,Athy,Co. Kildare,Ireland
Kilkenny Road,.,Athy,Co. Kildare,Ireland
To Other Countries 11 01 09 Yes 18.76sludges and filter cakes containing dangerous substances R4 M Weighed Abroad
Veolia Environmental Services Technical Solutions Ltd,W0050-02
Corrin,.,Fermoy,Co. Cork,Ireland
World Resources Comany GmbH,SL83A0032,IndustriesstraBe7,D-04808,Wurzen,.,Germany
IndustriesstraBe7,D-04808,Wurzen,.,Germany
To Other Countries 11 01 98 Yes 5.543other wastes containing dangerous substances R4 M Weighed Abroad
Veolia ES Techanical Solutions,W0054-02
Allied Industrial Estate,Unit 1,Kylemore Road,Dublin 10,Ireland
Mastermelt Refining Services Ltd,BL 1312,Staden Lane Industrial Estate,Ashbourne Road,Buxton,Derbyshire SK17 9RZ,United Kingdom
Staden Lane Industrial Estate,Ashbourne Road,Buxton,Derbyshire SK17 9RZ,United Kingdom
To Other Countries 16 05 04 Yes 0.06gases in pressure containers (including halons) containing dangerous substances R4 M Weighed Abroad Enva Ireland Ltd,W0184-01
Clonminam Industrial Estate,.,Portlaoise,Co. Laois,Ireland
SBH,121296753,Austrabe5,D74238,Krautheim,.,Germany
Austrabe5,D74238,Krautheim,.,Germany
Within the Country 13 02 08 Yes 9.7 other engine, gear and lubricating oils R9 M Weighed Onsite in Ireland Enva Ireland Ltd,W0184-01
Clonminam Industrial Estate,.,Portlaoise,Co. Laois,Ireland
Enva Ireland,W0194-01,Clonminam Industrial Estate,.,Portlaoise,Co. Laoise,Ireland
Clonminam Industrial Estate,.,Portlaoise,Co. Laoise,Ireland
To Other Countries 15 02 02 Yes 4.425
absorbents, filter materials (including oil filters not otherwise specified), wiping cloths, protective clothing contaminated by dangerous substances D10 M Weighed Abroad Enva Ireland Ltd,W0184-01
Clonminam Industrial Estate,.,Portlaoise,Co. Laois,Ireland
KWA,E17012100,Graftstr,25,47475 Kamp-Lintfort ,.,Germany
Graftstr,25,47475 Kamp-Lintfort ,.,Germany
Within the Country 15 01 02 No 8.81 plastic packaging R3 M Weighed Offsite in Ireland Danelle,WP01/08Kilnock,".",Ballon,Co. Carlow,Ireland
absorbents, filter materials (including oil Lindenschmidt KG,47148089,Krombacher
To Other Countries 15 02 02 Yes 0.078
absorbents, filter materials (including oil filters not otherwise specified), wiping cloths, protective clothing contaminated by dangerous substances R4 M Weighed Abroad ENVA Ireland,W0041/01
Smithstown Industrial Estate,.,Shannon.,Co. Clare.,Ireland
KG,47148089,Krombacher Str. 42-46,Kreuztal,Krombach ,Westfalen,Germany
Krombacher Str. 42-46,Kreuztal,Krombach ,Westfalen,Germany
Within the Country 06 02 04 Yes 1.0 sodium and potassium hydroxide D9 M Weighed Offsite in Ireland ENVA Ireland,WOO41-01
Smithstown Industrial Estate,.,Shannon.,Co. Clare.,Ireland
Enva Ireland Ltd,W0041-01,Smithstown Industrial Estate,Smithstown ,Shannon,Co. Clare,Ireland
Smithstown Industrial Estate,Smithstown,Shannon,Co. Clare,Ireland
* Select a row by double-clicking the Description of Waste then click the delete button
Link to previous years waste dataLink to previous years waste summary data & percentage change
Sheet : Releases to Waters AER Returns Workbook 25/3/2011 12:45
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
| PRTR# : P0288 | Facility Name : Molex Ireland Limited | Filename : P0288_2010_01 Eddeted.xls | Return Year : 2010 | Page 2 of 2
Molex Ireland Limited Annual Environmental Report 2010
APPENDIX E
BUND INTEGRITY REPORT 2010
Tel: + 353 (0)1 276 1428 Fax: + 353 (0)1 276 1561 Email: [email protected] www.enviro-consult.com
Registered Office as above. Registered Number 243 412
Directors: Noel J. McGrath, Robert B. Sutcliffe
Bund Integrity Test Report
for
Molex Ireland Ltd
IPPC Licence P0288-02
EEC Document No.1247-03
Molex Ireland Limited Bund Assessment Report
Environmental Efficiency Document No1247-03 v1.0; Page 2 of 13
QF 1. Document Lead Sheet Document Title Bund Integrity Test Report Project No. 1247 Document No. 1247-03 Client Molex Ireland Limited EPA Licence Number P0288-02
Issue Status Date Author Signed for and on behalf of
Environmental Efficiency
Client
1 Approved 19/07/2010 RBS
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: Bob Sutcliffe, CEng, MIMechE
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.
Molex Ireland Limited Bund Assessment Report
Environmental Efficiency Document No1247-03 v1.0; Page 3 of 13
1. Introduction Molex Ireland Ltd has an IPPC licence. This licence requires that the water tightness of all bunding structures and their resistance to penetration by water or other materials stored therein to be assessed. This report documents the assessment of the bunds on site against this requirement
2. Summary The bunds shown in the table below were assessed. The table describes the assessment method and the results.
Table 1 Tested bunds
Bund No. Bund description Bund Type
Sufficient Capacity?
Assessment Method
Pass/Fail Assessment
01 Plating Area Sump Local Yes VI Pass 02 Chemical Store Bund Local Yes VI Pass 03 Oil Storage Area Local Yes VI Pass 04 Oil storage Bund Local Yes VI Pass 05 Effluent Treatment Area Sump Local Yes VI Pass
Notes
1. The Bund Type is Local, Remote or Combined as per EPA Guidance Note on Storage and Transfer of Materials for Scheduled Activities. The bund types ‘Sump Pallet’ and ‘Double Skinned’ are variants of Local
2. Sufficient Capacity? Sufficient capacity refers to whether the bund meets the EPA 110%/25% capacity rule. Individual bunds should be sized so that their capacity is the greater of 110% of the largest tank within the bund or 25% of the total capacity of tanks and drums in the bund. Where this is not the case, it is commented on in the discussion section. Note that as Sump Pallets do not have a defined primary containment associated with them, the sufficient capacity criterion is not applicable.
3. Assessment Method. a. WRT. The preferred assessment method is a water retention test. The test is
normally to a height that tests the required capacity of the bund. Unless otherwise stated the test protocol is CIRIA 163.
b. VI. Sometimes this is not possible to undertake a water retention test due to low lying electrical equipment or other reason; where this is the case a visual inspection is carried out by a Chartered Engineer.
c. WRT + VI. Where a visual inspection is required, it is sometimes necessary to supplement the visual inspection by a water retention test of the test the bund floor or floor/wall joints.
4. Pass/Fail Integrity Test. If the bund fails the water retention test or visual inspection, then this is denoted as a fail and is commented upon elsewhere in the report.
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3. Assessment methods One or more of the following assessment methods were used.
3.1 Water retention test CIRIA 163 is published by Construction Industry Research and Information Association, 6 Storey’s Gate, Westminster, London, SW10 3AU, www.ciria.org.uk. The CIRIA protocol is specifically designed for the testing of bunds located in sites defined as being highly sensitive. This is a six-hour test over which there should be no loss of water after adjustments for rainfall. Environmental Efficiency now uses the CIRIA 163 protocol in preference to the protocol defined in BS8007. This is because BS8007 is primarily concerned with the design of concrete structures for retaining aqueous liquids, e.g. water tanks and reservoirs. BS8007 is not concerned with the secondary containment of hazardous liquids. In addition, the BS8007 test period is for seven days. This means that there is no bund protection for the test period.
3.2 Visual inspection In certain cases a water retention test is not possible. Potential reasons include • The water retention test would require an excessive amount of water • The test water would be contaminated • There is a danger of tank floatation where tanks are not full • Electrical equipment (such as pumps or trace heating) or insulation would be
damaged by flooding the bund • A water retention test would impede the normal operations of the plant
Where a water retention test is not possible then the assessment of water integrity is by means of a visual inspection by a Chartered Engineer. The visual inspection is to ensure that in the opinion of the engineer that the bund is capable of retaining the tanks contents in the event of tank failure. Where the tank is a self bunded tank, also known as a double skinned tank, then the visual inspection is to determine whether the inner skin is liquid tight and also whether the outer skin has any damage. This inspection is as follows
• To determine whether the inner skin is liquid tight a flexible tape is passed between the inner and outer skin to check for the presence of the tank contents (e.g. oil). If there is no trace of the tank contents, then this indicates that the tank is liquid tight. If there are traces of the tank contents, then the self bunded tank has failed the inspection.
• To determine whether the outer skin is liquid tight, the outer skin is examined for cracks, holes or other damage. Any damage will result in a fail.
Where a plastic self bunded tank has no protection from vehicle collision, then this will not result in a fail but remedial action to protect the tank will be recommended.
3.3 Water Retention Test plus Visual Inspection Where a Water Retention Test to the full capacity of the bund is not practical but the inspecting engineer is of the opinion that a Visual Inspection will not give the
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necessary degree of assurance as to integrity, a water retention test to a low level (e.g. to below the plinth of a motor) plus a visual inspection is carried out. Such a combination of assessment is applied where there is doubt as to the integrity of the bund floor or floor/wall joint.
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4. Bund assessments
4.1 Bund 01 Plating Area Sump
4.1.1 Capacity Contents Rinse water Bund Type Local Largest tank Approximately 1,000 litre Total tank capacity Approximately 4,030 litre Required bund capacity 1 m3
Bund floor area 4 m x 1.45 m = 5.8 m2
Bund wall height 2.2 m Actual bund capacity 12.76 m3
Status Pass
4.1.2 Construction Construction Sump in ground. Concrete walls lined with ceramic tiles. Status Pass
4.1.3 Defects There are no defects
4.1.4 Test A water retention test to full capacity is not possible as there is a danger of tank floatation. A visual inspection was therefore carried out by a Chartered Engineer. The walls and floor appear to be in good condition and assessed as being water tight and therefore the bund passed the visual inspection It is noted that the sump is below ground and that it is well documented that the water table is very high in the area. Any lack of integrity would result in ingress of water. There was no evidence of any water ingress. A channel directs spills in to the bund from the shop floor. This was also visually inspected and was found to be satisfactory.
4.1.5 Recommended remedial action There is no recommended remedial action.
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4.1.6 Photographs
Figure 1 View into Bund 01
4.2 Bund 02 Chemical Store bund
4.2.1 Capacity Contents Various drums of acids, plating solutions and other
chemicals. Bund Type Local Largest tank 2,000 litre Total tank capacity 5,440 litre Required bund capacity 2.2 m3
Bund floor area Area 1: 9.00 m x 8.55 m Area 2: 8.40 m x 8.55 m x 0.50 m
Bund wall height 0.50 m Actual bund capacity 74.39 m3
Status Pass
4.2.2 Construction Construction Reinforced mass concrete with ceramic tiled walls. Status Pass
4.2.3 Defects There are no defects
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4.2.4 Test A water retention test to full capacity is not possible as there is a danger of drum floatation. A visual inspection was therefore carried out by a Chartered Engineer. The walls and floor appear to be in good condition and assessed as being water tight and therefore the bund passed the visual inspection.
4.2.5 Recommended remedial action There is no recommended remedial action.
4.2.6 Photographs
Figure 2 Bund 02, typical condition of walls and floor
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4.3 Bund 03 Oil storage area
4.3.1 Capacity Contents Various oils including waste oil Bund Type Local Largest tank 2,500 litre Total tank capacity 8,100 litre Required bund capacity 2.75 m3
Bund floor area 10.0 m x 2.2 m = 22.2 m2
Bund wall height 0.45 m Actual bund capacity 9.99 m3
Status Pass
4.3.2 Construction Construction Mass concrete with rendered walls. Status Pass
4.3.3 Defects There are no defects
4.3.4 Test A water retention test is not possible as there is a test water would be contaminated (there are some oil spills on the floor of the bund). A visual inspection was therefore carried out by a Chartered Engineer. The walls and floor appear to be in good condition and assessed as being water tight and therefore the bund passed the visual inspection.
4.3.5 Recommended remedial action There is no recommended remedial action.
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4.3.6 Photographs
Figure 3 Bund 03, general view
4.4 Bund 04 Oil Storage Bund
4.4.1 Capacity Contents Gas oil Bund Type Local Largest tank 36,230 litre Total tank capacity 36,230 litre Required bund capacity 39.25 m3
Bund floor area 10.65 m x 4.75 m = 50.59 m2
Bund wall height 1.4 m Actual bund capacity 70.8 m3
Status Pass
4.4.2 Construction Construction Reinforced mass concrete with rendered walls. A sump is
present. Status Pass
4.4.3 Defects There are no defects
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4.4.4 Test A water retention test to full capacity is not possible as an excessive amount of test water would be required. A visual inspection was therefore carried out by a Chartered Engineer. The walls and floor appear to be in good condition and assessed as being water tight and therefore the bund passed the visual inspection
4.4.5 Recommended remedial action There is no recommended remedial action. It is however noted that the oil tank is showing signs of age (see photograph below). It is understood that the tank will be replaced at some time in the future.
4.4.6 Photographs
Figure 4 Bund 04, general view
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4.5 Bund 05 Effluent Treatment area sump
4.5.1 Capacity Contents Rinse water Bund Type Local Largest tank 5,666 litre Total tank capacity 17,000 litre Required bund capacity 6.23 m3
Bund floor area 6.00 m x 1.50 m = 9.00 m2
Bund wall height 3.3 m Actual bund capacity 29.7 m3
Status Pass
4.5.2 Construction Construction Reinforced mass concrete Status Pass
4.5.3 Defects There are no defects
4.5.4 Test A water retention test to full capacity is not possible as there is low lying electrical equipment and a danger of tank floatation. A visual inspection was therefore carried out by a Chartered Engineer. The bund is below ground and inspection from ground level is not practical. The bund was therefore entered (the inspecting engineer possessed a Confined Space Certificate). The walls and floor appear to be in good condition and assessed as being water tight and therefore the bund passed the visual inspection.
4.5.5 Recommended remedial action There is no recommended remedial action.
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4.5.6 Photographs
Figure 5 Bund 5, general view interior
Molex Ireland Limited Annual Environmental Report 2010
APPENDIX F
EXECUTIVE SUMMARY OF FIRE WATER RETENTION STUDY 2010
Executive Summary
Molex (Ireland) Ltd. has contracted Project Management Group Ltd. (PM) to carry out a
fire-water retention study on its electrical components manufacturing facility in the
Shannon Industrial Estate, in accordance with Condition 3.7 of its IPPC Licence, register
number P0288-02. The purpose of this study is to determine the requirement or otherwise
for the provision of dedicated on-site fire-water retention on the basis of an environmental
risk assessment. This document updates the previous Firewater Study and its
recommendations as reported in PM document reference 101155-22-RP-0001 of April 2006
which concluded that a 500m3 firewater retention facility be established.
Since 2006, the net number of electroplating lines on site has reduced by six, returning the
capacity to 1998 levels. Removal of plating lines has resulted in the removal of copper plating
and pure tin plating processes from the site. This has resulted in a reduction of the inventory
of polluting substances and a corresponding reduction in the risk of water pollution in the
case of fire.
An assessment of the overall changes in the risk to the environment from potentially
contaminated fire-water arising on the site has been performed in order to update the
findings of the previous firewater study in lines with the EPA’s “Draft Guidance Note on
Fire-water Retention Facilities”.
This study concludes that:
1. Having reviewed the inventory for the production area in light of the recent reduction of
plating lines, the volumes of materials are such that they are now below the threshold for
the requirement for a firewater retention facility. Every effort should be made to minimise
the inventory of the more hazardous substances used in plating.
2. The maximum quantities of potentially polluting materials stored and used within the
other areas of the facility are small in the context of national and European guidelines for
fire-water run-off environmental risk assessment, and the potential contamination level of
any fire-water release from these areas is low.
CONCLUSION Having reviewed the inventory for the production area in light of the recent reduction of
plating lines, the volumes of materials are such that they are now below the threshold for
the requirement for a firewater retention facility. Every effort should be made to minimise
the inventory of the more hazardous substances used in plating.
The principal potential pollutants on site which could contaminate fire water are the plating
solutions used in the plating shop as described in Scenario (ii) in Section 6. The total WGK 1
equivalent quantity for the four areas in Production is less than the 100 tonne guideline for
WGK 1 equivalent material requiring firewater retention capacity.
The maximum quantities of potentially polluting materials stored and used within the other
areas of the facility are small in the context of national and European guidelines for fire-
water run-off environmental risk assessment, and the potential contamination level of any
fire-water release from these areas is low.