attachment d - environmental protection agency, … of aluminium scrap) ... shredded alum. store 1...

Attachment D.

ATTACHMENT D

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EPA Export 25-07-2013:16:52:18

of 15 Attachment No D

OPERATIONAL INFORMATION REQUIREMENTS

Development and Operational History

P. CARNEY LTD. was founded in 1964 by the late Mr. Paddy Camey. The company was set up originally as a scrap metal deaiership, sourcing scrap metal from around Ireland and selling it to the metal recycling industry, both on the home and export markets.

In the 60’s, due to the availability of considerable quantities of aluminium scrap, the high freight rates associated with exporting scrap to the U.K. and because of Mr. Camey’s considerable knowledge of the aluminium alloy ingot manufacturing process, it was decided to commence manufacturing aluminium alloy ingots and the first furnaces were introduced for the manufacture of same. This process was developed and enhanced throughout the 1970’s and a Direct Reading Spectrograph was introduced in 1970 for analysing aluminium alloys. This technology for analysing aluminium allowed for specific markets to be targeted.

During the 1970’s the company decided to specialise in the recycling of aluminium scrap and copper and aluminium cables.

In the early 1980’s new granulation technology was introduced and all cables were subsequently granulated. This granulation technology involves the mechanical chopping of the cables and the separation of the copper and/or aluminium from its coverings using a combination of air and vibration. This is a totally environmentally friendly process with no heat involved whatsoever.

In the early 1980’s the aluminium ingot end of the business was expanded with the installation of new furnaces and the automotive industry was specifically targeted as the main customer. Throughout the 80’s a relationship was developed between the company and the customer. The 80’s also saw the introduction of newer spectrographic technology for analysing aluminium alloy ingots.

In the early 1990’s these furnaces were in-turn replaced by larger, more efficient and more environmentally friendly ones.

With the introduction of granulation technology in the early 1980’s the company developed a market for pure copper and pure aluminium granules. These markets were developed and by the end of the decade two further complete systems were

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of15 Attachment No D

added. These systems have now the capacity to treat approximately 10,000 tonnes of cables per year.

The copper granules manufactured by this process are exported and used directly in the production of copper pipe and tube. The aluminium granules are either used by steelworks as a deoxidant or are melted in our own aluminium alloy ingot production process.

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ACTIVITY 1 (ALUMINIUM ALLOY INGOT PRODUCTION) AT P. CARNEY LTD,

There is one product produced in the aluminium alloy ingot production area at P. CAGNEY LTD. namely aluminium alloy ingots. The site plan which follows on page 4 shows the part of the site in which this section of the activity is performed.

The flowchart on page 5 of this attachment shows the preparatory stages for the material before it enters the furnacing process. The main incoming materials (various types of aluminium scrap) come in from the supplierrs, are weighed, sorted and stored until that particular material type is required to make up a charge for the furnacing process.

In order to produce the particular aEuminium alloy required by the customer small qutintities bf other metals are added as part of the charge to produce an alioy with the correct material specification.

Page 6 of this attachment shows the overall plant layout of the ingot production area.

The last page of this attachment shows the flow of the material from when it enters the loading bin on the tinace to when it is a final product ready for despatch. This stage of the process involves loading the charge material into the fiu-nace, melting it and analysing the molten metal to ensure that it meets the customer’s exact specification. The molten metal is then poured into ingot moulds. The material solidifies and is now in the form of a solid aluminium alloy ingot. The ingots are then moved to the ingot store where they are stacked, strapped, marked, shrink - wrapped and stored ready for despatch.

In the course of the ingot production, aluminium skimmings is removed from the furnace. This material is then further treated in a machine called “The Press”. This Press recovers some of the aluminium on site by a pressing/cooling process and the remaining material is formed into a “skull” which still has a high aluminium content. These skulls are then sold and sent to a company in the U.K. where the remaining aluminium is recovered and further reused in aluminium alloy ingot production.

The gases from the furnace are collected from the furnace using an extraction hood which is located over the outlet flue of the furnace. The gas is then sucked along a duct into a ceramic filtration unit. The filtration plant contains 1,080 filter elements. Each element is 1.25 m long and is 50 mm in diameter. In this filtering unit the particulates contained in the gas stream are filtered from the gas and the gas is emitted to the atmosphere via a 22m high stack. The particulates which are removed from the gas stream are collected in a hopper and are emptied into a collection container. It is proposed that this material will be disposed of in a properly licenced landfill site.

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of15

Site Plan Sketch of P. CAFWEY LTE.

Attachment No D

System 4

a

~

System 2 &3

Maintenance Workshop

i

Lower Yard

Starage Area

Shredded Alum. Store

/

Offices

Cable Sorting Shed

Toilets / Wash Room

Alum. Sorting I Cutting I Baling Shed

AilUII. Sorting Area

Sorted Alum. Area

Alum. To be sorted/ Sorted Alum. Area

Ingot Store

Store

~

Furnace Shed

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MATERIAL PRZPARATORY STAGES BEFORE THE FURNACING PROCESS FOR THE PRODUCTION OF

ALUMINIUM ALLOY INGOTS

Sorting / Separating ‘; stores

I

Magnesium Magnesium From From

Supplier Supplier

Manganese Manganese From From

Supplier Supplier

Copper from I Copper Stores

I

Silicon From

Supplier

Aluminium Granules l%om Ali. Gran. Store

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of 1.5

ALUMINIIJM ALLOY INGOT PRODUCTION AREA

Abatement System

I Casting Machines x 2 I

Decommissioned I

I

#sting Machines x 2

Furnace 1 El

Attachment No D

Dross 0 Press

4Emission Poil_i

I

Single stack

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MATERIAL FLOW - ALUM~IUM ALLOY INGOT PRODUCTION

Mat&a-l In Ski-mmings Out , Bin + Press

Recovered Metal Out

Stores

Bin Exported for further recovery of metal

Ingot storE

1

eked, Strapped, Marked and Wrapped

1 Flow of material

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EPA Export 25-07-2013:16:52:19

ofiS Attachment No D

ACTIVXTY 2 (GRANULATION)

AT P. CAIWEV LTD.

There are two main products produced in the granulation area at P. CARNEY LTD, namely copper gram&s and ahm~inium granules. of this attachment {Attachment D) shows the genera1 area of the site where this section of the activity is performed.

The following flow chart (see page 10) shows the preparatory stages for the material before it is processed on the granulation systems. Similar to that for the aluminium in Activity 1, the incoming material (scrap cables) comes in from suppliers, is weighed, sorted and stored until that particular material is required for either of the granulation systems.

Page 11 of this attachment shows the overall plant layout of the granulation area.

Pages 12, 13 and 14 show the flow of material in each of the systems (2, 3 & 4). As can be seen from the diagrams these three systems are very similar. This stage of the process invsIves loading the scrap cable into the relevant granulating system. There are three outputs from the systems namely metal granules (copper or aluminium), granules and plastic mixed, and plastic. The metal granules (copper or aluminium) are finished product and can be despatched to the customer, the granules and plastic mix can be put through a granulating system again and the plastic sold and used as a floor covering for horse arenas.

Page 15 shows the flow of material through the R 1400 which is the first stage of system 3. This process involves the initial chopping of the wire before it goes through a granulahn system.

Page 15 also shows tie flow of material through the Eldan Shaker. Because of the nature (fineness etc.) of the metal in some cables it is not possible to remove 100% metal from the plastic in the granulation systems. The Shaker is a separate small machine with screens over which is passed the plastic that contains this very small percentage of metal - thus recovering practically all of the metal.

Waste materials generated from the granulation area are:

1. Dust/Plastic fines (Collected in dust Bags and disposed of in landfill j

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EPA Export 25-07-2013:16:52:19


SITE PLAN SKETCH OF P. C-Y LTD.

System 4

Eldan Shaker

System 2 853

ltenance Workshop

Lower Yard

Storage Area

Shredded Alum. Store 1 Store

I

Miscellaneous Storage Area

Cable SorGng Shed

Canteen

~ Ofiices

Toilets i Wash Room

Alum. Sorting I Cutting / Baling Shed

Alum. Sorting Area

sorted Alum. Area

Alum. To be sorted Sol-t4 Alum. Area

Ingot Store

Store

Furnace Shed

Lab Store Oil Storage Area

Alum. Skull Store

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MATERIAL PREPARATION STAGES BEFORE THE

GRANULATING PROCESSES FOR THE PRODUCTION

OF COPPER & ALUMI[NI[UM GRANULES

I I

Scrap Cable Scrap Cable From Supplier From Supplier

Weighed Weighed And Tipped And Tipped

Sorting / Separating

~ f Stored E

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Pagellof15 Attachment No D

PLANT LAYOUT OF GRANULATING AREA

AT P. CARNEY LTD.

System 4

-------------- l

i

I Aluminium

I Granule Stores

System3

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of 1.5 Attachment No D

MATERIAL FLOW - GRANULATING SYSTEM 3

Relt 1

Belt Collection

Granulator t

Dust Out

Silo

Auger

Separating Table

Belt 2 Belt 3

Bin Bin

4 Flow of material

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MATERIAL FLOW - GJRANULATING SYSTEM 4

Auger

I ? ~Belt

I

Hydraulic Grab

Cimp (chops)

Collection Bags

z

Belt with Magnets d Steel out \

Belt \

Belt \

Granulator - Dust Out \

4

Material in (Copper and/or Aluminium)

Belt 2

Bin

Auger

Bin 1 Flow of material

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EPA Export 25-07-2013:16:52:19


MATERIAL FLOW - GRANULATING SYSTEM 2

MaterialIn

Belt Collection Bags

Rasper (chops)

Belt with Magwts -b steel out

Belt

Belt

Granufator

Silo

Separating Table

Auger

Bin

I

Auger

1 Flow of material Shaker

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EPA Export 25-07-2013:16:52:19


,

k&ATE&&CAL FLOW - R 1400

Material In

Hydrdic Crab

R 1400 Super Rasper

Belt

Storage 1 Flow of material

MATERIAL FLOW - ELDAN SHAKER SYSTEM

Material In (Plastic with Copper)

Bin 1 Flow of material

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EPA Export 25-07-2013:16:52:19

attachment d - environmental protection agency, … of aluminium scrap) ... shredded alum. store 1...

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