clara road, millstreet, co. cork. · 2017-05-30 · 3. solvent emissions directive ... laser...
TRANSCRIPT
ALPS Electric (Ireland) Limited.
IPPC Licence (Reg: P0835-01) Clara Road, Millstreet, Co. Cork.
SOLVENT MANAGEMENT PLAN 2016
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Solvent Management Plan 2016
Contents
1. INTRODUCTION ...................................................................................................................................1
2. PROCESS DESCRIPTION ....................................................................................................................3
3. SOLVENT EMISSIONS DIRECTIVE ..................................................................................................6
3.1 COMPLIANCE REQUIREMENTS .......................................................................................................6
3.2 COMPLIANCE ...................................................................................................................................7
3.3 QUALITY CONTROL .........................................................................................................................8
3.4 ALPS ELECTRIC (IRELAND) LTD. SOLVENT STORAGE AND DISTRIBUTION .......................8
3.5 DISPOSAL OF USED SOLVENT FROM SITE ....................................................................................9
4. LICENCE EMISSION MONITORING LOCATIONS .................................................................. 10
4.1 SUMMARY OF AIR EMISSIONS .................................................................................................... 10
4.2 AIR COMPLIANCE SUMMARY ...................................................................................................... 12
5. SOLVENT CONSUMPTION AND MANAGEMENT ................................................................. 13
5.1 SOLVENT CONSUMPTION ............................................................................................................ 13
6. QUANTIFICATION OF SOLVENT ................................................................................................. 18
7. SOLVENT MASS BALANCE ............................................................................................................ 19
8. CONCLUSION..................................................................................................................................... 20
Appendix 1 Glossy of Terminology
Appendix 2 Summary of all Solvents used at ALPS Electric (Ireland) Ltd. in 2016
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1. Introduction
The Solvent Management Plan has been prepared by ALPS Electric (Ireland) Ltd.
to fulfill Condition 6.15 of the Integrated Pollution Prevention Control (IPPC)
Licence (Register No. P0835-01).
ALPS Electric (Ireland) Ltd. is located in Clara Road, Millstreet, Co. Cork. ALPS
Electric (Ireland) Ltd. is licenced for the principal activity of Surface Coatings
under Class 12.2.2 the Environmental Protection Agency Acts, 1992 to 2007. The
activity description in the IPPC Licence is as follows:
The manufacture or use of coating materials in processes with a capacity to make
or use at least 10 tonnes per year of organic solvents and powder coating
manufacture with a capacity to produce at least 50 tonnes per year, not included
in paragraph 12.2.1.
Condition 6.15 of the IPPC Licence is as follows:
The licensee shall prepare and report a Solvent Management Plan for the site for
each calendar year. The organic solvents to be included in the SMP shall be
determined by reference to the definition of an organic solvent in Council
Directive 1999/13/EC. The SMP shall be prepared in accordance with any
relevant guidelines in Annex Ill of the Directive or as issued by the Agency and
shall be submitted as part of the AER. The licensee shall keep records of the data
from which the reported information was derived and supporting documentation
including a description of the methodology used for data collection.
1.1 Purpose of the Report
The SMP has been prepared to verify compliance with the conditions of the
IPPC Licence by undertaking a mass balance of the annual solvent consumption
throughout the facility. The inputs amount of solvent to the site were weighed
against the outputs through emissions to air, water and waste. The resultant
difference between input and outputs is classified as fugitive emissions and is
evaluated to determine compliance with licenced limit values.
There are a number of pathways through which solvent can be lost as a result of
process within ALPS Electric (Ireland) Ltd. facility as outlined in Figure 1.
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Figure 1 Pathways of Solvent Loss
Solvent lost to waste
water treatment
Product
Chemical/
Physical Reaction
I2
Solvent A1-3,A2-1,A2-3
incinerated/adsorbed
Uncaptured Solvent
Air Emission
Solvent
Purchased
Solvent
Purchased
Solvent Recycled
I2
O5
O2
O7
O5
Collected Waste Solvent
Collected Waste Solvent
Solvent for reuse
elsewhere
Solvent for reuse
elsewhere
Chemical/ physical reaction physical reaction
Solvent Waste Gas Emission
Solvent
Purchased
Product
Residue
Solvent for Reuse
Elsewhere
Solvent Waste
Collected
Solvent lost to
wastewater
treatment
O8
O6
O3
O5
O1
O4
Solvent
Input
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2. Process Description
ALPS Electric (Ireland) Ltd. production process involves fabrication of plastic
parts and assembly of components onto printed wiring boards.
The main processes involved in the manufacture of the product are as follows:
Injection moulding of “non-cosmetic” plastic parts used in the assembly of
the products
Paint and lasering of decorative cosmetic parts.
Surface Mounting Process and wave soldering mount processes (Printed
wiring board stuffing)
Final assembly of units (assembling plastic parts to Printed wiring boards)
and including inspection and testing of finished units.
There are six key steps involved in the production of the wiring boards. A
description of the production process and how it relates to the Solvent Directive
is outlined in the following section.
Fabrication of plastic parts:
Fabrication of plastic parts:
1. Moulding Process
Plastic granules undergo injection moulding. The moulds are annealed, cooled
and cleaned.
2. Painting And Laser Tech Process
Moulds (plastic parts) requiring cosmetic coating are coated with a mixture of
paint, thinner and hardener using high volume low pressure (HVLP)
technology. Coated parts undergo a flash period of 15 minutes followed by
curing in an oven at 80oC.
Moulds are coated in two enclosed booths using automatic high volume low
pressure (HVLP) spray guns. Overspray is captured by a water curtain and
solvents are emitted without further abatement to emission point A1-3.
Solvent losses from mixing areas, flash off area and curing ovens are emitted
unabated through emission point reference A2-1. Solvent losses from manual
assembly process (flux and conformance coating) are directed unabated to
emission point A1-3 and A2-3. Emissions from these points vary on an annual
basis based on productivity however are approximately 3 kg/hr.
Laser etching of some parts is also undertaken. Annual solvent usage for this
coating activity varies on an annual basis based on productivity however is
estimated between 30-40 tonnes.
Licenced Activity: "Other Coating" Solvents Directive Annex IIA Activity 8.
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3. Raw Material Detrashing
Printed wiring boards and components are delivered to the site and
packaging is removed.
4. Surface Mount Technology (SMT) Process
Printed wiring boards are loaded onto a surface mount technology machine.
The boards are applied with solder paste, cleaned with solvent to remove dirt
and applied with glue (adhesive coating). Components are mounted
automatically onto the boards. The solder paste is cured and the boards are
inspected. Solvent used for adhesive coating in this area is approximately 1-2
tones per year.
Licenced Activity: "Adhesive Coating" Solvents Directive Annex IIA Activity
16. EPA Agreement for use >5 tonnes/year.
5. Manual Assembly Process
Larger components are manually placed onto the printed wiring boards from
the SMT process. Solder is applied by point spraying application. A solvent
based protective coating (conformance coating) is applied to the wiring
board followed by curing for certain products. The amount of solvent is used
in this process varies on an annual basis depending on productivity however
is approximately 0.5-1 tonnes per year.
6. Final Assembly
Moulds and wiring boards are assembled and parts are manually cleaned
using solvent. Solvent usage in final assembly varies on an annual basis
depending on productivity however is approximately 1.5 tonnes per annum.
Licenced Activity: "Other Coating" Solvents Directive Annex IIA Activity 8.
Licenced Activity: "Other Surface Cleaning" Solvents Directive Annex IIA
Activity 5. EPA agreement for use >2.
7. Cleaning of Pallets
Pallets from the manufacturing facility are cleaned within the chemical store
prior to reuse for transporting components within the processing areas.
Licenced Activity: Other Coating Solvents Directive Annex IIA Activity 8.
The amount of solvent utilized at the facility is influenced by customer
demand therefore input and output quantities may vary from year to year.
Table 2.1. provides indicative quantities of solvent used per annum for each
of the onsite processes.
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Table 2.1. Solvent Use and Estimated Quantities at Licence Emission
Points
Process Indicative
Solvent Use
Tonnes Per
Year
Emission
Point
Solvent Directive
Activity/Threshold
Coating of moulds:
- Spray booths
- Mixing, flash off, ovens
30-40 Tonnes A1-3
8. Other coating / >5
tonnes/year
Manual assembly:
- Conformance coating
- Flux coating
-SAM (Semi automaeted
manufacturin)
3
A1-3
,A2-3
8. Other coating / >5
tonnes/year
Surface Mount
Technology process
(adhesive coating)
1 A2-4 16. Adhesive coating /
>5 tonnes/year
Cleaning of Products 1.5 Fugitive 5. Other surface
cleaning / >2
tonnes/year
Cleaning of Pallets 3 Fugitive 8. Other coating / >5
tonnes/year
In order to achieve compliance with licenced emission limit ALPS Electric
(Ireland) Ltd. installed an abatement plant (A1-3). The abatement plant was
commissioned in April 2009 and replaced historical monitoring emission points
A2-6, and A2-7 (the Paint and Laser process stacks) and A2-2
(Solderwave/Concoat process stack). The abatement plant is based on a zeolite
concentrator followed by a regenerative thermal oxidiser. The exhaust air,
loaded with solvents from the process, is routed through a rotating activated
zeolite adsorption wheel. The Volatile Organic Carbons (VOC’s) are adsorbed in
the pores of the zeolite of the wheel in adsorption mode. The adsorption is
performed in one site while desorption is performed on the other site. The
outlet stream from the adsorption wheel is clean air and is discharged directly
to the atmosphere via a new stack (A1-3).
A small portion of the clean air (10%) is diverted to a heat exchange unit to be
heated by the clean air leaving the oxidation chamber. This warm air is then
directed back over a small isolated section of the spent zeolite in the desorption
section. The heated stream of gas is required to remove the VOC and allows
them to overcome the physical attraction forces of the zeolite adsorbent. By
using a smaller stream of air than the original VOC laden air stream the system
has effectively concentrated the exhaust gas. The resulting low-volume, high
concentration air is then directed to the oxidiser for oxidation of the VOC’s prior
to discharge to atmosphere.
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3. Solvent Emissions Directive
The European Council Directive (Limitation of Emissions of Volatile Organic
Compounds due to the Use of Organic Solvents in Certain Activities and
Installations) 1999/13/EEC has been implemented in Ireland by European Union
(Installations and Activities Using Organic Solvents) Regulations 2012 (S.I. No.
565 of 2012) and formerly through the Emissions of Volatile Organic
Compounds from Organic Solvents Regulations (SI. No. 543 of 2002) which are
now revoked by the 2012 Regulations.
The Regulations aim to prevent or reduce direct and indirect effects of
emissions of volatile organic compounds (VOC’s) into the environment and the
potential risks to human health by providing measures and procedures to be
implemented for specified activities and also to phase out the use of more
harmful solvents such as carcinogens, mutagens and those toxic to
reproduction.
The First Schedule of these Regulations requires that coating activity be subject
to compliance with the Regulations.
Under the Second Schedule of the Regulations the activity defined as “Other
Coating including metal, plastic, textile” (i.e. Activity number 8) detail the solvent
consumption thresholds under which ALPS Electric (Ireland) Ltd. must comply.
3.1 Compliance Requirements
An installation or activity operating above the solvent consumption threshold
will need to either:
Meet an emission limit value (Schedule 2) in waste gases (mg C/Nm3) and a
fugitive emission limit value (percentage of solvent use); or
Implement a solvent reduction scheme (Schedule 5) to reduce emissions
from the installation to equal to those that would be achieved by meeting
the total emission value.
Certain substances classified as carcinogenic, mutagenic or toxic (Risk Phrases
R45, R46, R49, R60, R61) must be replaced with less harmful substances, and
these substances along with halogenated volatile organic compounds with Risk
Phrase R40 must comply with separate emission limit values regardless of the
overall compliance method.
The Solvent Emission Directive states:
“For discharges of the VOCs with Risk Phrases R45, R46, R49, R60, R61, where the
mass flow of the sum of the compounds causing the labeling referred to in that
paragraph is greater than, or equal to, 10g/h, an emission limit value of 2
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mg/Nm3 shall be complied with. The emission limit refers to the mass sum of the
individual compounds.” And;
“For discharges of halogenated VOCs which are assigned the risk phrase R40,
where the mass flow of the sum of the compounds causing the labeling R40 is
greater than, or equal to, 100g/h, an emission limit value of 20 mg/Nm3 shall be
complied with. The emission limit value refers to the mass sum of the individual
compounds.”
To demonstrate compliance with the Regulations, ALPS Electric (Ireland) Ltd. will
use the Emission Limit Value Scheme.
Under the Second Schedule of the Regulations the activity defines as “Other
Coating including metal, plastic, textile” (i.e. Activity Number 8) detail the solvent
consumption and Emission Limit Value thresholds under ALPS Electric (Ireland)
Ltd. must comply.
Table 3.1: ALPS Electric (Ireland) Ltd. Emission Limit Values
Activity
Type
Activity (solvent
consumption in
tonnes/year)
Threshold
(solvent
consumption
threshold in
tonnes/year)
Emission limit values
in waste gases
(mg/C/Nm3
8 Other coating,
including metal,
plastic, textile(5), fabric,
film and paper coating
(>5)
5-15
> 15
100(1)(
1)
50/75
(2)(
3)(
4)
(1) Emission limit value applies to coating application and drying processes, operated
under contained conditions
(2) The first emission limit value applies to drying processes, the second to coating
application processes.
(3) For textile coating installations which use techniques which allow reuse of
recovered solvents, the emission limit applied to coating application and drying
processes taken together shall be 150.
(4) Coating activities which cannot be applied under contained conditions (such as
shipbuilding. aircraft painting) may be exempted from these values, in accordance with
Article 13(3).
(5) Rotary screen printing on textile is covered by activity
3.2 Compliance
The following sections outline the methodologies adopted for the
determination of solvent (including R-phrase solvents) and fugitive emission
levels from the ALPS Electric (Ireland) Ltd. facility and for the verification of
compliance.
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The solvent emission levels from the ALPS Electric (Ireland) Ltd. facility were
determined through a screening assessment of solvent (VOC) consumption
inventories and evaluation of VOC emission discharges.
For the purpose of this assessment, VOCs were defined as:
“Any organic compound having at 293.15 K a vapour pressure of 0.01 kPa or
more, or having a corresponding volatility under the particular conditions of use”
Only organic solvents used in process activities and in volumes exceeding 100
litres or named R phrases and deemed to satisfy the above definition for a VOC
(as defined in the Solvent Emission Directive) were included in the assessment.
Measurement of VOC emission at point source discharges was carried out to
determine compliance with the Regulations. All measurements were carried by
MCERTS accredited personnel.
3.3 Quality Control
ALPS Electric (Ireland) Ltd. utilize a wide variety of paints and thinners the
volumes of which are influenced by consumer demand. When a new paint is
ordered for a customer the Safety Data Sheet (SDS) sheet is reviewed by the
ALPS Electric (Ireland) Ltd. Health & Safety Engineer. The Risk Phrases for the
product are reviewed to assess the environmental and health hazards of a
substance.
Once deemed acceptable ALPS Electric (Ireland) Ltd. approve the product for
use within the site. Any product containing Risk Phrases R45, R46, R49, R60,
R61, or R40 and halogenated compounds will be issued for approval to the
Environmental Protection Agency prior to use onsite.
ALPS Electric (Ireland) Ltd. have an electronic quality control system known as
SAP (Systems, Applications, Products) MES (Manufacturing Execution System).
which enables the monitoring of inputs (paints, and thinners) containing
solvents onsite.
The SAP system allows ALPS Electric (Ireland) Ltd. to monitor the amount of
paint and solvent requested at the different process areas. Once an order has
been placed for the paint/solvent it will be logged on the MAPICS system and
all this information will be captured allowing a report on the amounts
consumed for process activities to be generated.
3.4 ALPS Electric (Ireland) Ltd. Solvent Storage & Distribution
Paints and thinners are stored within bunded storage rooms prior to dispatch to
processing areas within the facility.
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3.5 Disposal of Used Solvent from Site
Once used, solvents from waste paint, and paint sludge is removed offsite by a
licenced waste contractor. Some of the solvents are sent for disposal via
incineration, while some of the solvent is sent for recovery. A report detailing
the amounts of paint/thinners sent for disposal/recovery is received every
month by the Environmental Manager and is utilized to determine the amount
of waste solvent from the facility.
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4. Licence Emission Monitoring Locations
4.1 Summary of Air Emissions
The coating of moulds and printed circuit boards has been addressed within
the IPPC licence by the application of Emission Limit Values (ELV’s) for emission
points A1-3, A2-1 and A2-3 in accordance with activity No. 8 (Schedule 2 of S.I.
No. 565 of 2012) coating of moulds and printed circuit boards.
Air monitoring is undertaken in accordance with the IPPC licence requirements.
Monitoring was undertaken at the process vent stacks A1-3, A2-1, A2-3 and
A2-4 in 2016 by Odour Monitoring Ireland.
A description of the process area from which the air emission locations were
tested is provided in Table 4.1.
Table 4.1 Description of Process Area Emission Points
Monitoring Location Description
A1-3 Outlet from VOC Abatement system
A2-1 Paint and Lazer Process
A2-2 (Made redundant by A1-3) Concoat process & Wave solder 1&2
A2-3 Spot Dip (x3) and manual soldering
A2-4 SMT machine extract point
A2-6 (Made redundant by A1-3) PAL Area Extract 1
A2-7 (Made redundant by A1-3) PAL Area Extract 1
In order to achieve licenced emission limit values ALPS Electric (Ireland) Ltd.
installed an abatement plant to treat the exhaust air from the Paint and Laser
process stacks (A2-6 & A2-7) and the Solderwave/Concoat process stack (A2-2).
The abatement treatment plant was installed in April 2009 and a new emission
point A1-3 replaced previous emission points A2-2, A2-6, and A2-7.
The abatement plant comprised of a system based on a zeolite concentrator
followed by a regenerative thermal oxidiser. The exhausted air loaded with
solvents from the process is routed through a rotating activated zeolite
adsorption wheel. The VOCs are adsorbed in the pores of the zeolite in the area
of the wheel in the adsorption mode. The adsorption is performed in one site
while desorption is performed on the other site. The outlet stream from the
adsorption wheel is clean air and can be discharged directly to the atmosphere
via the new stack (A1-3).
Total Organic Carbon is monitored on a quarterly basis for emission points A3-
1, A2-1, A2-3, A2-4. The results of analysis for the 2016 reporting period are
outlined in Table 4.2
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Table 4.2 Total Organic Carbon Emissions from Process Vents during the 2016 Survey Period
Monitoring
Location
IPPC
Licence
Limit
Value
mg/m3
Measurement Period TOC conc. Normalised
Volumetric airflow
rate (Nm3/s)
Emission Limit
Value
Volumetric
airflow rate
(Nm3/hr)
Mass loading/
emission
Annual
Mass
Emission
Permitted
Mass
Emission
(mgC/Nm3)
(kg/hr)
Kg/Yr
Kg/Yr
A1-3 50
Quarter 1 4.180 19591
44,000
0.082 1494 19272
Quarter 2 18.070 18419 0.333
Quarter 3 22.510 21272 0.157
Quarter 4 8.44 19360 0.163
A2-1 50
Quarter 1 2.24 9678 16,619 0.022 1093 7279
Quarter 2 16.86 12069 0.203
Quarter 3 13.24 15235 0.202
Quarter 4 6.90 16050 0.111
A2-3 75
Quarter 1 16.5 2714 3,067 0.045 321 2015
Quarter 2 14.53 2586 0.038
Quarter 3 14.03 3016 0.042
Quarter 4 11.28 2920 0.033
A2-4 N/A
Quarter 1 11.73 2793
Not Licenced
0.033 228
Not
Licenced
Quarter 2 8.70 2504 0.022
Quarter 3 9.43 3165 0.030
Quarter 4 7.32 3665 0.027
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4.2 Air Compliance Summary
The overall combined annual mass emissions for TOC from all process sources
are significantly lower than annual permitted mass emissions. As a result
ALPS Electric (Ireland) Ltd. have demonstrated 100% compliance with
monitoring results were noted for the 2016 monitoring period.
Therefore as demonstrated above ALPS Electric (Ireland) Ltd. is in compliance
with Schedule two of the Regulations SI. No. 565 of 2012 (European Union
(Installations and Activities Using Organic Solvents) for the activity defined as
“Other Coating including metal, plastic, textile” (i.e. Activity number 8).
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5. Solvent Consumption and Management
The management and consumption of solvent onsite is outlined in the following
section of the report.
5.1 Solvent Consumption
The following tasks were considered as part of the scope of work in preparing
the SMP for:
Identification of all organic solvents used at the site and determination of
the amount of solvent used per annum.
Assessment to ensure that no carcinogenic, mutagenic or toxic (Risk Phrases
R45, R46, R49, R60, R61) solvent were used onsite
Identification and quantification of the potential loss pathways for the
various solvents used at the site,
Table 5.1 presents a summary of all organic solvents and materials which
contain organic solvents that are currently used at the site. The VOC content of
each material was determined by reference to the corresponding Safety Data
which are stored onsite.
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Condition 16.6 of the IPPC licence states that “solvent consumption in the
cleaning of product and adhesive coating shall not exceed 2 and 5 tonnes
respectively unless otherwise agreed by the agency.”
The amount of solvent used onsite for activities associated with cleaning of
product and adhesive coating was assessed with respect to Condition 6.16 of
the IPPC Licence is summarised in Table 5.2.
Table 5.2 Solvent Consumption for Cleaning of Product and Adhesive Coating
2016
S.I. No.543 of
2002) Activity
Category
Process Activity Solvent Consumed
in 2016 (Tonnes)
Threshold
Consumption
Emission Limit
Value
Activity 5 Cleaning of
Product
1.34
2
Activity 16 Adhesive Coating 0.3 5
As can be seen from Table 5.2 the solvent consumed in the cleaning of
product and adhesive coating are below the threshold limit value of 2
and 5 tonnes respectively and are compliant with Condition 6.16 of the
Licence.
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Table 5.3 Solvent Management Description and Relevance to ALPS Electric (Ireland) Ltd.
Solvent
Management
Reference
Description Relevance to process Where site Information can be
obtained
ALPS Electric (Ireland)
Ltd. Reference
I1 The quantity of organic solvents
(tonnes)/or their quantity in preparations
purchased which are used as input into
the process in the timeframe over which
the mass balance is being calculated.
Annual solvent (paint &
thinners) purchases for the
ALPS Electric (Ireland) Ltd.
facility.
Mapics quality control system will
log all paint and thinner uses with
in the plant.
Annual Solvent Input.
I2 The quantity of organic solvents or their
quantity in preparations recovered and
reused as solvent input into the process
(tonnes). (The recycled solvent is counted
every time it is used to carry out the
activity).
This does not take place at the
ALPS Electric (Ireland) Ltd.
facility. All solvent is used and
sent for recovery/disposal.
Not Applicable to operations. Recovered & Reused
C Consumption (C = I1 – O8) corresponds to
the quantity of organic solvent which iS
input into the process minus any that is
recovered and reused but not as input into
the process.
As no solvent is recycled
within the ALPS Electric
(Ireland) Ltd. facility
consumption is solely based
on the annual use of solvent.
Input or Usage
O1 Emissions in waste gases (tonnes)
The amount of solvent emitted
to air through licenced IPPC
emission points.
Obtain via monitoring of the waste
gases.
Complying with the ELV’s or
obtain via the solvent
management plan by difference if
complying with the reduction
scheme.
Air Emissions Licenced.
Monitoring of gases
from Pallet Cleaning
Store.
O2 Organic solvents lost in water (tonnes), if
appropriate taking into account waste
water treatment when calculating O5.
Solvent from the Paint and
Laser process is absorbed and
removed from the site in a
liquid sludge.
Laboratory analysis will determine
the percentage of solvent lost to
water.
O3 The quantity of organic solvents (tonnes) Paint residue in containers, Laboratory analysis will determine Lost to Product
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Page | 16
Solvent
Management
Reference
Description Relevance to process Where site Information can be
obtained
ALPS Electric (Ireland)
Ltd. Reference
which remain as contamination or residue
in products output from the process.
spray guns, and connection
tubes.
the percentage of solvent
remaining in used containers.
Preparation.
O4 Uncaptured emissions of organic solvents
to air (tonnes). This includes the general
ventilation of rooms, where air is released
to the outside environment via windows,
doors, vents and similar openings.
Solvents lost to air other than
though unlicensed emission
points. Solvent emissions from
areas which are not covered
by booth extraction systems,
e.g. some drying booths, gun
cleaning station, distillation
unit, paint mixing & storage
area, waste storage area
(containers, rags), spills, etc.
Obtain via the mass balance by
difference.
Air Fugitive Emission
O5 Organic solvents and/or organic
compounds lost due to chemical or
physical reactions
(tonnes) (including for example those
which are destroyed, e.g. by incineration
or other waste gas or waste water
treatments, or captured, e.g. by
adsorption, as long as they are not
counted under O6, O7 or O8).
The abatement plant
comprised of a system is
based on a zeolite
concentrator followed by a
regenerative thermal oxidiser.
This has an 95% efficiency
rate.
-
Quarterly Air Monitoring Results
for the abatement plant (A1-3)
Abatement Plant
O6 Organic solvents contained in collected
waste (tonnes)
The quantity of solvent
generated at the site. Consists
of waste sent off-site for
disposal and the change in
inventory of the waste.
Records on weight of solvent waste
sent off-site for disposal.
If there is no record of disposal of
the waste by an authorised outlet,
no credit will be allowed for the
waste. Analysis of VOC content of
any solvent waste sent off-site is
required (this may need to be
Waste Collected.
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Page | 17
Solvent
Management
Reference
Description Relevance to process Where site Information can be
obtained
ALPS Electric (Ireland)
Ltd. Reference
repeated on a periodic basis).
Representative sampling methods
should be used.
O7 Organic solvents, or organic solvents
contained in preparations, which are sold
or are intended to be sold as a
commercially valuable product (tonnes).
Solvent in finished
products/semi finished
product, intermediates/rejects
sold for use elsewhere.
No solvent remains in the finished
product and is burned off through
the curing process and/or diverted
by water through curtain the site.
Finished Product
O8 Organic solvents contained in
preparations recovered for reuse but not
as input into
the process (tonnes), as long as not
counted under O7
It is important to distinguish between
waste sent for disposal and waste sent for
reuse, as solvent sent for reuse will reduce
the Consumption term.
Solvent sent offsite for
recovery or reuse in other
applications (including use as
fuel).
Solvent is sent off site to
Veolia who recover some of it
for reuse offsite.
Records on weight of solvent waste
sent off-site for recovery & reuse
elsewhere.
Sent offsite for Reuse.
O9 Organic solvents released in other ways
(tonnes)
Should not occur under
normal operating conditions.
This would include that not-
otherwise accounted for
proportions of VOC released
following, for instance an
accidental release of solvent
from a bund.
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Page | 18
6. Quantification of Solvent
The waste register was used to determine the amount of waste solvent that was
sent offsite in 2016. In order to confirm the percentage of solvent present within
the waste paint, flux and thinners samples were collected in October and
November 2010 and sent to for solvent analysis. The samples were analysed
using GC-MS Headspace for the identification of solvent composition. The
percentage solvent concentrations were estimated by utilising available
solvents, namely Butan-l-ol, Propan -2-ol, m-xylene and ethyl acetate.
Quantitative analysis of the solvent composition was compromised due to the
sensitivity of the GC-MS. It was noted from the GC-MS scans that each sample
type varied in composition. This caused difficulties for absolute quantization;
therefore the results are semi-quantitative in nature.
A summary of the results of analysis are outlined in Table 6.1
Table 6.1 Percent of Solvent Analysis in Emissions to Waste
Date of
Analysis
Percentage Solvent
Wipes Waste Flux and
Thinners
Waste
Paint and
Thinners
Paint Sludge
14/10/10 5.21 98 70 6
2.41 98 100 7
1.74 98 68 6
26/11/10 0.44 98 98 8
0.83 98 98 6
1.78 98 98 9
Average 2.07 98 88.67 6.94
The results of analysis were used to quantify the percentage of solvent within
the waste categories removed from the site.
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Page | 19
7. Solvent Mass Balance
A solvent mass balance has been completed for the facility which evaluates the
solvent throughout consumption facility, and respective outputs via abatement,
air, waste, and recovery with the remainder accounting for fugitive emissions
Table 7.1.
Table 7.1 Solvent Inputs ALPS Electric (Ireland) Ltd.2016
I1 INPUTS Amount Consumed in 2016 (Tonnes)
Paint & Laser 32.47
Wave solder process 1.28
Concoat
SMT 0.70
Final Assembly 1.34
Total Amount of Solvent Input
(Tonnes) 35.79
Condition 5.3 of the licence notes that the Total fugitive emissions to air of
volatile organic compounds shall not exceed 20% of solvent input per calendar
year. Table 7.2 presents the outputs of solvent through the facility and the
resultant fugitive emissions.
Table 7.2 Solvent Outputs and Resultant Fugitive Emissions 2016
Solvent Outputs
Total Outputs
(Tonnes)
Organic Solvent Emissions to Air O1 3.14
A1-3 0.95
A2-1 0.86
A2-3 0.29
A2-4 0.95
Total Inlet to Abatement Plant (A1-3) Annual Mass Emission 29.48
Organic solvents via Incineration O5 27.99
Solvent Emissions as Waste (Disposal) O6 2.66
Organic Solvents for Reuse as Fuel O8 0.04
Total VOC emissions 33.82
F=I1-O1-O5-O6-O7-O8 Fugitive Emission 1.97
Paint & Lazer (Cleaning of Pallets) 0.04
Total Fugitive Emissions 2.01
Percentage of Total Fugitive Emissions 5.62%
As can be seen in the Solvent Mass Balance the amount of fugitive emissions for
the facility is estimated at 2.01 tonnes which comprises 5.62% of the overall mass
balance and as a result demonstrates compliance with Condition 5.3. of the
licence.
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ALPS Electric (Ireland) Ltd. Solvent Management Plan 2016
8. Conclusion
ALPS Electric (Ireland) Ltd. are compliant will all licenced air monitoring emission
requirements as set out in the Schedule B of the IPPC Licence as demonstrated in
Section 4 of the report.
Compliance with solvent consumption onsite is demonstrated in Table 8.1 and 8.2 for
each of the licenced conditions.
Table 8.1 Licence Compliance with IPPC licence Conditions
IPPC
Licence
Licence
Requirement
Process
Activity
Solvent
Consumed in
2016 (Tonnes)
Threshold
Consumption
Emission Limit
Value
6.16 Solvent
consumption in
the cleaning of
product and
adhesive coating
shall not exceed 2
and 5 tonnes
respectively
unless otherwise
agreed by the
agency.
Cleaning of
Product
1.34
2
Adhesive
Coating
0.3 5
Table 8.2 Licence Compliance with IPPC licence Conditions
IPPC
Licence
Licence
Requirement
Process
Activity
Percentage
Fugitive
Emissions
Threshold
Consumption
Emission Limit
Value
5.13 Total fugitive
emissions to air of
volatile organic
compounds shall
not exceed 20% of
solvent input per
calendar year.
Fugitive
Emissions
u
g
5.62% 20%
As can be seen from Table 8.1 the solvent consumed in the cleaning of product and
adhesive coating are below the threshold limit value of 2 and 5 tonnes respectively. The
percentage of fugitive solvent for 2016 was 5.6% which is substantially below the
consumption limit value of 20%. In conclusion the Solvent Management Plan for 2016
has demonstrated compliance the conditions of the IPPC Licence by providing
information on solvent consumption throughout the facility, demonstrating the
resultant solvent emissions via air and water, and compliance with the emission limit
values within the IPPC Licence.
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ALPS Electric (Ireland) Ltd. Solvent Management Plan 2016
Appendix 1 Glossary of Terminology
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ALPS Electric (Ireland) Ltd. Solvent Management Plan 2016
Glossary of Terminology
Activity Definition within the Schedule 1 of the of
Solvent Directive S.I. No. 565 of 2012
Coating Activity
Any activity in which a single or multiple application of a continuous
film of a coating is applied to:
(a) either of the following vehicles:
(i) new cars, defined as vehicles of category M1 in Directive
2007/46/EC of the European Parliament and of the Council of 5
September 2007 establishing a framework for the approval of
motor vehicles and their trailers, and of systems, components and
separate technical units intended for such vehicles3 and of
category N1 in so far as they are coated at the same installation
as M1 vehicles;
(ii) truck cabins, defined as the housing for the driver, and all
integrated housing for the technical equipment, of vehicles of
categories N2 and N3 in Directive 2007/46/EC;
(iii) vans and trucks, defined as vehicles of categories N1, N2 and N3 in
Directive 2007/46/EC, but not including truck cabins;
(iv) buses, defined as vehicles of categories M2 and M3 in Directive
2007/46/EC;
(v) trailers, defined in categories O1, O2, O3 and O4 in Directive
2007/46/EC;
(b) metallic and plastic surfaces including surfaces of airplanes, ships,
trains, etc.;
(c) wooden surfaces;
(d) textile, fabric, film and paper surfaces;
(e) leather.
Coating activities do not include the coating of substrate with metals
by electrophoretic and chemical spraying techniques. If the coating
activity includes a step in which the same article is printed by whatever
technique used, that printing step is considered part of the coating
activity. However, printing activities operated as a separate activity are
not included, but may be covered by these Regulations if the printing
activity falls within the scope thereof.
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ALPS Electric (Ireland) Ltd. Solvent Management Plan 2016
Surface Cleaning
Any activity except dry cleaning using organic solvents to remove
contamination from the surface of material including degreasing. A
cleaning activity consisting of more than one step before or after
any other activity shall be considered as one surface cleaning
activity. This activity does not refer to the cleaning of the
equipment but to the cleaning of the surface products.
Adhesive Coating
Any activity in which an adhesive is applied to a surface, with the
exception of adhesive coating and laminating associated with
printing activities.
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ALPS Electric (Ireland) Ltd. Solvent Management Plan 2016
Appendix 2 Summary of Solvents used in 2016
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ALPS Electric (Ireland) Ltd. Solvent Management Plan 2016
Summary of all Solvents used at ALPS Electric (Ireland) Ltd. in 2016
Area Item Number Item Desc UOM Converted to
Kgs
Total purchased in
Tonnes Percentage
Solvent
Total in Tonnes
CONCOAT 917K0004 HUMISEAL 1R32A2 L 200 0.2 50 0.10
CONCOAT 917K0012 HUMISEAL THINNER 503 L 200 0.2 100 0.20
FA IC5JA MEGAFAC F-761 (MVZ401B00) KG 1344 1.344 100 1.34
PAL 4AB-00079A VARNISH T200-0001 ML 16 0.016 20 0.00
PAL 4AD-00024A
PAINT 94:369:E6161/ADM
CH/SOL ML 40 0.04 50 0.02
PAL 4DF-00025A THINNER T200 100VR1450 ML 15 0.015 55 0.01
PAL 917K0071A N-BUTYLACETATE FLUID L 1600 1.6 100 1.60
PAL 918K002B
PAINT 94:369 E1416 ADM V CH
MA ML 7750 7.75 58 4.50
PAL 918K003A HARDNER 90:CA:01 ML 660 0.66 37 0.24
PAL 918K0133A 01:439 JAXA THINNERS ML 50 0.05 70 0.04
PAL 918K031B HARDENER 516309 2K BMW ML 15 0.015 40 0.01
PAL 918K032B THINNER 517848 ML 50 0.05 100 0.05
PAL 918K065A HARDENER FOR PSA INKS H1 ML 20 0.02 25 0.01
PAL 918K066A TPV DILUANT SM120100 ML 21 0.021 99.9 0.02
PAL 918K076A
PAINT BLACK TC
94:368:E3098/A ML 260 0.26 58 0.15
PAL 918K078A CLEANING AGENT UR3 L 890 0.89 100 0.89
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ALPS Electric (Ireland) Ltd. Solvent Management Plan 2016
Area Item Number Item Desc UOM Converted to
Kgs
Total purchased in
Tonnes Percentage
Solvent
Total in Tonnes
PAL 918K087A THINNERS S&R 09:378 ML 4850 4.85 100 4.85
PAL 918K111A THINNER 510128 ML 30 0.03 100 0.03
PAL 918K115A THINNERS 512-829 ML 40 0.04 100 0.04
PAL 918K121A INK M3817 38 439 Y283 GREEN ML 12 0.012 10 0.00
PAL 918K122A
INK M381738486 443+10%910
BLUE ML 20 0.02 10 0.00
PAL 918K123B PAINT 516514 ML 6 0.006 100 0.01
PAL 918K125B PAINT BC 516691 ML 15 0.015 55 0.01
PAL 918K130A PAINT 35F:37M:E5083 NH827L ML 15 0.015 85 0.01
PAL 918K131A THINNER 01:571 RECRACK STD ML 35 0.035 100 0.04
PAL 918K132A PAINT 94:364:E4976/A NH1L ML 20 0.02 85 0.02
PAL 918K134A PRIMER 343-29 ML 100 0.1 5 0.01
PAL 918K135A
PAINT CR-349-44 10TN OYSTER
71 ML 10 0.01 0 0.00
PAL 918K136A
PAINT CR-349-44 10UA
VEN/BEIGE ML 50 0.05 0 0.00
PAL 918K145A PAINT H/M 2P-500TXL 5140870 ML 45 0.045 100 0.05
PAL 918K146A
PAINT S/ACE HG-300 TXL
514.873 ML 70.5 0.0705 100 0.07
PAL 918K147A
HARDENER STRON #73 TXL
514.871 ML 10 0.01 75 0.01
PAL 918K148A
HARDENER STRON #143TXL
514.874 ML 75 0.075 100 0.08
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ALPS Electric (Ireland) Ltd. Solvent Management Plan 2016
Area Item Number Item Desc UOM Converted to
Kgs
Total purchased in
Tonnes Percentage
Solvent
Total in Tonnes
PAL 918K154A THINNERS RUCO 100-VR-1271 ML 5 0.005 100 0.01
PAL 918K155A
HARDENER RUCO 100VR1433
100 ML 2 0.002 50 0.00
PAL 918K156B INK RED T200 2320-M10780 G 3960 3.96 60 2.38
PAL 918K157B INK BLUE T200 SD10552 ML 4 0.004 65 0.00
PAL 918K158A PAINT 94:360:E5491/A LP79 ML 85 0.085 100 0.09
PAL 918K159A
PAINT ALEXITCR 349-44 IVORY
WH ML 20 0.02 0 0.00
PAL 918K162A PAINT 90:1520/A GLOSS TC C3 ML 55 0.055 100 0.06
PAL 918K165B INK RED T200 SD10562 ML 7 0.007 60 0.00
PAL 918K166B T200 SERIES INKS ML 10 0.01 60 0.01
PAL 918K167A
INK TPL DARK GREY
M381738533 ML 65 0.065 15 0.01
PAL 918K168B
PAINT EBONY
94:D3124/E0223B ML 634 0.634 70 0.44
PAL 918K170B THINNER 01:D51/734/7 ML 4750 4.75 100 4.75
PAL 918K171A HARDENER 90:CA-77 ML 565 0.565 100 0.57
PAL 918K172A
INK 88PD 11-4301 WHITE
200072 ML 105 0.105 100 0.11
PAL 918K173A
INK 88PD 100 MEDIUM
(CLEAR) ML 45 0.045 100 0.05
PAL 918K174A
PAINT 94:D71/89/1:E5873/A T
OR ML 5 0.005 85 0.00
PAL 918K175B
PAINT BASECOAT 463-
07.9200.9 ML 1500 1.5 40 0.60
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ALPS Electric (Ireland) Ltd. Solvent Management Plan 2016
Area Item Number Item Desc UOM Converted to
Kgs
Total purchased in
Tonnes Percentage
Solvent
Total in Tonnes
PAL 918K176A THINNER 901.26 ML 2125 2.125 100 2.13
PAL 918K177A HARDENER 402 ML 384 0.384 100 0.38
PAL 918K178A
PAINT T/C 460.22 90LX PIANO
BL ML 4100 4.1 100 4.10
PAL 918K179A THINNER 902.76 ML 710 0.71 100 0.71
PAL 918K180A HARDENER 450 ML 1230 1.23 100 1.23
PAL 918K183A PAINT 94:369:E6031/A NH863L ML 350 0.35 95 0.33
PAL 918K185A
PAINT 402.41 L/C 90DX
SCHWARZ ML 768 0.768 50 0.38
PAL 918K186A HARDENER 400 ML 366 0.366 100 0.37
PAL 918K187A THINNER :901.86 ML 685 0.685 100 0.69
PAL 918K189A THINNER 100VR1279 ML 5 0.005 100 0.01
PAL 919K009A INK TAMPO RED 88PD-1202140 ML 25 0.025 80 0.02
PAL 919K011A HARDENER 88PD TAMPO ML 10 0.01 100 0.01
PAL 919K012A THINNER PV-7 TAMPO ML 25 0.025 100 0.03
SMT 917K00103 SURCLEAN SCREEN CLEAN L 1360 1.36 50 0.68
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