galco (waterford) ltd. gracedieu road waterford city p0385-01 · 2016. 6. 3. · galco (waterford)...
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ANNUAL ENVIRONMENTAL REPORT
Galco (Waterford) Ltd.
Gracedieu Road
Waterford City
P0385-01
JANUARY 2015 TO DECEMBER 2015
GALCO (WATERFORD) LTD. ANNUAL ENVIRONMENTAL REPORT 2015
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Table of Contents
1.0 INTRODUCTION ................................................................................................................... 3
1.1 Site Contact Details .............................................................................................................. 3 1.2 Activities Licensed ............................................................................................................... 4 1.3 Process Description ................................................................................................................ 4 1.4 Environmental Health & Safety Policy ....................................................................................... 6
2.0 ENVIRONMENTAL MONITORING ..................................................................................... 7
2.1 Emissions to Sewer ............................................................................................................... 7 2.2 Ground Water ....................................................................................................................... 9 2.3 Air Emissions ......................................................................................................................10 2.4 Noise ...................................................................................................................................11
3.0 WASTE MANAGEMENT .....................................................................................................12
4.0 ENERGY CONSUMPTION ...................................................................................................13
5.0 ENVIRONMENTAL INCIDENTS .........................................................................................14
6.0 COMPLAINTS ......................................................................................................................14
7.0 ENVIRONMENTAL MANAGEMENT PROGRAMME REPORT .........................................15
GALCO (WATERFORD) LTD. ANNUAL ENVIRONMENTAL REPORT 2015
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1.0 INTRODUCTION
Galco (Waterford) Ltd. was formed when Galco Steel Ltd. purchased the former
Waterford Metal Industries (WMI) Ltd. WMI was established in 1949 as a greenfield
operation at Gracedieu on the outskirts of Waterford City. The main activity conducted
on site is galvanizing.
The company was granted an IPC Licence P0385-02, Class 3.4, in January 2000 and is
committed to compliance with all statutory and regulatory requirements.
The site is located in a predominately residential area. The total site area covers
approximately 2.2 hectares. The site Irish National Grid Reference is S 596 125.
Galco (Waterford) Ltd. employs 10 people.
1.1 Site Contact Details
Galco (Waterford) Limited
Gracedieu Road
Waterford City
County Waterford
Tel: +353 51 874254
Fax: +353 51 874456
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1.2 Activities Licensed
“the production, recovery or processing of non-ferrous metals, their compounds or other
alloys including antimony, arsenic, beryllium, chromium, lead, magnesium, manganese,
phosphorus, selenium, cadmium, or mercury, by thermal, chemical, or electrolytic
means in installations with a batch capacity exceeding 0.5 tonnes”.
1.3 Process Description
The main purpose of the activities at the installation is the immersion of steel articles in
molten zinc to apply a protective coating. All material processed by Galco Waterford
Ltd. is in accordance with I.S. EN ISO 1461: 1999.
Ø Receiving, Storage and Handling of Raw Materials - All deliveries of materials
take place during daytime hours. All storage areas are on an impermeable hard
concrete standing to prevent pathways to ground water receptors.
Ø Pre-treatment and Degreasing – The iron or steel will be inspected prior to
galvanising to determine is any pre-treatment is required, (such as degreasing,
etc.). The galvanising reaction will only occur on a chemically clean surface.
Like most coating processes the secret to achieving a good quality coating lies in
the preparation of the surface. It is essential that this is free of grease, dirt and
scale before galvanising takes place. Contamination is removed by a series of
processes. Firstly we degrease using an acidic solution into which the
component is dipped. Heavily soiled material may also be cleaned manually.
Ø Acid Pickling – This prepares the surface of the work by the removal of rust and
scale. This is carried in our pickling baths, located within the pre-treatment
bund, which contain up to 15% concentration of hydrochloric acid.
Ø Rinsing – This removes the hydrochloric acid that has adhered to the surfaces of
the steel articles and prevents carryover of iron salts on the surface of the metal
that would cause additional dross to be formed in the zinc bath. Rinse water,
GALCO (WATERFORD) LTD. ANNUAL ENVIRONMENTAL REPORT 2015
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once the concentration of hydrochloric acid becomes too high, is removed from
site for waste disposal.
Ø Fluxing – This is carried out in a bath of zinc ammonium chloride to prevent
oxidation of the metal before it is dipped and to enable the zinc to wet the
surface of the steel allowing a uniform coating of zinc to be achieved. The flux
bath is maintained at 65-80°C.
Ø Galvanising – When the clean iron or steel components are dipped into the
molten zinc (at 450°C) a series of zinc-iron alloy layers are formed by a
metallurgical reaction between the iron and zinc. Upon withdrawal from the
galvanizing bath a layer of molten zinc will be taken out on top of the alloy
layer. This cools to exhibit the bright shiny appearance associated with
galvanized products. During dipping the zinc bath is totally enclosed with the
only openings being for the extract ducting, crane cables and door seals. Fume
created during the dipping process, however, is extracted and vented through an
automatic reverse jet type bag filter before being vented to atmosphere through a
0.9m diameter stack at an elevation of 14m.
Ø Storage and Handling of Finished Products - All storage areas of finished
products are located on a hard standing concrete surface.
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1.4 Environmental Health & Safety Policy
At Galco we are committed to protecting the environment, health, safety and welfare of
its employees, customers, visitors and the community within which it operates so far as
is reasonably practicable. We seek to be recognized in the galvanizing industry as a
leader in terms of environmental and health & safety care. Environmental and health &
safety management programs are integrated into all aspects of our business and focus on
continuous improvement, involvement at all levels of the organisation and striving to
achieve sustainable development The environmental, health & safety management
programs in Galco seek to achieve the following:
§ Compliance with all relevant EHS legislative and regulatory requirements.
§ Promote continuous improvement through evaluation of EHS performance of our
management programs.
§ Establish EHS goals & objectives on an annual basis and review periodically.
§ Minimize adverse EHS impacts through our activities
§ Support research, training or agencies engaged in EHS matters.
§ Maintain communication, participation and consultation processes to ensure
employees, the community and other interested parties are informed on relevant
EHS matters.
§ Develop employee EHS awareness through ongoing relevant training programs.
§ Encourage employees to meet their EHS legislative and regulatory requirements
§ Audit and review of procedures and practices to help ensure continuous
improvement.
§ Maintain availability of EHS documentation to all employees and other interested
parties such as manuals, procedures and risk assessments.
Galco promotes EHS leadership, responsibility and innovation in the management of all
company facilities and operations. Senior management will lead the development and
implementation of management programs, policies, audits, compliance monitoring,
supervision of the EHS management system and provide public access to relevant EHS
information. All managers are responsible for implementing assigned action programs
based on this EHS policy and will provide sound EHS leadership to maintain
appropriate records and demonstrate compliance with programs, permits and practices.
GALCO (WATERFORD) LTD. ANNUAL ENVIRONMENTAL REPORT 2015
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2.0 ENVIRONMENTAL MONITORING
This report presents information specifically for the monitoring period January 2015 to
December 2015.
2.1 Emissions to Sewer
Table 1 presents the surface water monitoring results. A visual inspection was also
completed on a weekly basis which is available for inspection. The surface water
leaves the site at one point near the gate and is treated by the Waterford City Council
Sewer.
Surface Water Monitoring Results Q1 2015
No results for Q1 Surface Water results due to dry periods on the days of sampling
Surface Water Monitoring Results Q2 2015
No results for Q2 Surface Water results due to dry periods on the days of sampling
Surface Water Monitoring Results Q3 2015
Table 2: Surface Water Monitoring Results Q3 2015 (14th September)
Test Parameter Units SW1 SW2 SW3
COD mg/L 6 8 5
pH pH Units 7.1 7.2 7.4
Zinc μg/L 9.43 27.78 16.1
Surface Water Monitoring Results Q4 2015
No results for Q4 Surface Water results due to dry periods on the days of sampling
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Summary There were no non-compliances with ELVs recorded regarding surface water to sewer
for Galco Waterford in 2015. The mass emission rate in kg/annum of zinc entering the
sewer in Waterford will have no impact on the system. Furthermore the yard was fully
swept prior to sampling after a heavy rainfall event.
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2.2 Ground Water
Groundwater monitoring was completed at the site in February 2015 and June 2015;
data collated from these sampling events together with historical data for the site are
included in this combined report. The scope of works included field measurements of
static water levels, well purging, sample and well head parameter collection, followed
by a series of analytical testing and subsequent periodic reporting of results. See
appendix.
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2.3 Air Emissions
The results of the analysis are summarised in the tables below.
Table 3: A1 – Bag Filter Monitoring Results
Parameter
Annual Summary Permit Limit
(mg/Nm3) (mg/Nm3)
Particulates - 10
Lead 0.056 2
Zinc 0.7 5
Cadmium <0.0023 0.5
Chloride (as HCl) 0.1 30
Ammonia 0.3 -
Volume of Air Flow
(/hour) 5,498 10,500
Summary There were no non-compliances with ELVs recorded regarding air emissions for Galco
Waterford in 2015.
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2.4 Noise
The environmental noise survey was completed on 9th September 2015 as per the new
noise guidance documents. Noise levels were determined at two noise sensitive
locations. Analysis of the results from this noise survey indicates that the noise levels
at the nearest noise sensitive receptor are not adversely impacted upon by the site
related activities. This report was submitted to the Agency.
Table 4: Day Time Noise Survey Results
Monitoring
Location
Survey
Date and
Time
LAeq
dB
LA10
dB
LA90
dB Tonal*
Day-time Noise Monitoring Results
NSR1-1 09/09/2015
64.7 69.1 50 3.15KHZ
NSR1-2 09/09/2015
64 68.9 52 No Tone
NSR1-3 09/09/2015
65 67.1 54 No Tone
NSR2-1 09/09/2015
64 66 49.9 1.6KHz & 3.15KHz
NSR2-2 09/09/2015
58 66 51 600Hz
NSR2-3 09/09/2015
65 69 54 No Tone
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3.0 WASTE MANAGEMENT
A summary of the annual waste disposal data was submitted electronically in
accordance with the AER Electronic Reporting System & PRTR Requirements.
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4.0 ENERGY CONSUMPTION
The following tables present the sources of energy use and the quantities of each used
on site for the period of the report.
Energy and Water consumption Table 5: Energy Consumption Energy
Consumption
Unit 2012 2013 2014 2015
Light Fuel
Oil Litres 4,457 5842
6000
6560
Electricity kWh 110,150 79,450 85,142 94,700
Natural Gas kWh 1,705,241 1,883,315 1,919,252 1,693,375
CO2 Mass
Emissions
(0.234 kg
CO2/kWh)
KWh 424,801 459,287 469,028
418,409
Table 6: Water Usage
Water
Usage
Unit 2012 2013 2014 2015
Municipal
water
m3/yr 350 214 265 345
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5.0 ENVIRONMENTAL INCIDENTS
There were no environmental incidents to report during the reporting period.
An ongoing groundwater investigation is been carried out.
6.0 COMPLAINTS
There were no complaints during the year relating to the facility.
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7.0 ENVIRONMENTAL MANAGEMENT PROGRAMME REPORT
The table below summarises the objectives achieved to date in 2015:-
No.
Licence Objectives
Licensee Targets
1 Complete the remaining two rounds of groundwater
monitoring. Complete
2 Carry out a full review of the four rounds of groundwater
monitoring and submit a revised DQRA on the results Complete
3 Enforce Actions from the Metal Sector Enforcement
Findings and Priority Issues for 2015. Complete
4 Carry out a bund integrity test on all bunds on site Complete
5 Carry out an underground pipeline test on all
underground pipes Complete
6
Ensure all groundwater well heads are in good
functioning order and are sealed to prevent ingress of
surface water
Complete
7 Review Fire Water Risk Assessment and update it
accordingly Complete
8
Ensure yard sweeping is taking place on a monthly basis
to reduce the build up of zinc which may impact the
surface water quality
Complete
9 Repair all roof drain and down pipes on site Complete
10
Investigate the possibility of reducing energy and water
consumption per unit of output when compared to 2013
and 2014
Complete
11 Update Emergency Response Procedure where required Complete
12 Reduce hazardous and non-hazardous waste generation
per unit of output when compared to 2013 and 2014 Complete
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The following table is a schedule of objectives and targets that have been set out by
Galco (Waterford) Ltd for 2016, in order to reduce any environmental impacts and
improve environmental practices.
Table 8: Schedule of Environmental Objectives and Targets for 2015
No.
Licence Objectives
Licensee Targets
2016
1
Complete two rounds of Groundwater Monitoring on
all on site and off site wells to continue to monitor
trends in contaminants of concern
Q2
2 Carry out shallow subsoil investigations at a number or
locations around the site Q2
3 Carry out a pump test on site to establish the
permeability of the rock Q2
4 The dross plough to be stored indoors Q1
5 The zinc bath cover to be stored indoors Q1
6 Ceasing emptying of the dross outdoors. Q1
7 Storage of jigs indoors where at all possible Q1
8
Ensure yard sweeping is taking place on a monthly
basis to reduce the build up of zinc which may impact
the surface water quality
Q1
9 Maintenance records to be kept for the bag filter. Q1
10 Carry out roof integrity test and ensure roof is cleaned
to prevent zinc run off from the roof entering SW Q2
Appendix 1 June 2015
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February 2015
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5. ONSITE TREATMENT & OFFSITE TRANSFERS OF WASTE | PRTR# : P0385 | Facility Name : Galco (Waterford) Limited | Filename : P0385_2015.xls | Return Year : 2015 |
5 14 Please enter all quantities on this sheet in Tonnes
Quantity (Tonnes per Year) Method Used
Transfer Destination European
Waste Code Hazardous Quantity T/Year
Description of Waste
Waste Treatment Operation M/C/E Method Used
Location of Treatment
Within the Country 02 01 10 No 6.06 waste metal R4 M Weighed Offsite in Ireland
Within the Country 11 01 05 Yes 0.0 pickling acids R5 M Weighed Offsite in Ireland
To Other Countries 11 01 09 Yes 0.0 sludges and filter cakes containing dangerous substances R3 M Weighed Abroad
Within the Country 11 05 01 No 11.7 hard zinc R4 M Weighed Offsite in Ireland
To Other Countries 11 05 02 No 47.7 zinc ash R4 M Weighed Abroad
To Other Countries 11 05 03 Yes 0.0 solid wastes from gas treatment R4 M Weighed Abroad
Within the Country 17 06 05 Yes 0.0 construction materials containing asbestos (18) D12 M Weighed Offsite in Ireland
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Within the Country 20 01 38 No 0.0 wood other than that mentioned in 20 01 37 D1 M Weighed Offsite in Ireland
Within the Country 20 03 01 No 10.0 mixed municipal waste D1 M Weighed Offsite in Ireland