rye valley foodsrye valley fmds cmk their sauce products in stm-jacketed cookers supplied by a...
TRANSCRIPT
RYE VALLEY FOODS
E.P.A. I.P.P.C.
APPLICATION SUPPORT INFORMATION
Nov. '06
Date: Master COPY
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Rye Valley Foods IPPC Application Appliation support Informaon
November 2006
IPPC AppUcation Support Information (Page 1 of 3)
In reference to your letter dated 181 10/2006 (Reg No: P0806-01) requesting information in accordance with Article 11 (2) (bj (ii) of EPA (Licensing) Regulations see detail requested below.
1 , Submit a suitable scaled site map of the installation outlined in colour. See Attachment 1.2 Site map.
2. Complete Table E. 1 (ii) M a i n Emissions to Atmosphere for the two boilers. Include the maximum emissions from the boilers when operating on gas and when operating on oil.
See Attachment Table E.1 (ii) HDS Boiler Emissions and Attachment Table E. 1 (ii) Cochran Boiler Emissions. The boilers cannot currently run on oil therefore figures are unattainable.
3. Describe the abatement systems installed on the c o o h g vessel emissions to atmosphere. Identify the location of the emissions to atmosphere fiom the cookers on a map.
See Attachments 3.2 Description of Abatement on Cookers and 3.3 Cooker Emissions Map.
4. Please provide a location map for the spread lands used for the recovery of the wastewater treatment plant sludge.
See Attachment 4.2 Maps of Sludge Spreadlands.
5. Provide an assessment ofthe impact of the European Communities (Good Agncultural Practice for Protection of Waters) Regulations 2006, S I . No 378 of 2006 on the recovery of sludge by land spreading.
See Attachment 5.2 Consultants Letter on N.M.P.
6. Identify if the surface water interceptor is Class 1 or Class 2, full retention or a by-pass interceptor.
The Interceptor is a class 2 by-pass Interceptor. See Attachment 6.1 Diagram of KB0361/ 2 Interceptor
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Rye Va Hey Foods IPPC Application Application support Information
November 2006
IPPC Application Support Infomation [Page 2)
7. Surface water from Cloughvalley Industrial Estate drains through the installation and the on site interceptor, please clarify if the interceptor has capacity for t h 3 surface water flow. If you identifj. that the interceptor has inadequate capacity please propose remedial measures including time fiames for completion of the remedial measures. Identifv separate surface water monitoring points fur surface water arising on site and the surface water entering your site.
The interceptor was originally sized correctly for the sites: surface water with a total capacity of 36 Ltr/Sec. However with the additional flow h m UDC off site surface water
estimated at 26 Ltr/Sec it has been established that the unit is not sufficient to cater for both surface water supplies.
Monaghan County Council have been contacted in relation to organising a meeting to agree on what remedial action is to be taken.
W e believe the council have two options: Re-route their external surface water away €rom the RVF site. Install a second Interceptor on site to cater for the UDC surface water and provide separate monitoring stations.
As yet this meeling has not taken place but we will forward information, as it is available.
8. Clarify if the domestic effluent arising on site is treated with the trade effluent of directed to hcal Authority sewer without treatment.
Only the factory process efnuent is treated on site all domestic effluent is directed to Local Authority Sewer without treatment.
9. Clan@ the scale or volumetric weatment capacity of the “SCAF units” installed in the wastewater treatment plant.
The two on site “ S C W units are capable of handling 35M3/Hr each giving a total capacity 70M3/Hr
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Rye Valley Foods IPPC Application Application support Information
November 2006
IPPC Application Support Information [Page 3)
10. Provide a description of the site raw water treatment and processes.
See Attachment 10.2 Description of Water Treatment and 10.3 Diagram of Water Treatment
11, Clarify where the wastewater from the on site raw water treatment plant is discharged.
This water is discharged to the h a l sump in the on site emuent treatment plant
12. Provide an appropriate scaled map showing the path of the stream into which the surface water discharges.
See Attachment 12.2 Map of Rver Proules Flow
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Rye Valley Foods TPPC Application S u ~ ~ l o r t Information 2006 I f 7
K,EzRy I INDEX
1. Attachment 1.2 Site Map
2. Attachment Table E. 1 (ii) WDS Boiler Emissions (ii) Cochran Boiler Emissions
3. Attachment 3.2 Description of Abatement on Cookers Attachment 3.3 Cooker Emissions Map
4. Attachment 4.2 Maps of Sludge Spreadlands
5. Attachment 5.2 Consultants Letter N.M.P.
6. Attachment 6.1 Diagram of KBO361 / 2 Interceptor
10.Attachment 10.2 Description of Water Treatment Attachment 10.3 Diagram of Water Treatment
12.Attachment 12.2 Map of River Prodes Flow
Attachment A. 1 Rev 2 Non Technical Summary of Rye Valley Foods Ltd.
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Rye Valley Foods LPPC Applrcation Application support Information
November2008
TABLE E.l(ii) MAIN EMISSIONS TO ATMOSPHERE
Emission Point Ref. N?
Source of Emission:
tocation :
&id Ref- (12 digit, 6E,6N):
Vent Details
Diameter:
Height above Ground(rn):
Date of cnmmencement:
A3- 1
HDS B a r on Natural Gas
Main Stcam Boiler House
283819 - 304318
155 Meter
Jan 2M3
__ . . .
(i) Volume to be emitted:
(ii) Otherfactors
Temperature 117 "C (mh) 125°C (avg,
For Combustion Sources:
Volume terms expressed as : El wet. natY* 3.9 -7.4 602
(iii) Period ar pwiods during whicb emissions are made. mare to be made, including daily or MI SO^^^ wiatims (3taH-q hhutdmvn la be imlsrded):
Periods of Emission (avg)
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Rye Valley F& lPPC Applrcation Application s u m r l Informalion
November 2008
TABLE E.l(Y) MAIN EMISSIONS TO ATMOSPHERE
Emission Point Ref. l@:
Source of Emission:
matian :
Grid Ref. (12 digit, 6P6N):
Vent Details
Diameter:
Height above Ground(m):
Date of commencement:
Characteristim of Emission :
A 3 - 2
C o r c b Thenuax w Gas
Main Steam Boiler H o w
283815 - 304319
485 mm
155 Meter
Cold Stand-by Boiler
Ci) Volume to he emitted
{ii} otherfactors
For Combustion Sources:
Volume terms expressed as : El wet. ow. 3.4 - 5.5 kOz
(iii)
periods of Emission (avg) &midr -/day _14drry/yr
N& Boiler is a cdd s W + y and is only run when senicing the HDS boiler
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Eye Valley - C G ~ S IPPG Appl,ca:'on Application SLI ppart In:oi mation
Leo BCH Cooker Abatement System.
Nwernber 2006
=
Rye Valley Fmds cmk their sauce products in stm-jacketed cookers supplied by a company called BCH. These cookers are situated in two w k m m lwated within the factory. The "old BCW services production lines 1,2 & 3, while the "Leo BCH" supplies lines 4,5 & 6.85% of all sauce m h d for the factory is carried out in the Leo BCH.
There are two method8 of cooking " A t n w s ~ and "hssure" the latta pduces higher volume of steam and food vapours and for this reason the venting of the cookers when presswe cooking, passes through an abatement system desctihed below.
Abatement P r m s Each cooker in the Leo BCH has a vent valve cunnected to a biow down abatement vessel. U p completion of "Rasure Cooking" the vent valve optns on the cooker releasing the cooking vapours to the blow down vessel. At the same time water spray valves on the Mow down vesstl are openad by the SCADA system. The reclaimed water (from the vacuum cooling prweus) is pumperl through the spray v a l v a and condenses the venting vapours from the cooker. The condensate is then drained off to our effluent plant for furthtr Watment.
During the cooking process in@ents are added at various stages prompted by a computerid controlled "SCADA" system. Steam is then used as the heating medium to cook the sauce.
When a batch of sauce is ctluked the SBUW is immediately transferred via vac~urn t o its .waled cooling system. l h i a g the vacuum cooling process the volatile v3pours m removed and condensed in a sealed heat exchanger. The condensate is collected in a reclaim tank.
This reclaimed condensate is then used as the cooling medium in the abatement system for the high-pressure cook venting described above.
Atmospheric cooking uses lower temperatures and pressures. Emissions are significantly r e d u d but may enter the atmosphere though the standard cook room air change system.
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Rye Valley foods
Application support Information IPPC Application
Rye Valley Foods Cooker Emissions
November 2006
Reference No. Location Emkslon Point 1 I
A3-5
A3-6
BCH Cooking area - Exlsting Factory
BCH Cooking area - Existing Factory
BCtl Cooking area - Existing Factory
Steam Vent 1.5 Tonne Cooker 1 Stainless Steam Vent & Safety Pressure Relief Valve Vessel 5 Cooker 1 Mitd Steel - Stainless Steam Vent 8 Safety Pressure Relief Valve Vessel 4 Cooker
A3-7
1" Mild Steel - Stainless Steam Vent from Rice Cooker A3-8 BCH Cooking area - Existing Factory 3" Stainless Steam Vent from 1 Tonne Cooker A3-9 6CH Cooking area - Existing Factory 2" Stainless Atmospheric Vent for Leo BCH A3-10 BCH Cooking area - Existing Factory
I Abatement system
Site Map indicating emissions to atmosphere
Rye Valley toods Site Layout A4- 5 A4-3
Ste Map indicating :missions to atmosphere
- SITE BOUNDARY
A 4 2
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J d
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8- r
P-
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6-
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O'CONNELL AGRICULTURAL 8r ENVIRONMENTAL CONSULTANTS LTD, Ballinderry Home, Ballinderry, Enfleld, CO. Meath.
Td: 00 353 (OM-9555591 Fax: 00 353 (0)4&95556002
Mobile: 00 353 (OM7 23069901 E-mail: ocagriOiol.ie
26* Waber 2006
S.I. No. 378 of 2006, EUT~MZUI Cwnmuntiss ( G d Ayh~lh"l Practice fw Protection of Wsaers) Regulations 2006 came into effect on the 1 A u w 2006.
OCAE Consulhutswill revise the Nutrient Managemat Plan for Rye Valley Foods Ltd to comply with the umditions of SI No. 378. The rev id NMP will be completed by the 15* January 2007 in advance ofthe 2007 season.
If you bave any furtller queries, please don't hesitate to mtaEf me.
Rqlstratim No. 2851 30 Dublin
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I
JOHN MOlLOY ENGINEERING
8, Willowfield Park, Goat sto wn , Dublin 14.
c m s - w um SALE
KB015 036 CLASS I L 2
I
BYPASS SEPARA TOR 5
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Rye Valley Foods IPPC Application Application support Informatiun
November 2006
Raw Borehole Water enters the system through the two on site raw water borehole pumps. (See Attachment I .2 for bore hole locations)
The borehole pumps are complete with all necessary valves pipework and pressure gauges, and are selected tu generate sufficient energy to pump the requird flow of water through to the existing IOM3 blending balanclng tank. A level detection devlce is provided for the borehole water pumps to protect against the dry running of the pump. Process flow to the plant is controlled by a flow control loup comprising a flow meter and flow control valve and an analogue level probe and controller. At the blending tank a supplementary water supply is also provided by an Urban District Council Mains connection. This supplementary connection is provided as an emergency backup to ensure the required total quantity of water Is available should the boreholes output fall below an ameptable level during dry weather conditions or suffer contamination.
Water is abstracted from this tank to be pumped on to the initial Ozone stage of treatment, the Ozone contactor.
To allow injection of Ozone a water supply is taken from the Treated Water line using Motive Water pumps. Ozone gas generated by the Ozone generator is drawn into the motive water stream upstream of a mixer. Oxygen required to generate Ozone is provided by a compressed air supply and Oxygen concentrator I generator. The Oxygen generator removes other gases, such as nitrogen, from the air leaving the compressors and produces 93 to 95% pure Oxygen.
After mixing wlth Ozone solution water will pass to the reactor vessel. This vessel is a coded, insurance certified staintess steel pressure vessel fitted with an adequately sized pressure relief valve. An Ozone destruct fitter is connected to the top of the vessel to scrub excess. Ozonated water is continuously sampled and analysed on-line to assess the efficlency of the dosed Ozone. The primary purpose of Ozone in the process stream will be to oxidise dissohed metals and disinfect the water.
Water then passes to a sand filter, which is again, a coded, insurance certified pressure vessel, filled with a variety of filtering media. The filter is periodicdly cleaned (Backwashed) using air blowers and backwash pumps. Stored treated water is used for cleaning the fitters.
Spent or dirty washwater from this filter is discharged to the effluent treatment plant.
Treated Water Quality is monitored at a final Sample Point. On-line samples for pH and manganese are continuously taken and analysed. Provision is atso made to take sterile manual samples. Treated Water flow is measured and total flows are recordd.
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(P 0 0 cu
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I I .
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Rye Valley Foods IPPC Application Application support Information
November 2006
ATTACHMENT A. 1 Rev 2
Non Technical Summary of Rye Valley Foods Ltd.
Rye Valley Foods was established in 1988 and became ‘a subsidiary of Golden Vale Plc. in 1998. Which in turn became a subsidiary of Kerry Foods in 2001
Rye Valley Foods Ltd. Has IS014001 accreditation since June 2001 and is Europe’s largest producer of ready prepared meals, supplying Irish, UK, retail and catering markets.
The plant, which is on a site of nearly nine acres, with a production floor space of 175,000 sq/ft. is located in the Cloughvalley Industrial Estate on the outskirts of Carrickmacross. The plant operates on a five-day basis, 24 hours a day.
Rye Valley is a supplier of frozen ready meals primarily to the UK market. There are over 250 different products but typical products are Curry 8z Rice, Shepherds Pie, Lasagne and Spaghetti Bolognaise.
The facility has a total production capacity of 3 million meals per week currently averaging 2 million. The output from the factory varies from 700 to 1100 tonne per week of finished product depending on product mix.
Description of Process:
The manufacturing process is split into four stages:
1 Cooking
2 Assembly This involves cooking of mainly rice or sauce.
This is where all the elements of the meal are assembled and heat sealed into a c-pet tray.
This is a continuous conveyor belt process and meals are brought below minus 18 deg C.
3 Freezing
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Rye Valley Foods IPPC Application Application support Information
November 2006
4 Packaging This process includes cartoning for individual packs, stretch wrapping into bundles, followed by automatic palletising .
Rye Valley Foods are a member of Repak and as such all-recyclable materials are segregated on site for removal to Recycling centres.
A frozen ready meal mainly consists of the following elements:
Carbohydrate: This includes rice spaghetti and potato. All with the exception of potato are cooked on site. Vegetable: Variable e.g. Carrots, Peas, Broccoli. All are brought in IQF. (Individually Quick Frozen) Protein: This includes cooked Chicken, Turkey, Lamb, Pork or Beef. All are precooked and are brought in IQF. Sauce: There are a variety of sauces. Of this there are a small number of sauces, which use raw meat as their ingredient.
Rye Valley Foods cook their sauce products in steam- jacketed cookers supplied by a company called BCH. These cookers are situated in two cook rooms located within the factory. The “Old BCH” services production lines 1, 2 & 3, while the “Leo BCH” supplies lines 4, 5 & 6. 85% of all sauce cooked for the factory is carried out in the Leo BCH.
There are two methods of cooking “Atmospheric” and “Pressure” the latter produces higher volume of steam and food vapours and for this reason the venting of the cookers when pressure cooking, passes through an abatement system.
Atmospheric cooking uses lower temperatures and pressures. Emissions are significantly reduced, but may enter the atmosphere through the standard cook room air change system.
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Rye Valley Foods IPPC Application Application support Information
November 2006
The main emissions from the plant are as follows:
Effluent - Process effluent is treated on site (solids removal) in the effluent treatment plant, which discharges to the town sewage system under licence.
Effluent Sludge -The sludge generated by the effluent plant is land injected on a land bank in Co. Louth under licence.
Boiler Emissions - The factory uses a 9000kgs/hr boiler to generate the steam used in the process the boiler runs on natural gas and emissions are checked and recorded on a quarterly basis under an external contract.
Food Waste - This is removed from site for rendering in College Proteins. we are only concerned with C3 waste.
Steam - Venting from sauce cookers currently sent through a water cooled blowdown vessel to remove solids and odours.
Waste to landfd - Site recycles all clean cardboard, paper, plastics, steel and tin remaining waste goes to landfill in Monaghan Co. Council landfill site.
Surface water - this goes through a petrol interceptor before discharging to river and can be diverted to effluent plant in the event of contamination, spill etc.
Noise- All emissions are within legislation and a copy of sound audit report is attached to application
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