Quinn Group EIS

Polyurethane FUR / PtR tbam mumfacturing f5dIity

PART 1

PRELIlMINARIES

SECTION 1:

1.1 PREAMBLE

Following scoping meetings with County Council officials and after presenting an ’

: .I” .:, overview of the various environmental issues relevant to the proposed project, Quinn Group were advised that although there was no specific regulation which stipulated that an Environmental Impact Assessment (as defined in the amended European Communities *a ,r Environmental Impact Assessment regulations, ‘1999) was required to be submitted with a planning application of this type, it was considered that the EIS format was the most appropriate way of assessing various environmental issues arising and recommending appropriate ameliorative measuresto ensure the enivromental integrity of the area.

The consultants were thus contracted to compile an EIS to accompany this planning application. Having reviewed the terms of reference regarding the application, the consultants undertook an extensive study of the likely impacts to the receiving environs, both real and perceived, which the proposal would generate.

For inspection purposes only. This was carried outConsent through of copyright consultations owner required forand any othermeetings use. with the applicant and their

.,.. various professional advisors. Extensive consultations were also held with the local .* Planning Authority and various other relevant public bodies, agencies, non-governmental organisations and stakeholders to ensure that all relevant environmental issues and concerns were identified, Specific concerns relating to an issue, environmental or otherwise, could then be assessed and subsequent amendments or modifications implemented to ensure proper mitigation or avoidance of identified issue. From experience, this inchrsive approach facilitates the compilation of a whir and robust report.

Other similar sites were also visited during the preparation of this statement and relevant enviro~ental comparisons reviewed.

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EPA Export 25-07-2013:14:00:19 Quinn Group EIS Polytudhane PIR / PIR foam inam~facturing facility

Assumptions in&de that the area of land to which the proposed project relates and of the scale and aspect of buildings are those for which a planning application is being submitted during December 2002.

As with all such studies undertaken by the consultants, this EIS has been conducted in an independent and objective manner with factual comment and analysis of all relevant information. .

The areas which were reviewed include all areas which an Environmental Impact :,_... Assessmentwould cover including;- ...,‘.I.-e :‘: Human Beings Flora & Fauna Air Surface & Groundwater Landscape Climate Cultural Heritage Material Assets

,,’ Noise

Given the siting of the proposed unit in a mixed use industriaUcomrnercia1 - agricultural setting and following detailed scoping, elements required to be addressed in an EIS but which present only marginal relevance to the proposed project, are reviewed accordingly. .,:.,’ ; .! ::.‘I.. :..,. .I:.,/ iv:,j For inspection purposes only. ...: C- : Consent of copyright owner required for any other use. ._: .I...:‘I,./.::a (/.‘,_”.? ‘.;.: ;,. j,.1 .

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EPA Export 25-07-2013:14:00:19 This impact assessmentstudies the various identified environmental impacts associated with both the construction and operation of the proposed development in the Tds., of Rakeelan, Gortawee (Scotchtown), Ballyconneh, Co. Cavan.

The proposed development comprises of ;-

. The construction and operation of a Polyisocyanurate (WR / PIR) foam manufacturing facility inclusive of a main production area, laboratory facilities, dust extraction system, chemical blending and storage areas, raw material and final product storage area, underground pentane storage tank, designated off-loading area, truck spray cage, office, toilets, car parking facilities, smoking hut, and cogfete enclosure of site with suitable security fencing with

: aestheticaily finished entrance. ‘.. :, ’ * ,,’ :,: 3 ,.‘. ,, ‘,:. ;, “.‘.,, /$ 2.; .I, :.::... .‘? : * ‘. ” ~ ‘;‘.. ;

.: ‘,; The scope of this EIS covers environmental impacts associated with the development within the site curtilage apart For inspectionf?om traffic purposes only.movements of$?-site.Various ancillary services Consent of copyright owner required for any other use. relating to water supply, connection to town sewer, electricity and telecommunications have all been reviewed and no issues arose concerning servicing of the site.

Following an approved planning application, an IPC license from the EPA would be required to be applied for, specif&rg various emission thresholds and occupational healt. and safety limits as specified under the various Health & Safety regulations governing safe working conditions.

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EPA Export 25-07-2013:14:00:19 Polyxthane PUR ! PIR foam mam~~a‘actuingfacility ,

The findings of the EIS are presented in the following format:

Section I Introduction - including site works and project description

Section 2 Environmental Impacts inclusive of baseline information, prediction of likely impacts of the development and necessary ameliorative measuresproposed to ensure that all identified impacts are contained or avoided in a regulated manner.

Section 3 Non -Technical Summary

The EIS was prepared with direct reference to the polices and requirements of the Development Plan 1996, specific industry reports concerning the PUP. and PIR rigid insulation board long term strategies and the various EPA guideline documents regarding information to be contained in an EIS and preparation of an EIS (see references).

For inspection purposes only. Consent of copyright owner required for any other use.

EPA Export 25-07-2013:14:00:19 QuinnGroup EIS

SECTION 2: DESCRIPTION OF PROPOSED DEVELOPMENT

2.1 Project Background

Quinn Group have been rnanufkturkg Expanded Polystyrene (EPS) insulation boards at their existing f&A&y sited in Granard, Co. Longford for the past 8 years. Over this period they have gained considerable experience of the insulation market and have captured a

‘i’.,,,:...+ :‘. ,;: considerable share of the overall business. Given industry requirements and various .,.’ : .I treaty’s requiring the phasing out of CFCs in line with the Montreal Protocol and Seveso guidelines, together with Irelands obligations under various energy efficiency treaty’s, Quinn Group decided to invest a considerable amount of capital in developing an inherently efficient PUR - PIR rigid foam manuf&turing plant, whose insulation products, will comfortably achieve the required thermal efficiencies. required under amendments to the new building regulations, coming into force in January 2003.

The proposed development will be located on a 40,000m2 site in the Tds., of Rakeelan, Gortawee (Scotchtown) , Co. Cavan. The development will take place over a three-month period, providing the planning authorities treat the application favourably.

The proposed fbcility will manufhcture PUR - PJR closed-cell rigid laminate insulation

For inspection purposes only. foam board with flexibleConsent of copyrightf&zings owner for required use forin any walls,other use. roofs and floors of industrial,

commercial and domestic bu&ings. The finished product will have one of the lowest thermal conductivity values of insulation materials available in this country and will comfortably satisfy revised building regulations governing this area of the construction business, which require improved thermal conductivity values for rigid insulants.

2.2 Background to PUR / PIR process

Rigid Urethane Foam technology was developed in the 1960s by Bayer chemical company and has been developed to the widest end use and compatibility by the rigid urethane industry over the last four decades. The 1970 oil crises was the major catalyst in concentrating R&D development on PU insulation technology.

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EPA Export 25-07-2013:14:00:19 EIS

Polyrdhane PUR 1 PIR foam manufacturing facility

Since then, these products have come to dominate the insulation market and have undergone a period of rapid growth, principally due to;-

1) The products’ superior insulation properties. 2) The widest compatibility with associatedbuilding components and latest industry buikbng designs &d regulations.

Features which make Rigid. Urethane Foam unique.

1) Lowest K-Value 2) Compatibility / Versatility

The low K Value is as a direct result of the total encapsulation of the blowing agent within the closed cells of the foam core. ?he blowing agent composition and the thermal. properties of that gas is vital to final insulation performance.

In short the gas must have. 1) A molecular size large enough to remain trapped within the cells. 2) Must have the lowest possible thermal conductivity. 3) Must have a boiling point, which is compatible with the exothermic reaction of the rigid Forurethane inspection foam.purposes only. Consent of copyright owner required for any other use.

During the products’ initial development and subsequent in-service use for the first 30 years, the blowing agent which fitted all the above criteria was FREON Il. This material possessed all the required properties and therefore the products and systems including their insulants quickly became first choice where high levels of insulation were required.

In the late 1980’s it was established that the industry would have to eliminate CFC containing materials from it’s production processes and the polyurethane industry was required to step up efforts to develop and supply “cleaner” alternatives for rigid foams. Following the Montreal Protocol a phase out plan was put in place.

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EPA Export 25-07-2013:14:00:19 EIS Pal~wethane PUR / PIR ham manufacturing Bcilitv

Time allowance was made for the phase out of CFC products for the following reasons.

9 the blowing agent was totally encapsulated in the foam core and ii) in recognition of the products contribution to energy conservation and therefore the need to develop a suitable and sustainable long-term alternative.

Between 1991 and 1994 triak were carried out in conjunction with the major chemical companies. Assistance was also received from Brufma (British Rigid Urethane Foam Manufacturers Association) on long term ageing tests, to qualify the alternatives. This was particularly relevant to the industry as the products are designed to provide 4 level of insulation performance for the lifetime of the building where they are installed.

The initial route yas to phase out CFCs in line with the Montreal Protocol and at some time ensure the level of energy conservation provided by these products was maintained. Afker many triaIs the possibihties were reduced to three compounds;-

They were 141B - CO2 - and Per&me.

,141B while retaining the thermal properties and processing technology was only acceptable as a transition from CFC to CFC free and HCFC free.

CO2, while 100% CFC free, For inspectiondoes not purposes give only. the long term thermal performance that is Consent of copyright owner required for any other use. required.

Pentane whiIe involving major capita1 investment has been proven over the past 7 years to be compatible with the rigid urethane foam technology, providing the required long term thermal properties and meets all the current approvals while being 100% CFC and HCFC Free.

The PUWPIR process is now widely recognised as being the most thermally eEcient in the worid. Comparisons of the&l energy characteristics reveal that rigid PUPJPIR laminate boards can increase thermal efficiencies by a factor of 3-4 times that of traditional systems.

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EPA Export 25-07-2013:14:00:19 Quinn Group EIS

Polywethane FUR / PIR foam manufacturing facility

.2.3 Pentane Characteristics I Chemicals which will be used in the manufacture of PUUPIR foam will include polyols, isocyanate, various additives and 85% Cyclopentane / 15% Isopentane blend. The Pentanes are non-corrosive for all types of steel. They are classed as a highly flammable liquid - Rll - and consequently do not come under the Serveso Directive. The Safety Data Sheet for Pentane and various other chemicals involved in the process is included in appendices 2. Hydrocarbons are classified as zero ozone depletion potential (ODP) materials

2.4 Manufacturing Process Overview

The proposed method involves the installation of a Plama continuous processing line where bIended chemicals along with a blowing agent (Pentane) are introduced between two surface facings.

The proposed method is defined as an exothermic reaction meaning the process generates _ heat. The use of polyurethane foam composites for industry applications is dictated by demolding cycle times and co&o1 .of their dimensional stability (green strength). Several methods have been used for process monitoring of polymer reactions.

For inspection purposes only. Consent of copyright owner required for any other use. In order to optimise the cure time of any polyurethane foam system, the components require rapid mixing and injection, the polymer cure reaction must take place quickly and uniformiy, and be followed ‘by rapid cooling throughout the part. This results in optimal mechanical properties of the part and permits demolding without resulting in dimensional distortion.

In order to substantially reduce cycle time, critical control of heat transfer processes, which occur within the foam during curing, is required. This requires continuous monitoring and analysis of the temperature profiles within the foam under appropriate molding conditions. *

Temperature profiles are measured at various positions within the foam and at the foam surf&e for mold temperatures. The successof the reaction is determined from various

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EPA Export 25-07-2013:14:00:19 reaction kinetics and thermal conductivity.

Of critical importance is the establishment of the cure temperature profile of the foam system as a function of the molding conditions using single system chemistry.

The proposed commercial poIyisocyanurate/phenolic (IWWPIR) closed cell foam is the result of a chemical reaction between diphenylmethane-4-4’ - diisocyanate (MD& normally with an isocyanate index range between 230 - 270 and polyether /polyester polyols. The reaction process and physical properties of the fInished product are controlled by the addition of other chemicals including surfactants, catalysts, blowing agent (85% Cyclopentane / 15%Isopentane blend) and water. Industry specifications indicate that optimum production is achieved when the system has a cream timg of 20 seconds,rise time of 45 secondsand a tack free time of 65 seconds

After passing through the curing oven the edges of the laminate board are then trimmed and cut at computer controlled lengths. This method is accepted as being beneficial in significantly reducing production wastes. The board is then stacked and allowed to cure.

For inspection purposes only. Consent of copyright owner required for any other use.

EPA Export 25-07-2013:14:00:19 Quint Group EIS, Poiyttrethane PUR / PIR foam mnttfacttuing Bcilit):

2.5 Site Location

The proposed facility is to be located along the R205 main Ballyconnell to Derrylin road. The site is located approximately 1 km to the north of Ba~yconneh and 7 lan to the south of Denylm, Co. Fermanagh. The site entrance will be across from the accessroad to the Quinn Group, Scotchtown, Ballyconnell Cement Works. The area in and around the Cement Plant would be categorised as an industrial complex, however the site area itself would most likely be designated as ‘Mixed Use’. Quinn Group recently received planning permission for a 36,000m2 storage warehouse and ground works have already commenced. The proposed facility will be sited to the south and adjoining this warehouse on lands in the ownership of Quinn Group.

2.6 Spatial Contest

Over the last number of years this area has witnessed considerable commercial development. The catalyst for most of this developmental has been the success of the Quinn Group in the general area with 8s various quarrying and production facilities. Recent development within the functional envelope of the proposal has seen the construction of a service station, home d&or and tool hire commercial unit toward the For inspection purposes only. Bailyconnel! side of Consentthe proposed of copyright ownersite. required The forerection any other use.of the new storage warehouse and

ancillary components because of it’s size and aspect will influence the immersion of the proposed facility into the local landscape. Site curtilage is defmed as mixed use with extensive pastoral activities taking place in and around an industrial/commercial setting. Previous to the recent surge in commercial building in the area, the immediate area would have been described as being rural in nature, comprising settlement of scattered farms and individual dwellings. The closest structure to the site is the storage warehouse currently being constructed to the north of the site and a service station to the south of the proposed site. There is also a farm complex to the north of the site adjoining the proposed warehouse unit. This farmstead is used exclusively for storage and sheltering of livestock. There are several other dwellings within the vicinity of the proposal, however none of these dwellings overlook or access the proposed site.

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EPA Export 25-07-2013:14:00:20 alongside the Woodford River. It’s relatively good state of preservation is particularly : I..f .’ . ~‘, noted by the facade along Main Street and the presence of several listed buildings, including the impressive Market House, in the square. Besides the Quinn Group there is a vibrant commercial community in the town with an agriculturai mill and a plastic i;,*... . ~::.~l container plant located on the fringes of the town. : .:..:.

./ It is this deep inherent industrious culture of local people, which has most probably .a exerted the strongest influence on land use patterns over recent centuries. The commercial and industrial activities seen prospering today have developed largely as a result of two influences; -

‘% - the extent of the various natural resource based activities in the area - the strategic geographical location of Ballyconnell as a trading town with :‘. accessboth to waterways and busy trading routes

; ‘, This industrious ethos is interwoven in the cultural fabric of the community and is one of .“,. the dominating influences on local folklore and heritage. For inspection purposes only. To this day the industriousnessConsent of copyright of ownerlocal required people for anyand other their use. work ethic is the driving force of

_.: the areas’ success, a success built on their individual and combined endeavours and .m effchts.

,. ‘. ‘. : There are two main routes through the town. A national secondary route runs from on the Cavan - Fermanagh border through Ballyconnell toward and Cavan town in the east and the R205 classified as a Regional/County route, runs north- east through Ballyconnell to Derrylin in Co. Fermanagh, past the site of the proposed facility.

The Woodford River, which meanders through BalIyconnell, is a major scenic and recreational resource of the town. In more recent times it has been extended to form part

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EPA Export 25-07-2013:14:00:20 Quinn Group EIS

Polyrethane PUR i PIR foam ~nadacturing facility

of the Shannon-Erne waterway, which is an extensive inland waterway flowing from Carrick-on-Shannon in Co. Leitrim to Upper Lough Eme in Co. Fermanagh.

The field where the proposal is to be located runs from the road down to this canal corridor and the proposed structure will be approximately 60m from the canal. The general area in and around this corridor is designated as a ‘J3igh Landscape’ area. Given the sensitivity of views from the waterway, special attention will be required to ensure that the siting and aspect of the proposed building will not impinge on the inherent amenity value of the river and environs. As well as optimising aesthetic design character of the proposed structure, rehabilitation of embankments along the river edge will assist in screening views of the complex from recreational users of this waterway.

. .’ ; It was the area’s existing industrial / commercial landuse characterises which convinced Quinn Group to locate the proposed facility in this area. Qther sites and indeed premises were assessed,however few sites could compare with the one proposed. Given it’s relatively central position in relation to export routes (Dublin - Belfast) and it’s

I ,: proximity to other Quinn Group industries with knock-on benefits accruing from

: ..

‘. administration and management activities, the proposed site is strategically situated in

,. ‘,~. terms of overall logistical management. Following a lengthy process of elimination, the proposed site was deemed the most For inspection purposes only. suitable. Consent of copyright owner required for any other use.

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EPA Export 25-07-2013:14:00:20 Quinn Group EIS

Polyurhane PUR / FIR ham mcmuf8cnui.q facility

2.7 Duration and Phasing

Construction of the PuR/pR rigid laminate board facility will commence immediately following final planning approval is received and commencement notices signed and returned to Cavan County Council. It is anticipated that the physical construction of the unit will require three months to complete, with another four weeks required to install various production plant, chemical storage tanks, bunds, ducting and ancillary pipework.

. The anticipated time schedule for proposed works (following plannmg approval) is as follows;-

Site Preparation Weeks 1-2 Main Civil Engineering stage Weeks 3 - 12 Installation of production plant and ancillary Duotwork/piping/bunds/storage tanks weeks 13-16 Plant Commissioning & Testing Weeks 17- 28

It is anticipated the plant will have a working life of 35 years, in which case and in the event of closure, a final closure and decommissioning plan will be submitted to the PA for approval which will include an environmental exit audit. For inspection purposes only. Consent of copyright owner required for any other use.

EPA Export 25-07-2013:14:00:20 For inspection purposes only. Consent of copyright owner required for any other use.

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