Site Visit Report The site visit process is a sample on a particular day of an installation's compliance with some of its licence conditions. Where non-compliance against a particular condition has not been reported, this should not be construed to mean that there is full compliance with that condition of the licence. Instructions and actions arising from the visit shall be addressed, or where applicable noted, by the licensee in order to ensure compliance, to improve the environmental performance of the installation and to provide clarification on certain issues. The licensee shall take the actions specified to close out the non-compliances and observations raised in this Site Visit Report. Licensee Name of Installation Irish Cement Limited (Limerick) Licensee Irish Cement Limited Licence Register No. P0029-05 CRO Number 9212 Site Address Castlemungret, Limerick Site Visit Reference No. SV15944 Report Detail Issue Date 04/09/2018 Prepared By David Matthews Site Visit Detail Date Of Inspection 30/07/2018 Announced No Time In 09:30 Time Out 17:30 Visited by on behalf of the EPA Socotec Licensee Personnel and Role See report. Photo Taken No Samples Taken Yes Video Taken No Odour Assessment No Site Visit Report - SV15944 - Irish Cement Limited Page 1 of 45 Scope This is a technical report on the results of monitoring of emissions to atmosphere. Media Air. Site Areas Inspected See report. Documents Inspected See report. Site Visit Report - SV15944 - Irish Cement Limited Page 2 of 45 Site Visit Report - SV15944 - Irish Cement Limited Page 3 of 45 STACK EMISSIONS MONITORING REPORT 2-4 Langlands Place Kelvin South Business Park East Kilbride G75 0YF Tel: 01355 246 730 Fax: 01355 249 669 Your contact at SOCOTEC UK LTD David Hay Business Manager - North Tel: 01355 246 730 Email: [email protected] Operator & Address: Irish Cement Ltd Castlemungeret Limerick Co Limerick Permit Reference: IE Licence: P0029-05 Release Point: A2-01 Kiln 6 Rawmill Sampling Date(s): 30th July 2018 SOCOTEC UK Job Number: LEK 11247 - CAR18-02 Report Date: 24th August 2018 Version: 1 Report By: Enda Flood MCERTS Number: MM 12 1170 MCERTS Level: MCERTS Level 1 - Technician Technical Endorsements: - Report Approved By: David Hay MCERTS Number: MM 04 552 Business Title: MCERTS Level 2 - Business Manager Technical Endorsements: 1, 2, 3 & 4 Signature: Site Visit Report - SV15944 - Irish Cement Limited Page 4 of 45 SOCOTEC UK Reporting Template v3 Page 1 of 41 SOCOTEC UK LTD www.socotec.co.uk CONTENTS EXECUTIVE SUMMARY Stack Emissions Monitoring Objectives - Plant - Operator - Stack Emissions Monitoring Test House Emissions Summary Monitoring Times Process Details Monitoring Methods Analytical Methods - Sampling Methods with Subsequent Analysis - On-Site Testing Sampling Location - Sampling Plane Validation Criteria - Duct Characteristics - Sampling Lines & Sample Points - Sampling Platform - Sampling Location / Platform Improvement Recommendations Sampling and Analytical Method Deviations APPENDICES APPENDIX 1 - Monitoring Schedule, Calibration Checklist & Monitoring Team APPENDIX 2 - Summaries, Calculations, Raw Data and Charts APPENDIX 3 - Measurement Uncertainty Budget Calculations Irish Cement Ltd LEK 11247 - CAR18-02 / Version 1 Limerick 30th July 2018 Site Visit Report - SV15944 - Irish Cement Limited Page 5 of 45 A2-01 Kiln 6 Rawmill Page 2 of 41 IE Licence: P0029-05 SOCOTEC UK LTD www.socotec.co.uk EXECUTIVE SUMMARY MONITORING OBJECTIVES Irish Cement Ltd operates a kiln process at Limerick which is subject to IE Licence P0029-05, under the EPA Act 1992. SOCOTEC UK LTD were commissioned by EPA to carry out stack emissions monitoring to determine the release of prescribed pollutants from the following Plant under normal operating conditions. The results of these tests shall be used to demonstrate compliance with a set of emission limit values for prescribed pollutants as specified in the Plant's IE Licence, P0029-05. Plant A2-01 Kiln 6 Rawmill Operator Irish Cement Ltd Castlemungeret Limerick Co Limerick IE Licence: P0029-05 Stack Emissions Monitoring Test House SOCOTEC UK - East Kilbride Laboratory 2-4 Langlands Place Kelvin South Business Park East Kilbride G75 0YF UKAS and MCERTS Accreditation Number: 1015 Opinions and interpretations expressed herein are outside the scope of UKAS accreditation. MCERTS accredited results will only be claimed where both the sampling and analytical stages are UKAS accredited. This test report shall not be reproduced, except in full, without written approval of SOCOTEC UK LTD. Irish Cement Ltd LEK 11247 - CAR18-02 / Version 1 Limerick 30th July 2018 Site Visit Report - SV15944 - Irish Cement Limited Page 6 of 45 A2-01 Kiln 6 Rawmill Page 3 of 41 IE Licence: P0029-05 SOCOTEC UK LTD www.socotec.co.uk EXECUTIVE SUMMARY EMISSIONS SUMMARY Parameter Units Result Calculated ELV ISO 17025 Uncertainty accredited +/- result Cadmium & Thallium (average of tests) mg/m³ 0.003 0.004 0.05 P Cadmium & Thallium Emission Rate (average of tests) g/hr 0.822 1.021 - Cadmium & Thallium Run 1 mg/m³ 0.004 0.005 0.05 P Cadmium & Thallium Emission Rate Run 1 g/hr 1.019 1.267 - Cadmium & Thallium Run 2 mg/m³ 0.003 0.003 0.05 P Cadmium & Thallium Emission Rate Run 2 g/hr 0.624 0.776 - Heavy Metals (average of tests) mg/m³ 0.13 0.02 0.5 P Heavy Metals Emission Rate (average of tests) g/hr 31.34 5.77 - Heavy Metals Run 1 mg/m³ 0.13 0.02 0.5 P Heavy Metals Emission Rate Run 1 g/hr 34.84 6.41 - Heavy Metals Run 2 mg/m³ 0.12 0.02 0.5 P Heavy Metals Emission Rate Run 2 g/hr 27.84 5.12 - Mercury (average of tests) mg/m³ 0.004 0.005 0.05 P Mercury (average of tests) Emission Rate g/hr 0.922 1.178 - Mercury Run 1 mg/m³ 0.005 0.006 0.05 P Mercury Emission Rate Run1 g/hr 1.337 1.708 - Mercury Run 2 mg/m³ 0.002 0.003 0.05 P Mercury Emission Rate Run 2 g/hr 0.507 0.648 - Oxides of Nitrogen (as NO2) mg/m³ 495.5 10.4 500 P Oxides of Nitrogen (as NO2) Emission Rate g/hr 135273.9 2833.9 - Sulphur Dioxide mg/m³ 7.9 4.1 400 P Sulphur Dioxide Emission Rate g/hr 2153.8 1114.2 - Carbon Monoxide mg/m³ 457.9 6.6 1500 P Carbon Monoxide Emission Rate g/hr 125028.8 1797.8 - Carbon Dioxide % v/v 12.71 0.1 - P Oxygen (average of tests) % v/v 13.6 1.8 - P Oxygen Run 1 % v/v 13.6 1.8 - P Oxygen Run 2 % v/v 13.6 1.8 - P Oxygen Run 3 % v/v 13.7 1.9 - P Moisture (average of tests) % 8.9 0.33 - P Moisture Run 1 % 9.3 0.34 - P Moisture Run 2 % 8.6 0.32 - P Stack Gas Temperature oC 112 - - Stack Gas Velocity m/s 30.9 0.70 - Gas Volumetric Flow Rate (Actual) m³/hr 637409.3 32281.1 - P Gas Volumetric Flow Rate (STP, Wet) m³/hr 444436.2 22508.2 - Gas Volumetric Flow Rate (STP, Dry) m³/hr 404702.7 20495.9 - Gas Volumetric Flow Rate at Reference Conditions m³/hr 273024.9 13827.2 335000 ND = None Detected, Results at or below the limit of detection are highlighted by bold italic text. The above volumetric flow rate is calculated using data from the preliminary survey. Mass emissions for non isokinetic tests are calculated using these values. For all isokinetic testing the mass emission is calculated using test specific flow data and not the above values. Reference conditions are 273K, 101.3kPa, dry gas 10% Oxygen. Irish Cement Ltd LEK 11247 - CAR18-02 / Version 1 Limerick 30th July 2018 Site Visit Report - SV15944 - Irish Cement Limited Page 7 of 45 A2-01 Kiln 6 Rawmill Page 4 of 41 IE Licence: P0029-05 SOCOTEC UK LTD www.socotec.co.uk EXECUTIVE SUMMARY MONITORING TIMES Cadmium & Thallium Run 1 30 July 2018 14:51 - 15:54 60 minutes Cadmium & Thallium Run 2 30 July 2018 16:20 - 17:24 60 minutes Heavy Metals Run 1 30 July 2018 14:51 - 15:54 60 minutes Heavy Metals Run 2 30 July 2018 16:20 - 17:24 60 minutes Mercury Run 1 30 July 2018 14:51 - 15:54 60 minutes Mercury Run 2 30 July 2018 16:20 - 17:24 60 minutes Combustion Gases 30 July 2018 14:25 - 17:24 179 minutes Preliminary Stack Traverse 30 July 2018 13:43 - 14:05 - Irish Cement Ltd LEK 11247 - CAR18-02 / Version 1 Limerick 30th July 2018 Site Visit Report - SV15944 - Irish Cement Limited Page 8 of 45 A2-01 Kiln 6 Rawmill Page 5 of 41 IE Licence: P0029-05 SOCOTEC UK LTD www.socotec.co.uk EXECUTIVE SUMMARY PROCESS DETAILS Parameter Process Details Description of process Kiln Continuous or batch Continuous Product Details Cement Manufacture Part of batch to be monitored (if applicable) Normal operation Normal load, throughput or continuous rating 190 t/hr Fuel used during monitoring PET Coke Abatement Bag filter, SRCN Plume Appearance Visible Irish Cement Ltd LEK 11247 - CAR18-02 / Version 1 Limerick 30th July 2018 Site Visit Report - SV15944 - Irish Cement Limited Page 9 of 45 A2-01 Kiln 6 Rawmill Page 6 of 41 IE Licence: P0029-05 SOCOTEC UK LTD www.socotec.co.uk EXECUTIVE SUMMARY Monitoring Methods The selection of standard reference / alternative methods employed by SOCOTEC UK is determined, wherever possible by the hierarchy of method selection outlined in Environmental Protection Agency Technical Guidance Note (Monitoring) AG2. MONITORING METHODS Species Method SOCOTEC UK UKAS Lab ISO 17025 Limit of Calculated Standard Reference Method Technical Number Accredited Detection MU (SRM) / Alternative Method Procedure Method (LOD) +/- % (AM) Cadmium & SRM - EN 14385 AE 108 1015 Yes 0.00191 mg/m³ 124.3% Thallium Heavy Metals SRM - EN 14385 AE 108 1015 Yes 0.006 mg/m³ 18.4% Mercury SRM - EN 13211 / MID 14385 AE 107/AE 108 1015 Yes 0.0009 mg/m³ 127.8% Oxides of Nitrogen (as SRM - EN 14792:2017 AE 102 1015 Yes 3.05 mg/m³ 2.1% NO2) Sulphur Dioxide AM - EA TGN M21 AE 102 1015 Yes 2.98 mg/m³ 51.7% Carbon Monoxide SRM - EN 15058:2017 AE 102 1015 Yes 0.2 mg/m³ 1.4% Carbon Dioxide SRM - ISO 12039 AE 102 1015 Yes 0.002 % 0.7% Oxygen AM - EN 14789:2017 AE 102 1015 Yes 0.01% 13.6% Moisture SRM - EN 14790 AE 105 1015 Yes 0.01% 3.68% Velocity / Vol.