Attachment B.8 Site Notice, Newspaper Advertisement and ... · “Brewhouse” where they will pass through a weigher, a screen and a detoner to remove dust and other materials (e.g

Great Northern Distillery Limited Application for an IPC Licence

Attachments to Application

Doc. Ref. 500-X0002 July 2014

Attachment B.8 Site Notice, Newspaper Advertisement and Planning Authority Notice

This attachment contains the following:

B8.1 Copy of the text of the site notice.

B8.2 Drawing 13: Location of the site notice.

B8.3 Copy of the newspaper advertisement including the name of the newspaper

and the date of appearance of the advertisement (copies of the original

newspaper notice are included in the hardcopy application; the text of the

newspaper notice is included in the PDF copy of the application).

B8.4 Copy of GND’s letter advising Louth County Council of this IPC Licence

Application.

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TEXT OF SITE NOTICE

APPLICATION TO THE ENVIRONMENTAL PROTECTION AGENCY FOR A

LICENCE

Notice is hereby given in accordance with section 87(1)(a) of the Environmental Protection

Agency Acts 1992 to 2013, that Great Northern Distillery Limited, Carrick Road, Dundalk,

Co. Louth, National Grid Reference 304245E, 306899N, will submit information to support

the determination of an application for an IPC licence for Class 7.3.2: Distilling in

installations where the production capacity exceeds the equivalent of 1,500 tonnes per year

measured as pure alcohol, not included in paragraph 7.8.

A copy of the application for the IPC licence and such further information relating to the

application as may be furnished to the Agency in the course of the Agency’s consideration of

the application may be inspected at or obtained from the headquarters of the Agency, or

alternatively via the Agency’s website, as soon as is practicable after the receipt by the

Agency of the application for the licence.

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TEXT OF NEWSPAPER NOTICE

The following notice was published in the Dundalk Democrat on July 1st, 2014.

Application to the Environmental Protection Agency for a licence.

Notice is hereby given in accordance with section 87(1)(a) of the Environmental Protection

Agency Acts 1992 to 2013, that Great Northern Distillery Limited, Carrick Road, Dundalk,

Co. Louth, National Grid Reference 304245E, 306899N, will submit information to support

the determination of an application for an IPC licence for Class 7.3.2: Distilling in

installations where the production capacity exceeds the equivalent of 1,500 tonnes per year

measured as pure alcohol, not included in paragraph 7.8.






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TEXT OF NOTIFICATION TO PLANNING AUTHORITY

Planning Section

Louth County Council,

Planning Office,

County Hall,

Millenium Centre,

Dundalk,

Co. Louth

7th

July 2014

Re: Notification to the Planning Authority under Section 87(1)(a) of the EPA Acts

1992 and 2003.

Dear Sirs,

This Notification is submitted to Louth County Council in accordance with the requirements

of Section 87(1)(a) of the EPA Acts 1992 and 2003. We advise that Great Northern

Distillery Limited, Carrick Road, Dundalk, Co. Louth, National Grid Reference 304245E,

306899N, will submit information to support the determination of an IPC licence application

for Class 7.3.2: Distilling in installations where the production capacity exceeds the

equivalent of 1,500 tonnes per year measured as pure alcohol, not included in paragraph 7.8.






Yours faithfully,

__________________

David Hynes

Managing Director

Great Northern Distillery Limited

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ATTACHMENT C: MANAGEMENT OF THE INSTALLATION

Attachment C.2 Environmental Management System


C2.1 Copy of Great Northern Distillery Limited’s Environmental Policy.

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ATTACHMENT D: INFRASTRUCTURE & OPERATION

Attachment D.1 Infrastructure & Operation


D1.1 Descriptions of the production, support and ancillary / service operations at

Great Northern Distillery Limited.

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D.1.1 Operational Information Requirements

Descriptions of the production, support and ancillary / service operations carried out at the

site are provided in the following sections.

D.1.2 Overview of Whiskey Production

D.1.2.1 Unit Operations

The distillery will produce two types of whiskey: Malt Whiskey and Grain Whiskey. Malt

whiskey will be produced by batch mashing, fermentation and distillation. Grain whiskey

will be produced by continuous cooking and mashing, batch fermentation and continuous

distillation.

The main unit operations for production are:

Raw material intake, storage and transfer;

Milling;

Mashing / Cooking;

Fermentation;

Distillation;

Storage; and

Dispatch from the site.

The production of malt whiskey is described in Section D.1.4 and the production of grain

whiskey is described in Section D.1.5.

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Figure 1: Overview of Malt & Grain Whiskey Production at GND

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D.1.3 Raw materials intake, storage and transfer

Dry bulk raw materials (malted barley / grains) will be delivered to the site by truck to the

grain intake area. The trucks will report to the porter and each truck load will be weighed on

the weighbridge. Deliveries will be inspected and sampled, as required by the site’s sampling

plans and quality control system. Testing of raw material samples will be carried out by an

external laboratory. The materials will be unloaded from the trucks into a pit. The materials

will then be conveyed into separate storage silos for malted barley, unmalted barley and

grain. Silo levels will be controlled by comparing the weight of the incoming grain against

the weight of grain transferred to the mills. The receipt, offloading and conveying of malted

barley, unmalted barley and grains to the storage silos will be carried out in accordance with

GND’s operating procedures.

Malted barley and grains from the silos will be transferred to the mill via bucket elevators and

chain conveyors. Batch weighers will control the rate at which grain is fed to the screens,

destoners and mills. The screens will be in place to remove foreign material like corn husks,

stones, etc. and magnets will be used to prevent small metal pieces entering the mills. Both

the roller mill (for malt) and the hammer mill (for grain) will be equipped with dust

extraction systems.

D.1.4 Malt Whiskey Production

Milling

Barley (malted and/or unmalted) will be transferred from the storage silos to the

“Brewhouse” where they will pass through a weigher, a screen and a detoner to remove dust

and other materials (e.g. straw, stones and cereal chaff) before reaching the roller mill. The

grains are then milled, exposing the inside of the grain, to form the grist.

Mashing

The grist will then be mixed / mashed with hot water. During this process, enzymes are

released from the malted barley and starch is dissolved and converted into fermentable sugar.

Hot water will be added to extract the starch and sugar from the grain. The resulting solution

– the wort – will be filtered through the husk material and the leftover cereal solids – draff –

will be transferred for storage in silos outside the Distillery building. The wort will be

transferred to the fermenters and the draff will be treated as a by-product and will ultimately

be sent for use as an animal feed material. The last water added to the mash vessel will be

used to capture any remaining sugars in the vessel. This will be recycled into a hot liquor

tank and used as the first water on the next batch.

Fermentation

After mashing, the wort is transferred to the fermentation vessels and yeast is added. The

yeast converts the sugar in the wort into alcohol. The fermentation process will produce a

solution containing alcohol at a concentration of approximately 8% abv.

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Malt Distillation

From the fermentation vessels, the wash is transferred to a wash still for the first distillation.

A second distillation is then carried out in an intermediate still, which produces High Wines,

and a third distillation process is carried out in a spirit still. The distillation process produces

spirit at a concentration greater than 66% abv, which will be transferred to spirit storage vats.

The malt distillation process also produces spent wash and spent lees which will be sent to

the process effluent drain for treatment in the effluent treatment plant. Feints (the lower

alcohol content output from the still) produced during distillation will be added back to the

spirit still with the next batch.

D.1.5 Grain Whiskey Production

Milling

Grains will be transferred from the storage silos to the mill house where they pass through a

series of screens to remove dust and other materials (e.g. straw, stones and cereal chaff)

before reaching the mill. The grains are then milled in a hammer mill to expose the inside of

the grain, to form the grist.

Mashing

The mashing process for grain distilling involves two stages: a cooking stage and a

conversion stage. During the cooking stage, wheat or maize grist is mixed with water at high

temperature and the mixture is cooked to produce a porridge like material. This process

dissolves the starch from the grist into the water, which in turn is used as one of the input

materials for the next processing step: conversion.

The cooked wheat is cooled and a slurry of milled malted barley and water is added to the

starch from the cooking stage. This mixture is left to stand to allow the enzymes in the

malted barley to convert the starch to sugar; the malted barley added to the starch contains

enzymes produced naturally during the malting process. The resulting solution – the wort –

is sent to the fermentation.

Fermentation

After the cooking and conversion stages, the wort is cooled and transferred to the

fermentation vessels where yeast is added. The yeast converts the sugar in the wort into

alcohol. The fermentation process yields the wash, a solution containing alcohol at a

concentration of approximately 9% abv.

Grain Distillation

The grain distillation process is a continuous process (compared to the malt distillation

process, which is carried out in batches). The purpose of the distillation is to separate the

alcohol for whiskey production from the yeast and non-fermentable sugars, and to

concentrate it to a higher alcoholic strength. In the grain distillation process, the wash is first

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fed through a degassing column. It then enters the first distillation column and steam is

injected to evaporate the alcohol and transfer it up the still into the second column. After the

first column, the liquid reaches a distillation strength of approximately 55% abv. The alcohol

is then concentrated in two further distillation columns with the final distillate at a strength of

approximately 94.5% abv. The columns will be vented through condensers which will

discharge alcohol vapours to the atmosphere in the event of over-pressurisation.

D.1.6 Process Control

The main production operation will be entirely automated. A centralised SCADA system

will be operated by staff from the control room in the “Brewhouse”. The operators will be

able to start and stop production processes and CIP regimes from the work station. The

operator will also be able to view all the vital production parameters from the computer and

alarms will be triggered where equipment does not operate correctly or if a parameter is out

of specification. The following is a list of the main control equipment:

Level Transmitters:

High and Low level transmitters on the mash vessel;

High and Low level transmitters on the lauter tun;

Each fermentation vessel;

Each ethanol storage vessel;

Each CIP vessel (acid, caustic, water);

Each of the wash, intermediate, and spirit stills;

Each receiver;

Hot effluent storage vessel;

Warm effluent storage vessel;

Effluent buffer vessel;

Temperature Transmitters:

Mash Vessel;

Lauter Tun;

Each fermentation vessel;

Each of the wash, intermediate, and spirit stills;

Multiple transmitters on each of the column stills;

Hot effluent vessel;

Warm effluent vessel;

Effluent buffer vessel;

There will also be pressure and flow transmitters on other equipment for monitoring.

In addition to the process controls and monitoring systems, the production process and

associated systems will be supervised / monitored by trained and experienced operators.

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D.1.7 Storage

Spirit will be stored on site in spirit storage vats. The vats will range in size from 73,650

litres to 126,000 litres. The particular spirit stored in each vat will depend upon the particular

type of whiskey that is being produced and the operational requirements of the distillery.

D.1.8 Dispatch from the site

Spirit stored in the spirit storage vats will be dispatched from the site in bulk. Tankers will be

loaded with spirit from the storage vats and the product will then be shipped offsite to GND’s

customers. GND does not currently have any plans to store whiskey in casks for maturation

at the site. The number of tanker loadings per week will depend on the operational and

production requirements at GND. The activities carried out when filling tankers will be

carried out and supervised by trained and experienced operators.

D.1.9 Ancillary & Service Operations

D.1.9.1 Overview

In addition to the production operations carried out at the site, there will be a range of

ancillary / service operations, together with activities supporting the main production

activities. These operations are described in the following sub-sections and include:

By-Product Handling;

Canteen;

Chemical intake and storage;

Cleaning in Place (CIP);

Compressed Air;

Cooling;

Effluent Treatment System;

Electricity Import (via an onsite substation) and Distribution;

Laboratory Activities;

Steam Generation & Distribution;

Water Supply, Treatment & Distribution;

Workshop Activities.

D.1.9.2 By-Product Handling

A number of by-products will be generated at the site, including spent draff, spent maize,

grain dust and fusel oil. At the end of the mashing process, after the mash liquor has been

transferred to the fermentation vessel area, the remaining solids are known as spent draff.

This material consists of the remains of the grain and water from the production process.

Spent draff will be blown by pneumatic conveyor from the mash vessel to two 150,000 litre

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storage silos. The spent draff will ultimately be sold as animal feed. Spent maize from the

centrifuge will be transfer using a chain conveyor to trailers. Grain dust will also be

generated from the conveying system and dust collection system. Grain dust will also be

collected and sold as a by-product for use as animal feed material. During the column

distillation process, fusel oils are extracted at a rate of approximately 5kg/hour. Fusel oil will

be decanted using two 2,500 litre decanters and will be stored in two 12,000 litre receivers in

the distillery building. Fusel oil may ultimately be sold as an input material for perfume

manufacture or as a fuel.

D.1.9.3 Canteen

Canteen facilities will be provided for production and operational staff at the distillery. The

wastes arising from canteen area, including food waste, will be sent off site for recovery and

will be segregated at source where practicable.

D.1.9.4 Chemical Intake and Storage

A variety of materials will be used and stored throughout the site. Bulk chemicals (including

caustics for Cleaning-in-Place activities) will be delivered to the site in 1,000 litre IBCs.

Other materials will be delivered to the site in smaller quantities (packages), depending upon

the particular type of material and the nature / location of use. These packages (including

pallets, where required), will be unloaded from delivery vehicles by forklift truck and

transferred to their respective storage areas or designated points of use.

D.1.9.5 Cleaning-in-Place (CIP)

Cleaning in Place (CIP) is the cleaning and sterilising of vessels and pipework throughout the

production areas of the distillery. The CIP process includes the spraying, circulating,

flushing, washing and rinsing of dilute caustic solutions through the process equipment at

intervals between the production cycles. The CIP schedule will be dictated by the number of

batches and the particular nature of the production process and the operational (and quality)

requirements of the site.

D.1.9.6 Compressed Air

Compressed air will be used in a number of areas of the site, including for the control of

automated valves within the distillery buildings. At the time of submitting this application,

the final design and layout of the compressed air distribution system had yet to be finalised.

The compressors will be located in the building directly to the west of the fermentation area.

D.1.9.7 Cooling

The temperature of the final effluent will be managed by virtue of the heat recovery from the

effluent and the residence time within the effluent tanks. Where necessary, cooling may also

be used to control the effluent temperature. Cooling will be provided by three 1.5kW and one

0.5kW cooling towers.

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D.1.9.8 Effluent Treatment System

Effluent treatment at the site will consist of pH and temperature adjustment. All process

effluent will be collected in the process effluent collection vessel in the “Brewhouse”

basement. The temperature of the process effluent will be controlled through a combination

of heat recovery from the production areas (thereby reducing the overall heat input required

for the production process) and cooling (if required) to ensure that the effluent is discharged

at a temperature below the limits agreed with Irish Water / Louth County Council. Process

effluent from cleaning and washing will also be diverted to the effluent holding tanks, as

shown in Figure 2.

Figure 2 Effluent Treatment Plant (pH & temperature control)

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The process effluent from the holding tanks will be pumped to the effluent treatment plant at

the northernmost end of the site for pH balancing. Surface water and domestic effluent will

also be combined with the process effluent prior to entering the 50m3

effluent treatment plant

buffer tank. The pH level of the inflow will be measured, and then acid or caustic, as

appropriate, will be automatically dosed into the tank. The effluent treatment plant comprises

of one 15 m3 tank for storing sulphuric acid and one 11.6 m

3 tank for storing caustic. Once

the pH is within the agreed limits it will be released to the public sewers where it will

eventually reach the Wastewater Treatment Plant at Soldiers Point, Dundalk. It is expected

that the majority of the process effluent will be slightly acidic due to the nature of the

production process and acid dosing will rarely be required.

The temperature and pH of the effluent will be monitored to enable the controlled discharge

of effluent to the municipal sewer. The flow rate, temperature and pH of the discharge will

be monitored on a continuous basis, with additional monitoring of chemical oxygen demand,

biological oxygen demand, total suspended solids and total nitrogen carried out using an

automatic sampler.

The volume of effluent generated at the site will increase as the site increases its production

capacity. The daily effluent volumes will depend upon the particular production

requirements at the site and therefore will fluctuate from day-to-day. It is not expected that

the production activities will give rise to a significant seasonal fluctuation in effluent

volumes.

D.1.9.9 Electricity Import (via an onsite substation) and Distribution

Electricity will be imported to the site from the grid at 10kV and distributed from the

substation located to the southeast of the site (east of the spirit storage area). The operating

voltage will be reduced, as required, through a series of transformers distributed around site.

D.1.9.10 Laboratory Activities

The laboratory will be located on the third floor of the “Brewhouse” building. Samples of

materials from different stages throughout the production process will be collected in

accordance with the distillery’s sampling plan, with the samples analysed in the laboratories.

Laboratory staff will be responsible for the reporting of both internal analytical results and

external analytical results provided by contract laboratories and also for ensuring that all

instruments associated with performing the analysis are regularly calibrated, serviced and

maintained.

A variety of small scale waste materials will be generated within the laboratories, including

spent laboratory chemicals and solvents, waste samples, broken laboratory glassware /

equipment, packaging materials from laboratory chemicals, and general office wastes (e.g.

paper, ink cartridges).

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D.1.9.11 Steam Generation

Steam will be generated at the site within three steam boilers. The boilers have a rated

thermal input above the 5 MW threshold for consideration as boiler emission points (refer to

Section E.1.A.1 of the application). All boilers will be fired on natural gas.

The boilers will operate on a duty / standby basis to cover the varying loads of the distillery.

The boiler at emission point A1-1 will be the main duty boiler with the boiler at emission

point A1-3 acting as a standby boiler. The boiler at emission point A1-2 will not be used

initially because boilers A1-1 and A1-3 will have sufficient steam generation capacity for the

production output planned at the site. Brewing water, which has already been softened on

site, will be used to supply the boilers. The steam generated by the boilers will be transferred

via insulated pipes to the kettle, the stills, and to the CIP areas.

The main boiler controls will include pressure control, level control, temperature control,

boiler blowdown control and oxygen mixture control.

D.1.9.12 • Water Supply, Treatment & Distribution

Water will be supplied to the site from two water sources. Water for production of whiskey

will be provided from a reservoir above Ravensdale on the western flank of Slieve na gCloc

in the Cooley mountains. The Cooley water will be sand and carbon filtered onsite and

stored in two large water reservoirs below the workshop area. Water for use in other areas of

the site will be sourced directly from Irish Water/Louth County Council via the town water

supply.

D.1.9.13 Workshop Activities

A maintenance workshop will be located to the west of the fermentation area, which will be

used for a variety of site maintenance activities, including general equipment maintenance

and small scale fabrication / repairs. Waste materials generated in the workshop will include

metal and wood waste, together with waste oils, lubricants, paints and similar materials.

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ATTACHMENT E: EMISSIONS

Attachment E.1 Emissions to Atmosphere


E1.1 Drawing 14: Location of Emission Points to Atmosphere.

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Attachment E.2 Emissions to Surface Water

There are no attachments associated with Section E.2 of the IPC licence application.

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Attachment E.3 Emissions to Sewer


E3.1 Drawing 15: Location of Emission Point to Sewer.

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ATTACHMENT F: CONTROL & MONITORING

Attachment F.2 Emissions Monitoring & Sampling Points


F2.1 Drawing 16: Monitoring Locations for Emissions to Atmosphere.

F2.2 Drawing 17: Monitoring Location for Emission to Sewer.

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ATTACHMENT G: RESOURCE USE & ENERGY EFFICIENCY

There are no attachments associated with Section G of the IPC licence application.

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Documents

Attachment B.8 Site Notice, Newspaper Advertisement and ... · “Brewhouse” where they will pass through a weigher, a screen and a detoner to remove dust and other materials (e.g