Galco (Waterford) Ltd. Gracedieu Road Waterford City P0385-01 · 2016. 6. 3. · GALCO (WATERFORD) LTD. ANNUAL ENVIRONMENTAL REPORT 2015 6 1.4 Environmental Health & Safety Policy

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


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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,


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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.


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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




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




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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

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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

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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

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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

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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

Documents

Galco (Waterford) Ltd. Gracedieu Road Waterford City P0385-01 · 2016. 6. 3. · GALCO (WATERFORD) LTD. ANNUAL ENVIRONMENTAL REPORT 2015 6 1.4 Environmental Health & Safety Policy