Requested Information 3 - Environmental Protection Agency · Boiler blow down, condenser blow down, vacuum pump cooling water are also transferred to the River Derry through surface

Kerry Foods Shillelagh August 2007IPPC ApplicationRequested InformationNo. 3

REQUESTED INFORMATION

NO. 3

DETAIL ALL EMISSIONS TO SURFACE WATER

(DETAILED INFORMATION ON ABATEMENT SYSTEMS IS ALSO INCLUDED IN THIS SECTION)

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3.1

As stated in the original application, Kerry Foods Shillelagh has two emission points to the River Derry (SW-1 Effluent Treatment Plant final effluent) and (SW-2 surface water drains).

All contaminated wastewater is collected in the designated pipe work system and conveyed to the balancingtank prior to pumping to the effluent treatment plant.

Industrial effluents arise from the general washing within the processing areas. These wash waters containvarious chemical residues, which are employed to aid cleaning process and fat / oil residues. See appendix3.1 Figure 3.1.1 for chemical list and relevant Material Safety Data Sheets. There is a Clean in Place (C.I.P)system and the wash water contains fat / oil residues, which are retained in a fat trap. These wash watersare transferred to the effluent treatment plant and the treated effluent is discharged to the River Derry underthe conditions of Local Authority Discharge License L/5/98.

Potable water is used during the cooling process and again this is transferred to the effluent treatment plantthrough the designated pipe work within the factory. This cooling water contains no contaminated material.

Waste brine, which contains nitrate, nitrite and phosphate is collected in IBC’s and transferred to theeffluent treatment plant where it is drip-fed into the effluent plant.

All laboratory washings are transferred through the foul drainage line to the effluent treatment plant.

In addition to the above wash down and process sources, foul effluent emissions arise from canteen andtoilet areas. These are all conveyed to the effluent treatment plant.

Boiler blow down, condenser blow down, vacuum pump cooling water are also transferred to the RiverDerry through surface water drains. Analysis of boiler blow down, condenser blow down and vacuumcooling water are to be found in the original application in appendix E.2 Figure E.2.5.

Wash water from cleaning of the bone silo, which contains small bone particles, fats and oil residues, aretransferred through foul drains to the effluent treatment plant.

List of Emission Points

Emission PointReference No.

Description Grid Reference

SW –1 Treated Effluent Final Discharge to River Derry N167659E299090

SW –2 Surface Water Discharge to River Derry N167662E299087

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3.2 Treatment of Emissions

All process and sanitary drains are directed to the effluent treatment plant and enter at the raw effluentsump.

A flowchart of the treatment process is outlined below in Appendix 3.2 Figure 3.2.1.

Description of the Effluent Treatment Plant is as follows:

The primary treatment plant consists of the following stages:

Raw Effluent Sump

Two effluent lines are routed to the effluent plant from the factory premises.

One caters for the domestic sewage and terminates at the septic tank which is in turn connected to theadjacent raw effluent sump by an over flow pipe.

The other caters for the industrial effluent and outflows directly into the raw effluent sump.

Two submersible pumps are installed in the raw effluent sump from where effluent is pumped through theinlet screening and fat removal system and into the pre-treatment sump. These pumps operate on astandby / duty basis.

Pump specification: 18.9 litres per second @ 10m head Flygt pumps Model: CP3127.180 MT.

DAF Unit

The Dissolved Air Floatation unit is a pre-assembled package type unit contained in a treated mild steeltank. The unit has been specially designed to facilitate the mounting of a contra shear type fine screen ontop. The local pipe work is arranged so that the local pipe work can be bypassed. This is achieved byclosing the 150mm gate valve on the inlet to the DAF and opening the 150mm bypass line direct to the pre-treated effluent sump.

The DAF comprises the following

- Main Venturi Air Eductor.- Floatation cell- Air saturation system- Float scraper- Adjustable Outlet weir- Float holding sump- Screened Effluent Sump

A schematic of the DAF unit is outlined in Appendix 3.2 Figure 3.2.2

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Main Venturi Motorised Air Eductor

This is the lead air pressurisation system and has been added to the DAF as a more efficient and reliablemeans of lifting the solids and fats in the DAF.This is located at the infeed section of the DAF

Floatation Cell

The floatation cell is provided with a vertical and incline baffle to ensure even distribution of the inlet flowand recycle.

Air saturation system….. Standby Aeration System

The air saturation system consists of the following

- Air saturation vessel with level control- Recycle pump- Recirculation pump- Venture air eductor- Air flow meter- Air release valves- Ancillary pipe work and valves- Air line and solenoid

A portion of the treated effluent is pressurised by a recycle pump and fed to the air saturation vessel. Theair saturation vessel is provided with an external level gauge and switch. This ensures that the level of theair/water interface in the vessel is maintained in a narrow band. As the air is dissolved in the pressurisedliquid the level rises above the upper level position. This operates the switch and in turn operates a solenoidvalve on the compressed airline to the vessel. This adds air to the vessel until the level drops below thelower level position and the switch again closes the air solenoid.The air saturation vessel is provided with a pressure relief valve to protect the vessel against overpressure.The recirculation pump mixes the contents of the vessel and also draws air from the top of the vessel andinjects the air into the delivery line of the recirculation pump by means of the venture eductor. Thisarrangement ensures intense mixing of the air and pressurised recycle stream. The air saturated recyclestream is introduced into the floatation cell via a set of diaphragm they air release valves. The release of airfrom solution generates the air bubbles necessary for this floatation process.

Float Scraper

A chain and flight scraper removes the float solids from the surface of the floatation cell via a beachplatelocated at the end of the tank. This scraper mechanism is driven by a helical gear motor.

Adjustable Outer Weir

The treated effluent flows forward from the floatation cell via two 150mm pipes and into an outlet launder.This launder is provided with an electrically actuated outlet weir. This weir controls the liquid and float levelin the floatation cell and hence the manner of float removal.

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Float Holding Sump

The float scraper deposits the float into an integral float holding sump. This sump is contains an agitatorpump to keep the fats fluid. A pump pumps the fads into the inlet of the centrifuge where water is removed.

Pre – Treatment Sump

The raw effluent exits the DAF and flows into the Pre-Treatment sumps. Two submersible pumps areinstalled in the pre – treatment sump from where the effluent is pumped to the balance tanks on a duty /assist basis.Each pump is provided with:

- Automatic coupling pedestal - 2 No guide rail - Lifting chain - Non return valve - Shut off valve - Set 150 mm dia. ductile iron pipe work.

An ultrasonic level monitor is provided for pump on / off control. The pH of the effluent is controlled here,using sulphuric acid and caustic soda, to maintain a pH level between 6.5 and 8.5.

Balance Tanks

The pretreatment pumps discharge to the balance tanks. The two balance tanks each have a capacity of1545000 litres.

The function of the balance tanks is to allow for an even controlled flow of effluent forward for treatment,while allowing sufficient capacity to cater for extremes of inlet flow variation. Each balance tank is equippedas follows:

- 15kw high speed floating aerator positioned centrally in the tank.- 3 no. sets of S.S. mooring cables, fiberglass float and mooring column assembly- Local isolator- Ultrasonic level sensor/controller- Common observation platform and access ladder- 150mm dia. Inlet pipe work and gate valves

An ultrasonic level sensor/controller is fitted on each tank to provide aerator on/off control and forward feedpump on/off and speed control.

To minimize shock loads on the cables and mooring system each aerator is driven by an electronic ‘softstart’ unit mounted in the main electrical control panel.

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Forward Feed Pumps

Two progressive cavity P.D. pumps are located adjacent to the balance tanks. These pumps dischargeeffluent from the balance tanks to a break chamber, mounted on one of the balance tanks, from where itgravitates to the aeration tanks.

These pumps operate on a duty/standby basic. Flow variation is provided by speed control, using inverterdrives to allow forward pumping to treatment at a flow rate between 5 to 30 metres cubed per hour.

This allows the plant to treat daily flows of minimum 120 metres cubed per day to maximum 720 metrescubed per day, giving a ratio of 6:1

Automatic speed control of the pumps is based on maintaining a set high level (80% typically) in thebalance tanks during the 5 day production week, with this capacity being used up over the weekend, inmaintaining flow to treatment, even with minimal inflow.

The level in the duty balance tank is monitored by an ultrasonic level sensor. This signal is used by the localcontrol system to provide proportional control of the forward feed pumps over the range 40% to 80% of B.Tlevel. The set points are adjustable and are used to maintain a level in the tank during weekday periods

A low level set point will stop the pump when the tank level falls below a certain value (typically300mm).This will reset automatically. (Typically 400mm).

Aeration Basin

This is where the biological breakdown of the effluent takes place. The aeration system consists of twoaeration tanks, (1 main and 1 standby) access walkway, splitter box and local pipe work. Effluent enters theaeration tanks via a local splitter box, which can direct the flow into either aeration tank or both. Eachaeration tank is provided with a 15KW variable speed aerator, plant speed is varied by the plant controlsystem in response to signals received from a dissolved oxygen sensor mounted in each aeration tank. Themixed liquor from each aeration tank exits to the settlement tanks by overflowing an outlet box / baffleassembly.

The aeration system consists of two aerobic reactors, each of which include a variable speed verticalaerator, a dissolved oxygen sensor / monitor, an anti vortexing device and on outlet assembly. Alsoincluded is a common walkway and ladder, a splitter chamber an interlink pipe.

Effluent leaves the aerator tank and gravity feed to the two clarifiers

Settling Tanks / Clarifiers

There are two final settling tanks. Each tank is equipped with a diffusion drum, centre drive scraper, vee –notch launder channel with scum board, access walkway and a scum removal system. The supernatant isdecanted and drains into the tertiary filter – feed sump. The scum is collected and drained to a localconcrete tank, which must be periodically emptied and the sludge is sent for landspreading.

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Mixed liquor in the aerator tanks flows into the centrally mounted diffusion drum located in each settling tankvia an outlet assembly installed in each tank. Quiescent conditions in the settling tank allow the sludge tosettle on the tank floor, from where it is scraped into a central hopper and returned to the aeration tanks orwasted to the sludge holding tank via the return/excess sludge system.

The waste sludge is sent to the centrifuge for processing and drying.

Centrifuge

Model Westfalia Decanter AG CB 300-01-02.

The decanter is a horizontally arranged scroll centrifuge with a cylindrico-conical solid wall bowl for thecontinuous separation of solids from suspensions.

The process liquid enters the decanter through the centrally arranged feed tube and flows into the inletchamber of the scroll from where it flows through ports into the separation space of the bowl where it isaccelerated to operating speed. The solids particles settle against the bowl wall in the briefest space of timedue to the action of the centrifugal force.

The scroll, rotating at a slightly higher speed then the bowl shell, continuously conveys the centrifugallyremoved solids to the narrow end of the bowl. Due the conical shape of the bowl, the solids are lifted out ofthe liquid in the de-watering zone and rid of adhering liquid due to the action of the centrifugal force. Thesolids are discharged into the catch chamber of the housing at the end of the bowl where they are ejected.The liquid flows between the scroll flights to the cylindrical bowl end. The light impurities still present in theliquid are centrifugally removed on their path through the clarification zone and conveyed by the scroll to thesolids discharge and pumped to the skip for disposal. The clarified liquid leaves the separation space via anexchangeable/adjustable regulating ring and flows off under pressure where it is piped to the DAF infeedand returned to the process for treatment.

The sludge formed is delivered to a cake pump and pumped into the sludge waste skip. Schematic ofcentrifuge is outlined in Appendix 3.2 Figure 3.2.3.

Tertiary Filter Feed Pumps to sand filter

Two submersible pumps are provided, in the tertiary filter feed sump to pump settled effluent from thesettling tanks to the tertiary filter. Operation is on a duty / stand by basis. An ultrasonic level monitor isprovided for pump on / off control.

Tertiary Filter

Tertiary filtration consists of a continuously back washed sand filter. There is no need to take the sand filterout of operation for back washing or cleaning. The incoming effluent is filtered sub stream through the sandbed inside the filter while the sand is moving downwards. Simultaneously with the filtration process, foulsand is pumped into a sand washer by using an airlift and any suspended solids are discharged with thewash water.The effluent can flow into the flow measurement chamber prior to outfall or it can be diverted to the pre –treatment sump to complete a recycle loop. The wash water is returned to the aeration process via thesplitter box.

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Sand Specification is as follows:Quantity 7.7 tonnesDesignation 0.9-1.2mmEffective grain size 0.9 plus minus 0.05mmMaximum 1% grains smaller than 1.5mmMaximum 1% grains smaller than 0.6mmUniformity coefficient max 1.5Hydrochloric acid solubility max 1.5Iron content max 0.1%Humus content max 1000mg / 1pt

A schematic of the sand filter is outlined in Appendix 3.2 Figure 3.2.4.

Outlet Flow

A vee – notch weir chamber is provided on the outlet line and is equipped with an ultrasonic flow meter andautomatic wastewater sampler.

3.3 BAT Evaluation

For the purposes of BAT evaluation, the principal stages of wastewater treatment plant operation wereevaluated against the EPA draft note on Sector (BAT).

Element Abatement / Treatment Method Referenced in BAT

Primary Treatment Separation – Dissolved air flotation (DAF) Yes

Secondary Treatment Activated Sludge, Anaerobic Digestion Yes

Tertiary Treatment Sand Filters Yes

Sludge Treatment Centrifugation Yes

Sludge Management Landspreading (in accordance with NMP) Yes

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Appendix 3.1

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Figure 3.1.1

KERRY FOODS, WICKLOW

CLEANING MANUAL

SUBJECT: MSDS LIST OF CHEMICALS

SECTION: IndexPAGE: 1 of 1REVISION: OriginalDATE: 12th February 2007SIGNED:______________________ Technical Manager

SUPPLIER PRODUCT CODE PRODUCT DESCRIPTION

ECOLAB Triquart Super Liquid disinfectant

Triquart QD (DS 646) Alcohol-containing surface disinfectant

All Pass NU General Purpose liquid detergent

Trifax ST Mildy alkaline detergent for foam cleaning

P3 - topax 19 Liquid, alkaline cleaning agent for foam cleaning

Topax 37 Caustic foam detergent

Topax 63 Liquid alkaline, chlorine based, self foamingdetergent

Label Remover (NN 4483) Speciality label remover

Mip PB Based on caustic alkali

Mip Gel Caustic gel suitable for removing heavycarbonised deposits of fat or protein

Super LA Strong Alkaline powder detergent

Hypochloran RS Disinfectant

Hypochloran Tablets Disinfectant in tablet form

P3 - ansep CIP Liquid, alkaline cleaning agent with disinfectingproperties

P3 - oxysan Z5 Premium cold disinfectant

Topmaxx 520 Advanced liquid acidic detergent for descaling

Mip RS Caustic based liquid detergent

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Documents

Requested Information 3 - Environmental Protection Agency · Boiler blow down, condenser blow down, vacuum pump cooling water are also transferred to the River Derry through surface