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IPC Application Form
Noise.
SECTIONS 24,25,26
The plant runs twenty four hours per day, seven days per week and therefore with the exception of holiday periods, there are noise emissions from the plant.
We have conducted a limited survey of noise levels at the site boundaries towards the front and
back of the plant during daytime and night time running conditions and also at noise sensitive
locations outside the boundary of the plant.
The maximum noise levels from fixed plant were checked over a three day period. Each sampling duration was for 30 minutes.
Front boundary of plant (Front of main office)
Location:
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Night dBA
1)
53
2) 52
3) 52
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Day dBA
1)
53
54
2)
3)
53
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Location:
Back boundary of plant
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Day dBA
1)
55
2)
53
3)
5%
Night dBA
1 ) 49
2) 48
3) 50
The front boundary of the plant is located on the main Scariff - Ennis Road and the main source
of noise from the plant in this area is from trucks entering and leaving the premises. Maximum
sound levels recorded from trucks were 68 dBA. Approximately 40 trucks enter and leave the
plant each day. Trucks arrive at the plant between 07.00 Hrs and 23.00 Hrs each day Monday
- Friday. There are no truck movements into or out of the plant on Saturdays or Sundays.
Noise levels at the back of the plant peak due to activity in the timber yard area. Timber yard
fixed plant and mobile plant operate 08.00 Hrs to 22.00 Hrs Monday - Friday. The timber yard
does not work at weekends. However, there is a loading shovel which works on a four cycle
shift supplying sawdust and wood chips to their dosing systems.
Maximum noise levels experienced at the closest dwelling house to the factory are outlined
below. This house is on the main Scariff street and noise levels from general traffic were
excluded.
This house is adjoining the River Graney and this contributed to the noise levels.
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IPC Application Form
Day dBA
1)
2)
3)
54
55
56
Night dBA
1) 55
2)
3)
54
54
Noise levels across the road at the Bank ofIreland building are approximately M A lower.
Finsa Forest products Ltd. has been in operation since May 1984and there have been no complaints received re. noise levels from the plant. Prior to Finsa Forest Products Ltd. there were
two other companies which operated the plant and it appears that these companies did not have
any complaints re. noise either.
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Should the E.P.A. require a more detailed noise survey to be undertaken, we will do so.
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IPC Application Form
Noise.
24.
Sources and Emissions
Give particulars of the source, location, nature, level and the period or period during
which the noise emissions are made o r are to be made.
Total 24(i) should be completed, as relevant, for each source.
This information should form Attachment No. 24.
This' information will follow later.
Ambient Measurement.
(a)
State the maximum Sound Pressure Levels which will be experienced at typical points on the boundary of the operation.
(state sampling interval and duration)
SPL
Leq dBA
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Location:
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Location:
Location:
Location:
Leq dBA
SPL
Leq dBA
SPL
Leq dSA
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State the maximum Sound Pressure Levels which will be experienced at typical
noise sensitive locations, outside the boundary of the operation.
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(b)
SPL
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25.
Lucaticn (1)
(Daytime)
SPL
Leq dBA 30 minute
SPL
L q dBA
SPL
Leq dBA 30 minute
SPL
Leq
SPL
Leq dBA 30 minute
SPL
Leq dBA
(Night- time)
Location (2)
(Daytime)
(Night- time)
Location (3)
(Daytime)
(Night- time)
15 minute
dBA 15 minute
15 minute
(include details of day-time and night-time noise levels and state units).
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IPC Application Form
(c)
'
Give details of the background noise levels experienced a t the site in the
absence of noise from this operation.
Prediction models, maps, diagrams and supporting documents, including details of
noise attenuation and noise proposed control measures to be employed, should form
Attachment No.25.
This information will follow later.
26.
NoiseImpad.
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Give details and an assessment of the impacts of any existing or proposed emissions on
the environment, including environmental media other than those into which the emissions are to be made.
This information should form Attachment No. 26.
This information will follow later.
Monitoring and Sampling pointS.
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27.
Co
Identify monitoring and sampling points and outline proposals for monitoring emissions.
i
Include details of monitoring/sampling locations and methods. Tables 27(i) for air,
27(ii) for waters, and 27(iii) for sewers should be completed as relevant.
e
Attachment No. 27 should contain this information.
This information will follow lateE.
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IPC Application Form
27.
Monitoring and Sampling points.
Identify monitoring and sampling points and outline proposals for monitoring emissions.
Include details of monitoring/sampling locations and methods. Tables 27(i) for air,
27(ii) for waters, and 27(iii) for sewers should be completed as relevant.
Attachment No. 27 should contain this information.
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See Attachment 27
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IPC Application Form
Environmental Considerations.
28.
Describe any environmental considerations which have been made with respect to the
use of cleaner technologies, waste minimisation and raw material substitution.
AITACHMENT NO. 28
CLEANER TECHNOLOGIES
1.
2.
’
Eight new bag filters have been installed which have replaced cyclones and one old
inefficient bag filter.
..
Five high pressure blower systems have been installed’which have replaced suction
fans and ducting. These systems are much less prone to leaks.
WASIE MINIMISATION
We have reduced our electricity consumption by 3.1million kwhlyear and we have won
an ETA award for the mid-west region for this reduction.
2.
We have reduced our consumption of hot melt glue since we installed our new panel
lines.
3.
We installed a new resin blending system in 1992 which has reduced our resin consumption by approximately 5%.
4.
We installed new press plates in our main press in 1991 and this combined with the new
resin blending system has reduced our timber consumptim by approximately 9%.
5.
Waste wood and waste products are now used for the generation of heat thereby reducing the quantity of waste for disposal and reducing fuel oil purchases.
Where possible waste wood and waste products are recycled and used in the process.
6.
Timber runners have been replaced by ones made for second quality or reject product.
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1.
e
RAW MATERIAL S U B S T m I O N
1.
Urea formaldehyde resins have been changed for ones curtaining lower levels of
formaldehyde.
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8
2.
Ammonia has been replaced by hexamine as a resin retarder.
3.
Halon gases will be replaced for more environmentally friendly ones.
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IPC Application Form
Statutory Requirements.
Indicate how the requirements of section 83 ( 3 ) (a) to (e) of the Act shall be met, having regard, where appropriate, to any relevant specification issued by the Agency under
section 5 ( 3 ) of the Act and the reasons for the selection of the arrangements proposed.
29.
E.P.A. ACT 1992
Section 83 (3) The Agency shall not grant a licence or revised licence for an activity
unless it is satisfied thatany emissions from the activity will not result in the contravention of any relevant air quality standard specified under section 50 of the Air Pollution Act,
1987, and will comply with any relevant emission limit specified under section
51 of the Air Pollution Act, 1987.
(b)
any emissions from the activity will comply with, or will not result in the contravention of, any relevant quality standard for waters, trade effluents and
sewage effluents and standards in relation to treatment of such effluents prescribed under section 26 of the Local Government (Water Pollution) Act, 1977,
(c)
any emissions from the activity or any premises, plant, methods, processes,
operating procedures or other factors which affect such emissions will comply
with, or will not result in the contravention of, any relevant standard including
any standard for an environmental medium prescribed under regulations made
under the European Communities Act, 1972, or under any other enactment.
(d)
_any noise from the activity will comply with, or will not result in the contravention of, any regulations under sect
(e)
any emissions from the activity will not cause significant environmental pollution.
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(a)
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See Attachment No. 29
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IPC Application Form
30.
Surface Water and Ground Water PFotectiw
All relevant infomation on the management, control and protection of surface waters
arising on the site, and groundwater underneath the vicinity of the site should be provided.
This information should be submitted in Attachment No.30.
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This information will follow later.
.,
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IPC Application .Form
30.
Surface Water and Ground Water Protection
All relevant intonnation on the management, control and protection 01’ surface waters
arising on the site, and groundwater underneath the vicinity o f the site shouid be pro-
vided.
This information should be submitted in Attachment No. 30.
Surface Water Protection
There are cwrently two settling/interceptor tanks in operation on the site and some of the surface water from the plant flows through these prior to its discharge into the River Graney.
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There are four other discharges from the plant where surface water is currently discharged without treatment. Where there is a possibility of this surface water becoming contaminated with
wood chips etc. screenslinterceptors will be installed to prevent this matter from getting into
the river. Our proposals for screenslinterceptors will be submitted to the Agency separately.
The location of the surface water discharge points are shown in Attachment 30.
Ground Water Protection
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Three wells have been installed on site to access ground water quality. A report on the drilling
operation and the hydrogeology of the area is included in Attachment No. 30.
This report also_showsthe location of the wells.
Water samples have been taken from these wells and analysed. The report on this analysis is
included in Attachment No. 30.
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IPC Application Form
31.
Site Management & Control
Details should be provided on the management structures lor the activity.
Organisational charts, and all relevant cnvironmental management policy statements,
including provisions f‘or on-going assessment of‘ environmental performance are
required.
This inl’onnation should form Attachment 31.
Attachment No. 3 1 contains an organisational chart for the activity.
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.
The plant is never left unattended and consequently should an incident arise there I S always
somebody available to raise the alarm.
1.
Managing Director:
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Environmental ResDonsibilitv Levels.
The Managing Director has ultimate responsibility for ensuring that the plant is managed in such a manner that the company’s environmental standards are maintained.
This includes the stopping of production where necessary to avoid environmental contamination.
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Production Managers:
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2.
Production Managers are responsible for ensuring that production lines for which they
have responsibility and authority are operated so that emissions and water are minimised.
3.
0
Maintenance Manager:
The Maintenance Manager,is responsible for ensuring that new plant installed does not
adversely affect the company’s environmental standards and that all machines are adequately maintained so as to minimise environmental emissions.
4.
Suwrvisors:
Supervisors have to ensure that the plant is operated as per the operating manuals and
written instructions. They have to report to their manager or the manager on call out
duty any plant malfunction which may have environmental considerations.
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Environmental CO-ordi nator:
The Environmental Co-ordinator has the following duties/res~)nsibiiities:
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3)
Liaising with regulatory authonties such U the EPA.
Maintaining monitoring programmes U specified by the EPA.
Maintaining adequate records I'or demons4ration o f conformance to env ironmental requirements.
Establishing and documenting the company's Environmental standards.
Contracting the services of external companies/individuals to provide environmen tal experti se/assi stance where necessary.
Internally disseminating environmental information.
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5.
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IPC Application Form
32.
Accidental Emissions.
Describe the existing or proposed measures, including emergency procedures, to minimise the impact on the environment of an accidental emission or spillage.
Also outline what provisions have been made for response to emergency situations out-
side of normal working hours, i.e. during night-time, weekends and holiday periods.
ATTACHMENT NO. 32.
ACCIDENTAL EMISSIONS:
Accidental emissions to the atmosphere can occur for the following reasons:
Cyclones can become blocked and dust is then emitted from the cyclone discharge.
2.
Dust is an abrasive substance which eventually wears away the pipes in which
it is transported and this leads to leaks in dust transport systems.
3.
Bags in bag filters can become holed which leads to dust being discharged from
the filter.
4.
Dust transport lines can become blocked. When this happens the line needs to
be opened and cleaned out. This results in dust discharges to the atmosphere.
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1.
\
.
I
All managers-and supervisors have been instructed to repair leaks in dust lines as quickly as
possible, to shut down bag filters should bags become torn, to shut off dust transport systems
feeding blocked cyclones and to get such cyclones cleared as quickly as possible.
e
A log of all accidental emission will be maintained which will show:
1.
The reason for the emission.
2.
The duration of the emission.
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IPC Application Form
ATTACHMENT NO. 32. - continued
SPILLAGES:
As per our safety statement, the procedure which we have adopted for dealing with spillages is
as follows: .
I
1.
The person who notices the spillage:
(a)
(b)
activates the fire alarm.
phones the dryer operator with details.
The dryer operator contacts the fire brigade and the manager on call out duty.
3.
The emergency crew, shift electrician and fitter assemble at the emergency assembly
point at the corner of the dryer control room and puts on the following protective equipment, if instructed to do so by the shift manager:
-
-
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2.
,Chemical splash suit.
Wellington boots.
Arm-length chemical gloves.
Face visor or respirator.
In the event urea formaldehyde precondensate spillages, instead of a face
visor use a respirator fitted with a formaldehyde-absorbing filter.
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NOTE
4.
The shzlft manager instructs one of this operators to go to the Weighbridge and direct
the fire brigade to the area of the spillage.
5.
During the emergency procedure, the Weighbridge is to be kept clear and traffic flow
stopped until further instructions are received.
6.
In the event of a chemicabspillage, the priorities are as fallows:(unless otherwise decided by a shift manager or a person in a senior position to him)
'
. I
'
(1)
(2)
(3)
(4)
Contain the spillage in as small an area as possible.
Apply sawdust/wood chip to soak up the spillage where possible.
Try to prevent the spillage from entering the river.
In the following list, items 6, 7, 8, 9 and 10 are flammable, therefore, be vigilant of the spillage coming into contact with heat or electrical equipment.
!
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IPC Application Form
ATTACHMENT NO. 32. - continued
The following is a list of bulk liquid chemicals stored on site:
Urea formaldehyde concentrate.
2.
Urea formaldehyde resins.
3.
Sodium hydroxide 50%.
4.
Paraffin wax emulsion 60%.
5.
Formic acid 85%and 50%.
6.
Heavy fuel oil.
7.
Gas oil.
8.
Hydraulk / lubricating oils.
9.
LPG
10.
Thermo oil.
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1.
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PROVISIONS FOR RESPONSETO EMERGENCY SITUATIONS OUTSIDE NORMAL
WORKING HOURS.
The plant runs continuously and therefore the only times which are outside normal working
hours are during holiday periods.
a
Maintenance work is concentrated during holiday periods and consequently there is a lot of
personnel in the plant between 800am and 8.00pm. During the hours 8.00pm to 8.00am and
hi other times when there are no Finsa personnel in the plant, the plant is patrolled by a security guard.
Should he be faced with an emergency, his instructions as per our safety statement are to:
(a)
Ring the manger on call out duty.
(b)
Ring the fire brigade.
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IPC Applicalion Form
33.
Cessation of Activity.
Describe the existing or proposed measures to minimise the impact on the environment
after the activity or part of the activity ceases operation.
Attachment No. 33
The nature of the plant and the operations on site are such that the potential for adverse environmental effects resulting from the cessation of the activity on parts thereof are minimal.
In the event of the activity ceasing operations, the following will apply:
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Stocks of raw materials, service materials, spare parts and finished stock will be
reduced to a minimum prior to decommissioning. Remaining materials will be disposed of as follows:
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Finished stock will be sold.
Wood based raw materials will be sold within the industry for re-use.
R e s i d w a x e s will either be sold within the industry or returned to suppliers/manufacturers.
Other raw materials/service materials will be removed from the plant for reuse.
Spare parts will be removed to other plants within the Finsa Group or returned
to manufacturers.
Thermal oil systems will be drained and the oil will be removed from the plant
for recycling.
Plant and machinery will be either left on the site in running order or will be
removed from the site to be used within the Finsa Group, to be sold or to be
recycled/scrapped.
Where material is to be disposed of as waste, this disposal will be undertaken
by licenced contractors approved by the Environmental Protection Agency.
There is a land filled area within the site boundary and at the time of cessation of the activity,
arrangements will be approved with the Environmental Protection Agency re the continued
monitoring of this area.
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IPC Application I;orm
Declaration
I hereby make application for a licence / revised licence, pursuant to the provisions of
the Environmental Protection Agency Act, 1992 and Regulations made thereunder.
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I certify that the information given in this application is truthful, accurate and complete.
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I have no objection to the provision by the Agency of a copy of the application or parts
thereof to any person.
Co
Date:
Position in organisation:
IJ=PFa
PGbf-r
14-
0)
- 34
hPrJAG&
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EPA Export 25-07-2013:18:55:41
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CLARE COUNTY COUNCIL
LOCAL GOVEIWA~ENT(PLANNING AND DEVELOPAfEN13 ACTS, 1963 - 1993
NOTIFICATION OF A GRANT OF PERMISSION (SUBJECT TO CONDITIONS)
TO:
F i n s a F o r e s t Products L t d . ,
c / o 3ohn T . G a r r e t t ,
3 Church S t r e e t ,
3ohn's Square,
LIMERICK.
Applicstr'ort by
Reference No in
Register of Clare
County Council:
PY5/65
F i n s a F o r e s t Products
of
c / o 30th T . G a r r e t t , 3 Church S t r e e t , John's Square, Limerick
0 I1
2nd February, 1995
for permission
t o r e t a i n f u r n i t u r e manufacturing b u i l d i n g and 2 np. s t o r a g e sheds a t e x i s t i n g
plaht a t Scariff.
- 8
7j
- __
1.
.
.
__-.
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.
LPG storage (if any) shall comply with Council's requirements.
a.
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b.
IS 3216 (1988) Bulk Storage of Liquefied Petroleum Gas.
IS 3213 (1987) Code of Practice for storage of LPG cylinders and
cartridges.
2.
Oiled fired equipment, boiler house and oil storage is to comply with the Clare
County Council requirements for such installations, plus the requirements of BS
5410 Part 1 1976.
3.
Access for fire fighting appliances shall be in accordance with Section 5 of TGD
B Fire to Building-Regulations. "Access and facilities for the Fire Service"
4.
Adequate water supply shall be provided for fire fighting purposes in accordance
with the requirements of the Council and BS 5306 Part 11988.
5.
No surface water fun off from the development shall be allowed to flow onto the
public road or adjoining land.
6.
Adequate toilet facilities shall be provided for the development. Details o f same
shall be agreed Mth the Council.
7.
The applicant shall pay to the Council a contribution towards the expenditure
incurred by the Council in providing the public water supply in the area which
work will facilitate the development. The contribution shall be calculated at the
standard rate obtaining at the time of payment. The current rate is &600.
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condition(s):
.
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A permission lias been granted for the development described above subject to the
1,
v
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.
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8.
No signdnameplates relating to the development s h d be erected on the external
facades of the building or on the site without the prior consent of the Council.
DATE:
10th August, 1995
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CLARE COUNTY COUNCIL
BUILDING CONTROL ACT, 1 9 9 0 .
FIRE SAFETY CERTIFICATE
Reference No. in Register BC
95/3.
TO: FINSA FOREST PRODUCTS LTD.,
C.O. CANTWELL KEOGIh AND ASSOCIATES,
TARA HOUSE,
3 WASHINGTON
STREET WEST,
CORK.
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Application of Finsa For*est Products Ltd., C.O. Cantwell. Keogh and
for a Fire
ASSOCiateS,' Tara House, 3 Washington Street West, Cork
Safety Certificate (Ref. No. BC 9 5 1 3 in respect of extension to
production building at Finsa Forest Products Ltd., Scarriff.
Clare
County Council hereby certifies that the building or works to which the
application relates, will; if constructed in accordance with the plans,
drawings and techhical bubmission submitted, date stamped 9th June,
1995, 11th June, 1995 and 18th May, 1995 respectively, comply with the
requirements of Part B of the First Schedule to the Building
Regulations, 1991.
In considering the application, no assessmept has
been made as to whether the building or works will comply with the other
requirements of the First Schedule to the Building Regulations, 1991.
This certificate is granted subject to the following conditions:( 5 conditions)
The following areas sliall be separated in an non combustible enclosure which sliall attain
a minimum fire resistance of 1 hour when tested in accordance with BS 476 Parts 20-24
1987.
1.
a.
b.
boiler house
switch room
c.
transformer room.
REASON
To comply with B3 of the Building Regulations.
Walkway over stefani 2 machine shall be of adequate width and structural strength and
shall comply with the requirements of Part "K"to the Building Regulations.
REASON
To eomply with B1 of the Building Regulations.
Co
ns
en
2.
Fire &ann system shall comply with the relevant section of BS 5839 Part 1 1988 i.e.
manual call points and radio linked systems and BS 5839 Part 2 1983.
REASON
To comply with B1 of the Building Regulations.
3.
,
Oil storage tank and roof of boiler house shall be provided with a concrete bund capable of
containing I 10%ofthe capacity of the oil tank. Bund shall be protected from the ingress
of rain water or provision shall be made for the automatic removal of rain water from the
bunded atea. Provision shall be made for the monitoring of the bund from ground level.
. REASON
I4 the interests of safety.
. . I ,,I,5.' * ' Access'for lite fighting appliance$sliall be in accordance with Section 5 o f tGD B Fire to
Building Regulations. "Access and facilities for the Fire Service".
4.
j
3
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'DehilS 6fauks5 laybut to be agrekd with Building Control Authority.
REASON :'
To comply with BS of the Building Regulations.
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EPA Export 25-07-2013:18:55:41
NOTE
my changes in plan and information submitted in above application shall
be resubmitted to County Council for approval.
Such changes may
necessitate a new Fire Safety Certificate application.
Any fit out of
t h e premises may also require a further Fire Safety Certificate
Application.
DAY
OF
JUNE,
1995.
ru
I
he
!
nt
o
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
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eq os
ui es
re o
d nl
fo y.
ra
ny
ot
I
se
' I
Co
n
'
se
.
,
a
EPA Export 25-07-2013:18:55:41
Clare Cou-iity Council,
tiow Road,..'
Ennls,
Tal: (065) 21618
Telex: 20144
ar,
ru
se
.
Comhairie Chontae ari Chid&,
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
PLANNING APPLICATION FORM
Co
n
se
nt
o
FOIRM /ARRA TA IS PLEANALA
....
.. .
.... .
. *. .....
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Completed appllcatlon forms should be addressed lo:
Pfannlng Secllon,
Clare County Councll,
New Hoed Otllces,
ENNIS.
Ba chdir loirmeacha iairafaiscomltllonfe R sheoladh
An tlolnn Phleandla,
Comhalrle Chonfas d n Chldfr,
Olflgldn Bh#hefr Nua,
INK. .
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EPA Export 25-07-2013:18:55:41
1
t
. 1
i COUNTY COUNCIL
.
3iAIRLE CNONTAEAIV CI-fLAlR
':
GOVERNMENT
LOCAL
(PLANNING AND DEVELOPMENT) ACTS, 1963 TO 1 9 y 3
APPLICATION TO PLANNING AUTHORITY FOR PERMISSION FOR DEVELOPMENT OF LAND
ACHTANNA AN RIALTAIS A/T/ti/L
(PLEANAIL AGUS FORBAIRT), 1963 GO D T l l 9 9 3
IARRATAIS CHUIG AN f-UL?At?ASPLEANALA AR CHEAD CHUN TALAMH A FHORBAIRT
1. Name ofApplicant
Airim an larralasora
-
F I N S A FOREST PRODUCTS L T D . , S C A R I F F
2. Address for correspondence
Seoladh do chomhlhr'eagras
(a) Name
Ainm
o JOllN T_ . GARRETT
_c /_
_ _ _ _& -ASSUCIA'J'ES,
j6ijN ' 9 S Q U A R E ,
1.1N I ~ R I C K
(C) Qualifications
J ,,_GhRREXT-B
CQilioclrlai --
JOHN T o GAREEXT-.& ASSOCIATES __-__
.I,J u r J n g - + C .
F . I.E. I .
En[
~(d)Telephone No. AS-I\BOVE----Uirnh. Tlieil.
of permission sought. (delete the words which do not apply). ~ U l n e p e r m l s s l e r s r F ~ l ~- ~ i ~ permission to retain.
as cead a iarradh. (Scrios na focail nach bhluil feidlim /eo). Cead i m l i n e a c l i , ~ d n c h e a ~ , ~ a coinnedla.
o~d
t een-.thousanhpounds ) - C H E Q U L -
.
IS,QO-Q--@fl
se
(Stale whether cash. cheque. postal order or money order. I Luaigh ctl8cu eirgeadfirlm. sek. ordc p i s f nd o d d Jrrgid)
ru
Of fee enclos9dt
M i d ha fdi//efaOi iamh,
to
f c Fo
op r i
yr ns
ig pe
ht ct
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ne pu
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eq os
ui es
re o
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fo y.
ra
ny
NOTE: Information regarding planning fees is given in accompanying sheet.
NdTA: TA eolas ar lhdilllpleandla le ldil ar,bliilleog asfailhe.
S C A R I F F , CO. CLARE.
..--___-._
he
6.
CONSULTING
ENGINI:I:RS,- 3 , CIIURCll
ST.,
--- - -- -
-
3 9 CHURCH S T R E E T , J O H N ' S SQUARE, LIm.
(b) Address -____--- _ - _ _ _ _
Seoladh
5' @agh
___.
ot
il
___ - - -
-
8. Existing use of land or properly.
FYRNIXU-RE- W U F A C T U R Z N G - A N D
An lisdid Idithreach den lalamh n6 den Qifresbh.
_____
-_
._ . -
___
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WOOD-. C I I L E S T O R A G E
__
AS
10.(a) Area of land to which the application relates
Achar na fattin a mbalneann an I-larralas lei
.SEE_DRAW.LNG -0E.EINSh SLTE-ATTAGMED,---hPPLIGhTION-
Co
ns
en
9. Particulars ol the development proposed (including use)
Sonral ar an blifords afQbearfailhe (cisdid san direariili).
@umber
of dwellings (if any) to be provided .
Llon na n-ditreabh(mas ann ddibli) a18 le sofdltiar
ABOVE
- __-
-
RELATES ONLY TO B U I L D I N G S I N D I C A T E D BELOW.
-.n/.a-.
.__
__
----
---___
--
FURNITURE MANUFACTURING BLDG 603!
(c) Gross floor space of any proposed building or buildings olher lhan dwelling hovses -CQVJRER STORAGESI-0
U
81 !
Ollachar urlQlrag gach foirgneamhnd loirgnimh atQ bearfailhe lasmuigh de hitlie cdnaflhe COVERED STORI\GE SMED NO. 2
1262
11.Particulars 01 Meres1 held by applicanl in Ihe land or slructure where the development
Is proposed I.e. full owner (fee simple), leasehold,prospectivebuyer etc. -_
Sonraf arphdirllochfan iarratasdra sa lalamh nd sa sfruchflira mbearfdlar 6
a lhorbairt I.e. ciin6ir sldn (Idille shimplf). leas-seilbh, ceannai agus rl.
F U L L OWNERS
SI
__-----
NOTE:If applicant is not the lull owner, submit evldence that !he owner consents to the making of the application for permission.
N6TA: Munarb d an I-iarralasdir an I-ciindlr sldn. fabhair fianaise go bhfuilan I-lilnbir loilleanach go nddanlaf an I-iarralas.
12. Public nolice of intention to apply for permission was given by ITugadh f6gra fiorblfgur bearfaiodha; chead a lorg le
935(b) Erection of notice on the land on Ihe
Znd
(Copy of which should be enclosed).
Fdgra a cuireadh ar an lalamh ar an
.
(ba cheari cd@ a sholdlliar taoi iamli).
--
day 01
l5 de
- FEBRUARY-,1995
13. Have !he requirements 01 the Proposed Building Regulations been taken into account in the preparation
of your proposals?
,
____
T--
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__--Y E S
Ar 16gadh coinnlollacha na Rialachdn urn Tlrdgdil Blrea~ailltssan Qirearnhsna pleananna atd beartailhe agaf?
.
EPA Export 25-07-2013:18:55:41
(1) Exisling Seplic Tank
9,
Datdiacii ~ e i ~ e a cat8
h ann clieana
(a) lndicale proposed melliod 01 sewerage by placing an X in Ihe
appropriale box.
Ldirigh an cdras sdarach atA bearlailiie lrl x.a chur sa bhosca cui.
'
'
(3) Exisling Connection lo Public Mains
Ceangal ald ann cheana le Prlomhllnle Poibll
n
(4) New Conneclion lo Public Mains
Ceangal Nua le Priomhlinte Poibli
(b) lndicale proposed source of waler supply by placing an X In the
appropriale box.
Ldirigh an lhoinse uisce ald beariaithe tri x a chur sa bhosca CUI.
0
0
(1) Existing Bored Well
Tobar Tollla alri ann cheana.
(2) New Bored Well
Tobar Toilla Nua
..
N0TE:Where it is proposed to conned a dwelling lo a Group Waler
Scheme, an applicanl musl submit a certilicale from the Secrelary
of the Scheme staling lhal the proposed conneclion is acceplable.
N6TA:Sa chds go bhluil sd beartailhe Bilreabh a cheangal le Grup-scBim
Uisce, nf mdr don iarralasdir leaslas a chur isleach b R h a l na
Scdime a dhearbhalonn go mbeadli glacadh leis an gceangal ald
beartaillie.
U'
(3) Exisling Conneclion to Public Mains
Ceangai le Prlomhline Poibll alA ann cheana
U
(4) New Connection lo Public Mains
Ceangal nua le Prlomhllns Poibli
(5) Exisling Corineclion lo Group Waler Scheme
Ceangai aid ann cheana le Grtjp-scdim Ulsce
I
se
.
(6)New Connection to Group Waler Scheme
8_1
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ne pu
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ot
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ru
Ceangal nua le Grcip-scdim Ulsce
( 7 ) Olher sources (specify)
FoinsI eile (mds ann ddibh).
Where application relales lo individual dwellings:
S a chds go mbaineann an 1-iarralasle hdilreabh ar leilh.
15.Is proposed dwelling a replacement lor a subslandard house?
An in Bif ti a14 faoi bhun caighdedin ald an 1-dilreabhbeadailhe.
---nb---
--.
nla
16. Is proposed dwelling a new larm house on applicanl's farm?
Co
ns
en
An teach leirme nua ar lheirm an iarralasdra an I-dilreabh a14 beadailhe?
17. Name and Address of personfrom whom Ihe site was purchased.
Ainm agus seoladli an 16 ar:ceannalodh an idilhredn uaidh.
n/ a
____
__
.
18. Relalionshlp,II any, of applicant lo exlsling or prevlous owner of land.
Gaol, mais ann dd. ldir an I-iarrafasdiragus an 16 ar leis, nd a mba leis, an lalamh.
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19. Total area of land owned by applicanl or his family In the vlcinily of the proposed sile.
Achar iomidn na falin ald isellbh an iarralasdra nd I seilbh a clilainne ingiorrachl don Idilhredn bearfailhe.
Acres
Acral TQTAL-SJ.TE..BPEBOX -28 -ACRES-= SEE-ATTACHED-.LOCAT-ION-MAP
NOTE: All such lands should be outlined in blue on Ihe submitled sile localion map.
NOTA: Ea chearl an falamh seo vile a imllniu ingorm ar an Idarscclil lriilhredin a chuidear isleach.
20.Proposed use of dwelling,e.g. for sala, lelling, holiday house, normal place of residense
An &did a bheartailear a dhdanamh dsn ditreabh, m. sli. le dlol, cur ar dos, leach samhraidh, gndlhdif clidnaillie.
/
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I certify lhal lhe inf&nation given in lhis lorrn Is correk
Dearbhaim go bhluil an kola? ald luglha sa bhloirm seo cruinn.
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C.Eng, F. IEI
DATE
DA TA -ZZ-6--FEBRUARP-.-TV9
5-
EPA Export 25-07-2013:18:55:41
I
I
CRES OF GRAZING FOR
ON THE 11 MONTH BA
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GENERAL SHEEP SALE
C L A R E C O U N T Y COUNCIL.
K N O C K A G U L t A , LISDOON.
VARNA
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iLECTlON
Alter G e n e r a l S a l e for E w e s in Lam1
vith Lambs. S c a n n i n g f r o m 10.30 to 11.30 a.m
ANNUAL SHOW & SA
: '
AnBEYSTREET*ENNIS
.
BAREFltl,D
Tnke notice that John l'errill intends to npply for 'outline plan.
rtiric permiscion to erect a dwcl.
. liriglioirse and septic tank at R I K I W
, address.
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ild at tho Salaayard. N e w p o r t on Thursday 26th
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p.m.
RIES: (1) 17 Hdrelord and Continental Helfers In
tion: 12) Clearance Sale of Entire Suckling Herd of 17 ' .
oung Cows (Owner availing of Retirement Scheme).
Oalry Heifere from well known Herds and Hereford
".
DI Suckling Heifers will be on offer. .
ilo: JOHN LEE 6 SON M.I.A.V.I., Msln St,qrt. . ,
, _
;Tlpporary. Tel. 061-378121.
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nrcriomof Mn. Eddget Iregurty, who d retiring
/turn \urmirtg)
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Publlc Auctlon on Saturday, 28th Janugood quality young suckling COWS,
lo P.B. Her. bull.
'
a Muckspreador. D o u b l e boater, Welger A.P.
lood working order.
I m o r n i n g of hale. T e r m s 01 Auction.
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GALLONS MILKQUOTA
' y Private Treaty lor ihe
.
regd. owner.
-
ti,
norice
.
:;
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Take
"AZELcRoVE* R"SLEVAN
'.
.
t h a t Joe llussci
in.
tends to apply to the phmning
authority for pcrnilsslon to demol-
p r o v f d e cmr a h o w r o o m s .
~
,,
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car
~ ~ ; ~
" , ~
~ ; i 3 a~ ~ a~
and sccommodation, and
~
, ~
~
Tnke notice that Kieran and Car.
.Ish existing cottage and tb con-,.':&ated
s,te works at Kllrush
me1 Cummlns are applying to
6truct 3 no..apartments a.t . above
(Signed): Linm
Enhis U r b a n District Council . address.'
. ' ! ,.---.
ucary
(Planning Authority) for permis.
*
sion to construct a garagdfuel
shed at the above address.
CLARE: C O U N T Y C O U N C I L
'
C L A R E COUNTY COUNCIL
e
'
ScllOoL ROAD, LAIllNCll
COAD. K I L N A B O Y
. t a k e notice that C . llanralian in- Take notice that Michael Leahy h
1
.
.. .
C t A R E c o u N T Y C o u N C l i : . tend4 to apply to the planning Partners. Architects. arc kppiying
'.: euthority for outline permission t o . . to Clare County Council on behalf
'
BEALKELLY TU.
. consiruct two no. dwellltlghouses' ' of Ron and Linda Josephson for
Tak; hotice ,hht ~~l~~
Sexton
address. ' 8 . : . . . .
' permission
to erect a .dwelling
tends to apply to the planning .,'t
house at above address.
authority for'outlirie permission . , , . ' . .
for 2 sites With. SdptlC tanks 81 :
CmkE COUNTY C O ~ N C ~ L
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kilrush
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iils 1rom.Auclioneer.
INE. A u c l i o n e b r , Valuet, Property and Llves-
in. Kilrnihil. Tel. 50065.
.
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K T Y COUNCIL
KEE. CO. C L A R E
tat S. llaugh has
h n n i n g section of
'ouncil for Permish t e d house tind
bove address.
.
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E N N l S U n L h DISTRICT
COUNCIL.
21'hACRE k)rhM
H tt.100
, . I
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IANCE SALE OF SUCKLING HERD
,
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Co
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MOYASTA, KILRUSH
~
ot
lesledlncalf Heifers .
f c Fo
op r i
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ig pe
ht ct
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ne pu
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eq os
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ny
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Take notice that 1. RoV O'KceIfe, ' " C L A R E C O U N T Y COUNCII,
nm making npplication to the E n . . - I.IShlUSE. LISDEEN. KII.KEI:
. . nis Urlinn District Collncil for Per-' Tnke notice that Joseph 1,inrianc
niission to change the ground floor. iiitcndi to apply 1.0 Clarc Cotiiity
, . C L A R E C O U N T Y COUNCIL. ,
O U l N GARDENS. O U l N .
' use from private rCSidCntial I O
Council for planninc pcrmissinn
Tnke notice that F. Keating In- commercial. to retain the ' ~ X I C I I ~to build e new biinqalow. with
sion at the rear of the buildine fnr wnter and sewerace fnriliticc nt
tends to apply to Clare County
Council for planning permisslon c6mmcrclal use, to retain the first
to gonstruct dwelhghouse. gar- floor terrace and nccess: ntnirs
nge and teptictank , a t ab;ye :., with *toraw area under for pdvatf
. ,.
...3",., . . .:v.. , . use, and condmct' d connecting '
nddr+,.
' * S C A R I F F . CO. C I A R E , ' ,
'
, '. passage at the north side of the
I
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Take notice that Finsa Forest Pto
'
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:
: .. . ' btillding. The planning appllca:
i':"
ducts Ltd., Scariff. d o John T.
tlon may be lnspec!fd at the
.CLARECOUNTYCOU~~~IL.
?' officesol
the Ennis b r b a n District Garrett & Associates. Consultine
'1
1 . WLFENORA
.. Council
:. , ...
. . , E n g i n e e r s . 3 C h u r c h Street.
,
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rake notice (hat Geraldine Ilow- ' !'
I.
ley intends.to spply for planning: '
CLARE COUNTY COuNCl
permisi!on - t o extend dwelling- '
. ..
5, FIRIIILL. F A R T E E N
notice that we wish td
for full planning permission
' 2 1 storey extension:'tomp
?lcrtuRcrr~
RoRToN*
family room; study and bedroom
1
;
C,O R O F l N
,
' at 5 Firhill. Partcen C o ' C l a r e ;
.. nA,,LYAMCAVLEY,
,
'
rake notlce that Canon T a d r e , Signed, John O ' d o r d a n ayd Caro- .,? . ::.
ENNIS
:
'
Intends to apply to the Planning .line ORiordan.
.
T
a
k
e
notice
tliat
I
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M
i
c
h
a
e
l
.<
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Authorlty lor planning permi*-. *
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McCarthy Intend tu apply to Clare '
County Council for f u l l planning ' :
t
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h COUNTY
~
C O~U N C l L~ .
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ULACKWATER,
permission to erect bungalow, gar- . I
address::
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ARDNACRUSItA,CO. C L A R E ;
age and septic' tank at *above ;;
. . I.r. .. ,. . . . :
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. . , Tnke notice that I. Noel Martyn.
address:
I
,
f
couNtv
COUNCIL. * d o John T. Garrett & Associates, i
I ,;
Consulting Engineers. 3 Church . , CLARE C O U N T Y C O U N C I L
' :
i
luc'lSTREGT'
coRoF'N*co~
n
' . 1. Street. John's Square, Limerick. : 1 ' ~ ~ I o M O N
IIOUSP,
D
' 1
,
. . . , r ir n
.
L"""n
' ..
. : a m . bpp!ying
C l a r e - County :.- . D R O h l O u N D ESTATE;
J'!'
Tnke notice ihat Anthony F n l v i; . couitcil for outline plnnnlrtg per- ~ E W B M R K E T O N - F E R C U S . CO.
intends I d apply to the Planning
mission to con6truct
dwelling- .: ; , I '
CLARE
chatcllc
tlon, tire
Autllon'tyforPermission torgtain ':house and assokiated tire works , Take
commercial atorage and exten- - on my elre dt abovC address. ; . ;., iord lhchlq,lin
to apply
d o n to'exlitlng thop to retain
,
,.I to the Planning Authority far per.
.:.;
extension. to existing dwelling ' -.
an
house end complete work on ex- !, C L A R E COWNTY C O U N C I L ' :. mission 10
tension.: t. .
: I. .
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ARI~NATAOLE,; .
. . td Thomond IlousC wlth pueit
.
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O~~RIE~SUR~D
CO.
G ECLARE
,
'.;Qccommodation at above address.
' C L A R E C O U N T Y C O U N C I L . ' Take notice that we, John and .I::'
E N N i S U R B A N DlSTRICl
. ,MOYS,CLARISFORT,KIL- : : Ann-Marie Ryan, intend to apply
; , IALOE * : ',
to the planning aiithority for full
COUNCIL.
KIIAUSII R O A D , E N N l S
planning permission to construct ,
rlanillng
permisiion
sougllt for
bungalow and
lnak
"almv.e
Take nolice that planning permis.
10 dwcll]ng houses. septic tank,
address..
'
d o n Is belng sought from Ennis
and anciilery works at the above
address for J. Joyce.
, :
., , CLAn'E COUNTY
,
Urban Dlstrlct Council for part
. : : .
,
change of use and extension to
..
NEWM*RKET-ON-PERCuS
L I M E R I C K ROAD,
existing industrial prcmiseg to
I
1. '.' MONDAY, FEBRUARY 6
.
,'
Ennls Urban District Council
,
s l a t t e d house ' n t the above
.
address. '
'
.
" above address.
nect roofs of exiension
to
'
\Y.JANUARY 23 AT 12 NOON SHARP
~
Take notice that Gus Fitzgernld Is
npplying for permisiion to con-
'. * . .
I
Take notice that Mark Ilclmnre IS
applying for planning pcrmiwion
fnr
rrnovntfons
to dwcllinnhorrce
.-. .
-.
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I
~ U RCOUNTY
E
COUNCIL .
MEELICK
I
Take notice that permission !
sough by Fred Power lor foul
private dwellings, ancillary sitc
works and septic tank at abovc
address
above
, . . Rddrcss.
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~
BALLINCRACGA, :
:' C L A R E C O U N T Y C O U N C I L
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NEWMARKET-ON-FERCUS
POULAGOUR, SCARIFF
l .~Take notice that Michael and Ber- Take notice that Patrick Minogue
CLARECOUNTY c o u N ~;
I nadette Lynch intends to Apply for
intends to apply to the planning
C O R T Y C E E ~ ~ E E N T ~, .
T&b hotice that pstrlck *reen, outline planning permission to re-. authority for permission I O coninten& lo
t o thr
'novate Into a unique furnishing . struct slatted shed, covered feed&thorily for
for house premises incorporating tea rooms inp, area end'silage slab at above
extension at above address.
at above address.
. address.
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TRANSFER OF APPLICATION FOR A LICENCE
TO THE ENVIRONMENTAL PROTECTION AGENCY
Finsa Forest Products Limited, Scarriff, Co. Clare (Grid Reference E 163920 N184300) hereby applies for a transfer of application for a licence to the Environmental Protection Agency.
Finsa Forest Products Limited is making the application under the following classes in accordance with the First Schedule of the Act.
The manufacture of board
5.9
The chemical manufacture of glue
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A copy of the application may be inspected at or obtained from the Headquarters of the
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Agency.
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UNIT OPERATIONS
Woodstorage
Chipping
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Milling
Flaking
Sawdust Screening
Drying
Screening
Blending
Forming
Pressing
Cooling
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Sanding
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Trimming / Cutting to Standard Sizes
Stacking
Flooring Line
Melamine Lines
Veneering Line
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Cut to Size Line
Panel Lines
Fe1t Line
Resin Manufacture
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WOOD STORAGE
The plant uses approximately 160,000 tonnes of timber per year. This is made up of the following:
(1)
Pulpwood: 55,000 tonnes. This consists of low grade logs purchased from Coillte
and also from sawmills.
(2)
Woodchippings/offcuts: 45,000 tonnes. These are by-products of the sawmilling
industry.
Sawdust: 60,OOO tonnes. This is a by-product of the sawmilling industry.
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(3)
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PULPWOOD STORAGE
Pulpwood logs are stored in a hardcore area at the back of the factory. The quantity stored
varies between 5,000 tonnes and 30,000 tonnes. Logs are purchased and put into stock during
the Summer months and are then removed from stock and used as required during the Winter.
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Each log pile is numbered and logs are used in rotation.
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WOODCHIP OFFCUT STORAGE
B)
Offcuts are not stored They are chipped directly on arrival at the plant.
Woodchips are stored n a purpos,e built shed and any excesses are stored in a concrete area at
tEe front of the shed.
SAWDUST
Sawdust is normally stored in a purpose built shed. However, the supply of sawdust is seasonal
and during the Summer months the excess is stored in a concrete area around the sawdust shed
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CHIPPING (hacking)
Logs and sawmill offcuts are chipped into pieces approximately 50m x 50mm. These are then
stored in the chip shed along with those purchased from the sawmills.
Logs are fed into the infeed conveyor using one of the Poclaim Grabs from where they pass
through a series of belt conveyors and into the Pallman Chipper. The chipped material is
removed by the Volvo loading shovel and placed in the chip shed. Loose bark which falls from
the logs as they are being conveyed to the chipper is collected and used in the hot gas generator as a source of energy.
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MILLING
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The chips from the chip shed are fed into the bunker using the Volvo loading shovel from where
they pass through a screen where excessively large and excessively small pieces are removed.
The large pieces are used as a source of fuel in the hot gas generator and the small pieces are
mixed with sawdust and used in the process. From the screener the chips move through a sepnt
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ai-ator where high density particles and some dust is removed. The high density particles
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includes stones. This waste is used as a fuel in the hot gas generator. The chips then pass
through a series of conveyors to a bunker which feeds three Pallman F Z mills.
The milled chips are transported through a series of conveyors to a storage silo. All of the
above with the exception of the milled chip storage silo is located indoors.
FLAKING
hlpwood logs are purchased in lengths of 2.44 metres.
At the start of the flaking operation
they are cut into lengths 1.22 metres and may then be stofed in the yard area near the chip shed
or be used directly as feed stock for the Bezner flaker.
1.22 metre logs are either fed directly from the saw dr with the Volvo loading shovel into the
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Hombak storage bin from where they pass along a series of conveyors into the Bezner flaker.
The flakes are then transported via a conveyor to a storage bunker. Loose bark which falls from
the logs as they pass along the conveyor system is collected and used as a fuel in the hot gas
generator.
SAWDUST SCREENING
The Volvo loading shovel loads the sawdust into a feeding bunker from where it passes through
a rotating screen where large pieces are removed. These oversize pieces are returned to the
chip shed and are used in the process.
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DRYING
Milled chip sawdust and flakes are fed from their respective silos through a series cf convey-
ors and into the dryer. The dryer consists of two stages. At the start there is a pre dryer which
consists of a long tube approximately 30 metres long through which the chips pass very rapidly. The inlet temperature to the pre-dryer is 5 W C - 70O0C,it depends on the moisture content
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of the incoming material and the quantity of material required by the production line. After the
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pre-dryer the material passes through the main dryer which consists of a rotating drum. The
inlet temperature to the main dryer is 28WC - 360OC and the chip retention time is approximately 20 minutes. The dryer outlet temperature varies between 12OOC and 145OC. After the
dryer the chips and drying gases are fed through a series of nine cyclones where they are sep-
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arated. The dryer gases are then exhausted to atmosphere. (air discharge point EPl)
SCREENING
The chipboard manufactured in Finsa is a 3 layer construction and it is necessary to segregate
the dried chips into the fractions required for the outer layer and the inner layer. The board has
a fine outer layer for smoothness and a course inner layer for mechanical strength. The outer
layer material is that fraction which passes through a LOmm screen and the inner layer is that
fraction which passes through a 7.0mm screen. Particles greater than 7.0mm are refined in a
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conduct refining mill and returned for screening. Material can also be diverted through a
Pallman refining mill which creates additional outer layer material should it he required.
The outer layer material is transported pneumatically to the outer layer silo and the transport
air is filtered through a bag filter prior to exhaust to atmosphere. (air discharge point E D )
Particles of less than 0.4mm are transported pneumatically to the dust silo at the hot gas generator and used as a fuel. .The air from this transport system passes through a cyclone located
on top of the silo and exhausted to atmosphere. (air discharge point EP 4)
BLENDING
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Blending consists of two operations:
(1) The preparation of resin mixtures of the inner layer and outer layer.
(2) The addition of the resin mixtures to the dried chips.
The normal resin used is a 65% urea formaldehyde resin while a 65% melamine urea formalde-
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hyde resin is used for the manufacture of boards with increased moisture resistance.
The resins are pumped from the glue plant to the glue kitchen where they are mixed with additives and produce the inner layer and outer layer resin mixtures.
An ammonium sulphate solution is added to the inner layer which acts as a hardener when the
boards are being pressed.
. A hexamethylenetetramine (hexamine) solution is added to the outer layer of some products
which acts as a resin retarder and to some extent also as a formaldehyde sdavenger.
A 60% paraffin wax emulsion is pumped from its main storage tank to a metering system in
the glue kitchen and added separately to the glue blenders. This acts as a water repellent in the
finished product and as a lubricant for the chips as they pass through the glue blenders and the
conveyor system to the forming line.
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From the inner layer and outer layer dry silos, the chips are transported to two Imal Scales
which weigh the quantity of material being used per minute. This information is fed to the resin
pumps in the glue kitchen which then adjust their speed as required to ensure that the ratio of
wood chip to resin remains constant.
After the scales the wood chips pass through the resin blenders where the resin mixtures, paraffin wax emulsion and water are injected through a series of nozzles.
During the manufacture of moisture resistant flooring boards a green dye is also added at the
resin blenders. This is used for identification purposes.
Floor washings from the resin blending areas are passed through a settling tank prior to dis-
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charge into the River Graney (Discharge Point 3).
FORMING
There are two spreading heads each for the inner layer and outer layer and the chips are spread
onto a series of moving boxes. The boxes move in both directions under the spreading heads.
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As they move back the forming line, the bottom outer layer and half of the inner layer is
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deposited and as they move forward again the other half of the inner layer and the top outer
layer is deposited.
There is a suction system installed along the forming line which collects some of the wood
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chips which fall from the line and transports them pneumatically to a holding silo at the back
of the old boiler house from where they are transported via a high pressure blower to the
screening area where they are re-introduced into the process.
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The silo at the back of the boiler house is fitted with a cyclone and the exhaust from the cyclone
is passed through a scrubber prior to exhaust to atmosphere.
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The forming line is cleaned daily and wood chips cleaned from the floor are transported with
a loading shovel to the sawdust shed where they are returned to the process.
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PRESSING
The plant is fitted with a Siempelkamp six day light press which manufactures boards 3.66
metres long and 2.44 metres wide.
The boxes from the forming line pass into the open press and as they are withdrawn from the
press they deposit their formed mattresses onto the press plates. The press then closes and in
the presence of heat and pressure the resins cure and produce the raw boards. The press temperature is approximately 1 9 0 O C and the press pressure is 25 kg/cm2. At the end of the pressing cycle as the press opens there is some steam, formaldehyde and dust emitted from the press.
These are exhausted through fans on the roof. (air discharge point EP6)
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COOLING
After pressing, the boards are cooled on a star cooler prior to stacking them. This is to allow
excess heat to escape from the boards and consequently eliminate heat damage caused by the
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SANDING
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boards being stacked too hot.
The plant has two Steinemann sanding machines. The first uses 40 grit sander belts and its
function is to calibrate the board thickness. The second machine uses 80 grit sander belts and
graphite pads to achieve a smooth closed surface. The feel stock removed during sanding is
extracted via a suction system through two bag filters located at the back of the old boiler house
and from here the dust is transported via a high pressure blower to the dust silo at the hot gas
generator where it is used as a fuel. The transport air used by the blower is exhausted through
a bag filter located on top of the dust silo. (air discharge points EP2A and EP2B)
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TRIMMING / CUTTING
Board edges are trimmed and boards are cut to standard sizes on two trim saws. Offcuts are
broken up by hogger units on the saws and this material along with dust from the cutting operation is exhausted via a fan through a bag filter. This material is discharged from the bag filter into a storage silo from where it is transported via a high pressure blower to the screening
area where it is reintroduced into the process.
Material cleaned from the floor at the sanders and trim saws is transported via a loading shovel to either the sawdust shed to be reintroduced into the process or to the fuel pile for burning
in the hot gas generator.
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STACKING
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After the trimsaws the boards are classified according to quality and stacked in bales which are
either transported to the warehouse or stored in the factory for value added processing.
MELAMINE LINES
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We have two of these lines and the operating principles of both are the same. On these lines
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melamine formaldehyde impregnated cellulose papers are bonded to the board surfaces using
a combination of heat and pressure.
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Sheets of the above paper are placed on both board surfaces and are then transported into a
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hydraulic press with a temperature of approximately 18OOC and a pressure of 35kg/cm2.
Under these conditions the resins-on the paper fully cure, bonding the paper to the board and
consequently additional bonding agents are not required. The products, melamine faced chipboard and melamine faced MDF are used predominantly in furniture manufacture.
There are no emissions to atmosphere from these lines.
The dimensions of the papers are approximately 20mm larger than the board and this excess is
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cleared off the finished product. These offcuts are placed in bins and are transported by forklift truck to the hot gas generator where they are used as a fuel.
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VENEER LINE
On this line natural wood veneers are bonded onto both chipboard and MDF.
The boards pass through glue rollers where a film of resin is applied to both surfaces. Veneer
sheets are then placed on both board surfaces and are transported to a hydraulic press where
with a temperature of approximately 14OOC and a pressure of approximately 5Kg/cm2, the resin
cures and bonds the veneers to the boards.
The veneers are approximately 20mm larger than the boards and this excess is trimmed off with
saws. These offcuts are placed in bins and are transported to the hot gas generator by forklift
truck where they are used as a fuel.
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After trimming both board surfaces are sanded. The dust generated during this sanding operato
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tion is extracted through a bag filter and is then transported via a high pressure blower to the
dust silo located near the hot gas generator. The bag filter exhausts to atmosphere. (air discharge point EP5)
There is normally no discharge to atmosphere from the veneer line. However, during warm
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weather extraction fans on the side of the building are switched on to remove excess heat. As
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part of our air emissions monitoring the fan near the press was analysed. (air discharge point
FLOORING LINE
On entering this line boards are split in two and each piece then passes through a series of cutters where tongues and grooves are cut on the board edges. The waste generated during this
operation is extracted via a fan to a bag filter located near the warehouse. From the filter the
waste is passed to a silo and from the silo it is transported via a high pressure blower to the
screening section where it is reintroduced into the process.
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CUT TO SIZE LINE
This line consists of a beam saw on which boards are cut to specific dimensions as required by
customers or as required internally for further value added processing. Dust from the saw is
extracted through a bag filter and then transported via a high-pressure blower to the dust silo
located near the hot gas generator. The bag filter exhausts to atmosphere. (air discharge point
EBC)
Board offcuts are passed through a guillotine where they are cut into pieces approximately
50mm long which are then transported via conveyors to the outside of the building from where
they are removed by the Volvo loading shovel and transported to the chip shed where they are
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returned to the process.
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PANEL LINES (Edge Banding Lines1
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There are two of these lines and their operation is the same. Melamine faced and veneer faced
chipboard boards are cut to various sizes on the cut-to-size line and these pieces are then passed
through these lines where either a melamine formaldehyde paper edging or a veneer edging is
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-bonded to the board edges. The edgings are bonded to the boards using a polyvinyl acetate hot
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melt adhesive. This adhesive is purchased in pellet form, heated to approximately 19OOC, at
which point it is molten and then applied to the board edges.
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The edgings are then applied using pressure rollers and as the adhesive cools it bonds the edg-
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ing to the board.
The edging is approximately 4mm wider than the board being edged and this excess is removed
bri the machine using cutters and is extracted via a fan to a bag filter from where it is transported via a high pressure blower to the dust silo located near the hot gas generator. The bag
filter exhausts to atmosphere. (air discharge point E B B )
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Vapours from the adhesive are also extracted through'the bag filter a d are emitted to the
atmosphere with the transport air.
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DRILLING MACHINES
There are two identical drilling machines which drill holes on board surfaces and edges. These
pieces are then ready for customers to attach hinges and other fixtures. Dust generated during
the drilling operation is extracted through a bag filter and then transported via a high pressure
blower to the dust silo located near the hot gas generator. The bag filter exhausts to atmosphere. (air discharge point E B B )
CROSS CUT SAW
This is used for cutting pre-edged panels into various lengths. Dust generated during the cutting operation is extracted through a bag filter and then extracted via a high pressure blower to
the dust silo located near the hot gas generator. The bag filter exhausts to atmosphere. (air dis-
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charge point EBB)
TABLE SAW
This is used for cutting board samples required by the laboratory and also required by cusns
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tomers. It is also used by the carpenters for cutting boards and other timber based products.
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Dust generated during the cutting operation is extracted through a small bag filter located nearby. There is no discharge to the atmosphere.
Dust is collected in special bags which are emptied as required. The dust is placed in bins and
is transported by forklift trucks to the hot gas generator where it is used as a fuel.
SMALL BEAM SAWS
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There are two old Halzma beam saws in the factory which are currently not in use. However,
they may again be used in the future. Their dust is elitracted on the same extraction system
hsed in the flooring line.
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P
E L T LINE
On this line a bitumen based felt is applied to one of the board surfaces. The felt is heated using
a propane flame until some of the bitumen melts and it is then rolled onto the board surface.
As it cools it bonds onto the board surface. There is no discharge to atmosphere from this line.
RESIN PLANT
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The Resin Plant is a separate operation and all information relating to this is included in
Attachment No. 9.
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RESIN PLANT
We have been manufacturing urea formaldehyde resins (used in the manufacture of normal
grades of chipboard) and melamine urea formaldehyde resins (used for the manufacture of
moisture resistant grades of chipboard) since 1985.
Resins are manufactured from an 80%’urea formaldehyde concentrate containing 57%
forkaldehyde and 23% urea. The finished resins have a 65% solids content.
Our reasons for manufacturing resins on site are as follows:
(2)
From a transport point of view it is as much more economical to transport an 80%concentrate than a 65% finished resin.
(3)
Urea is manufactured in Ireland and therefore we have a ready supply of this product.
(4)
It is cheaper to manufacture resins on site than to purchase them from other manufacturers. (The actual prices involved will be made available to the agency if required.)
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Resins are manufactured in Spain by a company called FORESA in which the Finsa
Group have a majority shareholding and therefore we have the technology available to
us to allow us to manufacture our own resins.
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CHEMISTRY OF THE RESIN MANUFACTURING PROCESS
Both urea and melamine react with formaldehyde to form long chain polymers. As the polymer length increases the viscosity increases. Eventually the polymer chains cross link to form
a 3-D solid structure.
The actual chemical reactions involved are attached.
The reaction rate is influenced by temperature and pH, an increase in temperature or a reduction in the pH accelerates the reaction. Consequently during the resin manufacturing process
the reaction is controlled by a combination of temperature and pH.
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The required quantity of urea formaldehyde concentrate is added to the reactor and water is
added. The reactor is then heated to approximately 8OOC. During the heating process formic
acid is added to reduce the pH. When the temperature and pH are at their required levels urea
is added. As the urea dissolves the temperature drops by approximately 5OC. However, initial
reactions are exothermic and the temperature increases to approximately 95OC. Samples are
taken from the reactor every 10-15minutes and their viscosities are checked. The viscosities
are plotted on a viscosity/time graph and from this graph the reaction rate can be determined.
The reaction rate can be reduced if necessary by cooling the reactor contents by approximately 5oc.
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When the viscosity has reached its required level the reaction is stopped by adding sodium
hydroxide. The reactor contents are then cooled to approximateIy 65OC at which point additional urea is added to achieve the correct urea: formaldehyde molar ratio in the final resin. The
reactor is then cooled to approximately 3OoC, final pH adjustments are made and the resin is
pumped to the storage tank.
Currently there are two resins manufactured in our resin plant, namely FC-544(a urea
formaldehyde resin) and C-143(a melamine urea formaldehyde resin). The step by step procedures for the manufacture of these resins is attached.
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A plant layout drawing for the resin plant is also attached.
NOTE
In the manufacture*of melamine urea formaldehyde resins a reaction occurs
under alkaline conditions and therefore instead of formic acid, sodium hydroxide is added.
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