ippc application form v2/12 · ippc application form v2/12 page 133 of 217 d.1.1 basic process...
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IPPC Application Form V2/12
Page 132 of 217
ATTACHMENT D.1
OPERATIONAL INFORMATION REQUIREMENTS
PROPOSED SITE LAYOUT DRAWING (IE0310818-48-DR-0002)
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D.1.1 Basic Process Description (including unit operations)
The plant will take in deliveries of raw milk in tankers, remove excess cream fat, dry and
evaporate the milk into powder of whole or skimmed milk grade, and bag off the powder
for onward distribution. Some powder will be enriched during processing by the addition
of vegetable fats. Cream will be a by-product of the process.
It is intended that the proposed development will have milk dryers of combined capacity
15 Tonnes per hour (Tph) throughput.
It is proposed that operations will take place 24 hours a day, 7 days a week, all year
around, allowing for a 10-day planned annual shutdown. The stages of production are
described in more detail below.
A site plan showing the locations of the buildings and utilities is included in this IPPC
licence application (Drawing No. IE0310818-48-DR-0002).
It is noted that at this stage detailed design has not yet commenced and that only front end
design has taken place for the purposes of planning. Therefore, there is limited detail on
the processes and activities that will be in operation as part of the proposed development.
Process flow diagrams and/or process and instrumentation diagrams (P&IDs) have not yet
been developed.
Milk Intake
Milk will arrive to site in 23,000 litre road tankers. These tankers will be weighed via a
weigh-bridge and then proceed to the unloading stations. The tanker driver will connect
the tanker to the intake station by means of a hose connection. Once the tanker is
connected the system will begin pumping milk out of the tanker. The milk will then be
passed through a heat exchanger where the temperature will be automatically controlled to
a set-point before routing via a mix-proof valve block to storage in one of the raw milk
silos. There will be 6 tanker intake bays, operating 24 hours a day, 7 days a week.
The intake lines will be automatically flushed with fresh water after each unload. Clean in
Place (CIP) of the intake lines will take place at the end of the unload cycle once per day.
Raw Milk Silos
Cooled milk will be routed via a mix-proof valve block to one of the raw storage silos.
Full flexibility is considered so that each intake line can feed to any silo. There will be 6
No. silos, each provisionally sized at 275m3. Each silo will be fitted with two agitators to
ensure homogenous mixing of the milk over the storage period. Storage volume will be
provided to store 16 hours capacity of raw milk. From the storage silos, milk can be
routed via a mix-proof valve block to one of the milk pasteurisers for processing.
All silos will be fully capable of CIP. It is considered that silos will be cleaned once
during every 24 hour cycle. Silos can be cleaned independently of the milk intake lines,
meaning that milk may still be received provided any one of the silos is not in CIP.
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Milk Pasteurisers
Raw milk from the silos will be routed via the mix-proof valve block to one of the milk
pasteuriser systems. There will be 3 No. pasteurising systems (2 duty and 1 standby).
Each pasteuriser system will be sized at 60m3/hr and consist of a plate heat exchanger, a
separator with in-line standardisation, and a homogeniser.
The pasteurisers will be sterilised by circulating hot water prior to production. It is
envisaged that each system will pasteurise milk for 18 hours per day. This will include
time for an intermediate CIP during the production cycle. A final, long CIP will take place
once the processing has been completed.
Cream standardisation will be controlled automatically in the in-line standardisation
system. Surplus cream will be routed to cream storage tanks for further processing.
Standardised Milk Storage
Once the milk has been pasteurised, standardised and homogenised it will be routed
automatically to one of the storage silos via a mix-proof valve block. Full flexibility will
be provided so that all pasteuriser systems can feed to all silos. There will be 6 No.
standardised milk storage silos, each provisionally sized at 275m3. Each silo will be fitted
with 2 agitators to ensure homogenous mixing of the milk over the storage period. Storage
volume will be provided to provide 16 hours capacity of standardised milk in the silos.
From these storage silos, milk can be routed via a mix-proof valve block to one of the
evaporators for further processing.
All silos will be fully capable of CIP. It is considered that silos will be cleaned once
during every 24 hour cycle. Silos can be cleaned independently of the milk pasteuriser
systems meaning that milk may still be pasteurised provided any one of the silos is not in
CIP.
Evaporators
Milk from the standardised milk silos will be routed to the evaporators via the mix-proof
valve block and a filter system. Evaporators will operate continuously for 24 hours with
CIP taking place on each evaporator once every 2 days. The evaporators will be set up on
a duty / stand-by system so that the dryers can be fed continuously at full capacity while
an evaporator is on CIP. There will be 3 No. evaporators (2 duty and 1 standby during
CIP or product changeover), each provisionally sized with a capacity of 7.5m3/hr.
Evaporators will be mechanical vapour recompression (MVR) type with a Reverse
Osmosis (RO) filtration system provided to recover the condensate for re-use.
Dryers
Concentrate from the evaporators will be routed to the dryers via high pressure
homogeniser pumps. There will be two dryers sized at 7.5 Tph each. The dryers will
operate continuously over a 24 hour period with CIP taking place once per week. It is
proposed that the dryers will be gas-fired.
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Powder will exit the dryer outlet and be routed via the fluidiser to one of the powder
storage silos where it can be stored up to 24 hours prior to packing.
Cream Handling
Surplus cream will be generated as a by-product of the process as standardised milk is
being produced. For the purposes of calculating the volume of cream produced, it is
assumed that Raw Milk has a cream content of 4.4% and that standardisation will be at
3.3%. There will be one cream pasteuriser, 3 raw cream tanks of 20m3 each, and 3
pasteurised cream tanks of 20m3 each.
Surplus cream will be routed from the standardisation system to a cream buffer tank.
Once a suitable volume of cream has been produced, the cream pasteuriser will be started
and the cream will be pasteurised. From the cream pasteuriser, the cream will be routed to
storage silos where it will be held until it is loaded into road tankers and transported from
site. The process design intends that the cream will be pasteurised within a short time of
standardisation and, therefore, large buffer storage and inline cooling is not considered at
this point.
Cream export will be via dedicated export bays. It is intended that cream will be exported
from the site in bulk tankers on a daily basis.
Clean In Place (CIP)
CIP is an integral part of the installation and operation of the plant. For reasons of
contamination and cGMP zoning four independent CIP stations have been allowed for
which will clean different areas of the plant with no possibility of cross-contamination.
These CIP stations are:
• Tanker CIP: for washing of road tankers only;
• Raw CIP: for washing of intakes, raw silos and pasteuriser transfer lines;
• Pasteurised CIP: to wash all equipment after the pasteurisers up to the dryers;
• Dryer CIP: dedicated CIP station for dryers.
Each CIP station will have four tanks:
• Recovered Rinse Water;
• Caustic (sodium hydroxide solution);
• Acid (nitric acid or sulphuric acid solution); and
• Fresh Water.
The caustic and acid tanks will include circulating heaters and chemical and temperature
control instrumentation. Each tank will have the ability to feed multiple CIP circuits via
mix-proof valve manifolds with each circuit having an inline steam heater. There will also
be the possibility to dose cold sterilant in-line if required.
The pasteurisers will be washed by the addition of concentrated chemicals to the balance
tanks and, therefore, will not need a dedicated CIP station.
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Vegetable Oil and Other Dairy Products Intake
The proposed facility will require the intake of vegetable oil and other dairy products,
including buttermilk, milk permeate and other pasteurised non-skim milk solids. These
products are ingredients in the finished product. The quantities added vary depending on
the product being manufactured however can be up to 190,000kg / day of vegetable oil
and 240,000 kg / day of milk permeate or other milk solids.
D.1.2 Site Utilities
In general, main utility distribution pipework installed will be sized adequately for the
provision of utility services to the site.
Heat Demand
The variable space heating load will be taken up by low pressure hot water through steam
heat exchangers. The process steam load will be generated by a Heat Recovery Steam
Generator (HRSG) at 15barg, along with backup Steam Boilers.
The overall steam load (15 t/h throughput) will vary between 18MWth (29,000kg/h) and
26MWth (41,000kg/h). The electrical load will vary between 9MWe and 11.5MWe.
Steam
Gas-fired steam boilers, each rated at 15 barg, will be provided for steam generation. A
central feed water tank and de-aerator head to accommodate the full peak load will be
included.
Steam will be distributed at 15barg and reduced locally to 6barg where required. All
condensate will be brought back to atmospheric pressure in a central feedwater tank.
Low Pressure Hot Water
Low pressure hot water (LPHW) will be generated by heat exchangers using steam at
15barg. The heat exchangers will be located in the Central Utilities Building (CUB). Each
heat exchanger will have a duty/standby pumping circuit to distribute LPHW to the air
handling units (AHUs) and/or unit heaters.
An alternative option is to have dedicated LPHW natural gas condensing boilers located
in the CUB, which would operate at a higher efficiency but take up greater footprint and
require additional equipment.
Natural Gas
The natural gas demand by the facility at maximum usage has been estimated at:
• 2510 Nm³/hr for dryer operation.
• 4312 Nm³/hr for boiler operation.
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An 8” (200mm) diameter main header will run from the gas supplier’s above-ground
installation to the Central Utilities Building. Separate 6” (150mm) diameter lateral lines at
15barg will be installed to both the boilers and the dryers.
Refrigeration
The refrigeration plant shall be located in the plant-room of the CUB. To ensure a high
level of flexibility and the maximum standby capacity in the case of component failure,
the refrigeration load will be catered for by a purpose-designed system using ammonia as
the primary refrigerant. The system shall comprise the following main refrigeration
circuits:
• Ammonia refrigeration/chilling plant (1ºC circuit);
• HVAC chilled water/glycol generation (5ºC circuit).
Compressed Air
Compressed air is required for instrumentation, plant and process air duties. The
compressed air system will comprise air compressors, air receivers, air dryers, air filters
and a distribution network. The compressed air plant will be located in the CUB.
Compressed air will be supplied to the main distribution system at a pressure of 7.0 barg.
Pressure dew point temperature of the compressed air system will be + 3ºC.
Potable Water
Site water will be necessary for:
• Process water
• Wash water
• Domestic non-potable services
• Domestic potable services
• Evaporative condenser and cooling tower make-up
• Boiler water make-up
• Fire protection.
Potable water will be supplied by Kilkenny County Council from its mains water supply.
2,000m3 of potable water will be stored in a tank onsite to provide backup in the event of
loss of supply from the mains.
A separate 500 m3 firewater supply tank will be provided at the facility.
A reverse osmosis (RO) filter will be used to clean the water generated in the process by
the evaporators. There will be 4 x 50 m3 tanks for storage of post-RO water for re-use in
various applications across the site. The quality of post-RO (filtered) water is not suitable
for direct use in the production process, but may be used for cleaning or flushing use.
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Carbon Dioxide and Nitrogen Gas Systems
Carbon dioxide and nitrogen distribution pipework from the central storage tanks will be
run to serve the process lines. Pipework will be stainless steel (schedule 10, type 304L). A
mixed gas receiver will be installed adjacent to the packing lines.
D.1.3 Building Overview
The main buildings to be provided on site will be as follows:
• Raw Materials Intake
• Raw Materials Warehouse
• Evaporator Building
• Dryer Building
• Powder Processing
• Packaging
• Finished Product Warehouse
• Administration, Laboratory and Canteen Building
• Central Utilities Building
• Waste Water Balancing Plant
• Electrical Substation
• Natural Gas Above-Ground Installation.
D.1.4 Hazardous Waste Management
All hazardous waste will be labelled appropriately, covered where necessary, and stored
in contained areas on site before being collected by a permitted hazardous waste
contractor and brought to a licensed facility for disposal, recovery or recycling. This will
include: laboratory wastes, empty hazardous containers; and waste oils. All
documentation will be retained on site in accordance with legislative requirements and the
site’s Environmental Management System.
D.1.5 Process Control
The plant will be controlled by a network of programmable logic controllers (PLCs),
which will in turn be linked into and controlled by a network of PCs running supervisory
control and data acquisition software. Operator interface and maintenance troubleshooting
will be generally via these PCs or via dedicated operator interface panels at key control
points. The system will have various levels of password protection to prevent
unauthorised access.
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ATTACHMENT D.2
DEVELOPMENTAL AND OPERATIONAL HISTORY OF THE SITE
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D.2 Developmental and Operational History of the Site
The site of the proposed facility is a greenfield site used in recent times as pastureland for
grazing cattle. It was acquired by IDA Ireland for the development of a strategic industrial
landbank to encourage enterprise to the Belview Port/South Kilkenny/Waterford city
environs area.
The only known development at the IDA landbank to date is the following:
• Construction of a roundabout and new access road to the Waterford City
WWTP to the south of the subject site (grounds of the former Springfield
House)
• Inclusion of drains to take road runoff and to link the industrial landbank to
the WWTP
• Construction of a short stretch of road into the subject lands
• Construction of a set of lagoons to take surface water, provide a landscape
feature, and provide a compensatory habitat for flora displaced during the
construction of the WWTP
• Installation of a production well at the western side of the subject lands
• Installation of several groundwater boreholes on the site.
Archaeological and geotechnical studies of the site indicate nothing noteworthy from an
archaeological or geotechnical perspective, and no evidence of land contamination or use
other than agricultural is known.
Further information on the archaeological and geotechnical surveys of the site is given in
the Environmental Impact Statement included in Attachment B.5 of this IPPC licence
application.
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