Environmental Protection Unit

Permit Ref No. 23(273)A2 Notice Ref: AON.EPU.11720.VAR.GJ

Environmental Protection Unit

Pollution Control

SCHEDULE 1 TO VARIATION NOTICE

REFERENCE: AON.EPU.11720.VAR.GJ

PERMIT WITH EXPLANATORY NOTE REFERENCE: 23(273)A2

Pollution Prevention and Control Act 1999

Environmental Permitting (England and Wales)

Regulations 2010

Company Name:
Arkinstall Galvanizing Limited
Installation Address: / Registered Office Address:
12-13 Barn Street, Digbeth, Birmingham, B5 5QD / Arkinstall Galvanizing Limited, 40 Lichfield Street, Walsall, West Midlands, WS1 1UU

Contact Details: Birmingham City Council, Environmental Protection

Pollution Control Team, 581 Tyburn Road

Erdington, Birmingham, B24 9RX

Tel: 0121 303 9900 Fax: 0121 303 9901

/
/ /

Part I

Introductory Note and Process Description

/
/

Introductory Note

Process Description

Part II

Permit Conditions

Section 1

General Conditions

Section 2

Upgrading

Section 3

Emissions Limits and Controls: Air

Section 4

Emissions Limits and Controls: Controlled Waters

Section 5

Emissions Limits and Controls: Sewers

Section 6

Emissions Limits and Controls: Land

Section 7

Emissions Monitoring

Section 8

Abnormal Emissions

Section 9

Solvent Management

Section 10

Materials Handling and Storage

Section 11

Maintenance

Section 12

Accidents

Section 13

Operating Conditions

Section 14

Management and Training

Section 15

Raw Materials

Section 16

Energy

Section 17

Noise

Section 18

Waste

Part III

Explanatory Note and Appendices

/
/

Explanatory Note

Appendix 1

Installation Location

Appendix 2

Installation Layout

Part I

Introductory Note

Permit Holder: /

Arkinstalls Galvanizing Limited

Installation Address: / 12- 13 Barn Street, Digbeth, Birmingham,
B5 5QD
Registered Address of Company: / 40 Lichfield Street, Walsall, West Midlands, WS1 1UU
Provenance / Date
Application Received / July 2004
Application Duly Made / September 2004
Issued Reference 23(273))A2 / March 2007
Variation Notice Ref: AON.EPU.11720.VAR.GJ Issued / 29 April 2010

Arkinstall Galvanizing Limited is hereby permitted by Birmingham City Council to carry on a surface treatment of metals activity, followed by a hot dip galvanizing activity in conjunction with the melting of zinc and zinc alloy activity as prescribed in Schedule 1, Part 2, Chapter 2, Section 2.3 Part A2 (a) and Schedule 1, Part 2, Chapter 2, Section 2.2 Part B (c) of The Environmental Permitting (England and Wales) Regulations 2010, namely Surface treating metals using an electrolytic or chemical process where the aggregated volume of the treatment vats is more than 30m3 and where the activity is carried on at the same installation as Melting zinc or a zinc alloy in conjunction with a galvanising activity at a rate of 20 or less tonnes per day. This Permit incorporates the refining of zinc ash from the permitted galvanizing bath and Arkinstall Galvanizing Limited’s galvanizing bath permitted by Sandwell Metropolitan Borough Council under reference IPPC91636. Activities shall be carried on in accordance with the conditions detailed in this Permit.

Date: 29 April 2010 Signed………………………………………….

Pollution Control Team Leader

Contact Details: Birmingham City Council, Environmental Protection Unit,

581 Tyburn Road, Erdington, Birmingham, B24 9RX

Tel: 0121 303 9900 Fax: 0121 303 9901

E-mail:

Process Description

Arkistall Galvanising Ltd. is located towards the centre of Birmingham in an industrial and commercial area as indicated by shading on the plan in Appendix 1 of this Permit. There is a boundary with the River Rea to the east side of the site.

The activities incorporate the surface treatment of metal items along the pickling line, located as indicated on plan in Appendix 2 which comprises automated dipping of the eurobins by overhead crane into one of four tanks containing hydrochloric acid. This is followed by rinses in water and subsequent immersion in zinc ammonium chloride flux. The capacity of each tank is approximately 16,000 litres. The flux tank is heated to 50-60oC using latent heat from the kettle extraction ducts. The temperatures are controlled by thermostats.

The items are transferred from the pickling line to the galvanising hoist which can hold up to 2 at a time. The hoist lifts them into the galvanising bath (4m long x 1.7 m wide x 2.4 m deep) which is contained within an enclosure. Dross is periodically removed by dredging and ash is collected during dipping. The galvanizing kettle is heated by natural gas. When ready the items are removed for cooling and finishing (fettling / deburring, quality control inspection) prior to storage on site and subsequent dispatch.

The galvanising enclosure is served by an extraction system and reverse jet bag filters which exhausts to atmosphere through a stack located at X on the plan in Appendix 2.

Zinc ash from the galvanising process is periodically collected from the top of the bath. It is subsequently cooled and stored before being refined at a zinc-off furnace which is served by a stack located at Y on the plan in Appendix 2. Refined zinc is reused within the galvanising bath. Zinc ash from Arkistall’s installation in Tivdale, Sandwell is also refined using this furnace.

Indicative continuous particulate monitors are installed in stack X.

Zinc, additives and other materials required in the process are stored on site. Fresh acid is delivered by tanker directly to the acid baths on a rotation basis. Acid is made up to the required strength using water from the final rinse bath. Waste liquids are removed directly from the surface treatment tanks when they become too contaminated for use. Water, acid and additives are added as required to replenish the tanks.

Solid wastes are stored on site prior to removal as required.

Runoff from site roofs and roadways is directed through an interceptor (indicated by I on the plan in Schedule 2) before discharge to the River Rea at point Z on the plan in Schedule 2.

Part II

Permit Conditions

1 / General Conditions
1.1 / The requirements of the conditions attached to this permit shall come into effect on the date indicated in the individual condition or if no date is indicated shall take effect forthwith.
1.2 / In relation to any aspect of the activity, and without prejudice to any other condition of this Permit, the activity shall be operated so as to meet the requirements of the Clean Air Act 1993 and Part III of the Environmental Protection Act 1990 and any regulations made thereunder.
1.3 / At all times during which this permit is in force a copy of the permit shall be kept posted at the installation in such a position as to be conveniently read by persons having duties which are or may be affected by the conditions set out in the permit.
1.4 / Permitted activities shall only be carried on within the boundary as indicated by shading on the Installation Location reproduced in Appendix 1 of this Permit.
1.5 / Permitted activities shall only be carried on using the plant and equipment as detailed in the Process Description and on the Installation Layout reproduced in Appendix 2 of this Permit.
1.6 / The best available techniques shall be used to prevent or, where that is not practicable, reduce emissions from the installation in relation to any aspect of the operation of the installation which is not regulated by any other condition of this permit.
1.7 / The operator shall notify the Regulator at least 28 days in advance of any modification to the activity, including ancillary operations within the boundary, or any change in the manner of operation, other than routine maintenance or the fitting of standard replacement parts. Written approval shall be obtained prior to any such change or modification.
1.8 / The Operator shall keep a scheme of works for decommissioning the installation. The scheme shall be made available to the Regulator upon request. Upon cessation of activities, the installation shall be decommissioned in accordance with the scheme.
• The removal or the flushing out of pipelines and vessels and their complete emptying and removal of any harmful pollutants,
• Plans of all underground pipelines and vessels,
• The removal of asbestos and other potentially harmful materials unless an agreement is made to leave such liabilities to future owners,
• Methods of dismantling buildings and other structures to ensure protection is given to environmental receptors
1.9 / Prior to cessation of permitted activities, the Operator shall submit a method statement for intrusive sampling of land to the Regulator. Once agreed, the Operator shall carry out the intrusive sampling and forward results within 8 weeks of the sampling to the Regulator. The Operator shall then undertake remediation of the land to a level and within timescales agreed in writing by the regulator, in order to remove contamination that may be attributable to permitted activities.
2 / Upgrading
2.1 / By 31 May 2010, the top ground covering in the pickling and galvanizing building installation shall be comprised of acid resistant bitumen.
2.2 / Within 12 months of the date of this Permit, stacks X and Y (located as indicated on the plan in Appendix 2) shall be fitted with continuous indicative monitors for emissions particulate matter and periodic monitoring meeting MCerts[1] standards.
3 / Emissions Limits and Controls: Air
3.1 / The emissions limits specified in the following Table shall apply to releases to air and shall not be exceeded unless otherwise specified in this Permit:
Pollutant / Emission Limit / Periodic Monitoring Method / Frequency of Monitoring / Applicable To *
Total Particulate Matter / 15mg/m3 / BS EN 13284-1 / Annual / X
Total particulate matter / 20mg/m3 / BS EN 13284-1 / Annual / Y
* located as indicated on the site layout shown in Appendix 2 to this Permit
3.2 / All emissions to the external air, other than steam or condensed water vapour, shall be free from droplets and from persistent mist and persistent fume.
3.3 / All emissions shall be free from offensive odour outside the site boundary as perceived by the Regulator.
3.4 / Emissions from combustion processes shall not exceed the equivalent of Ringelmann Shade 1, as described in BS 2742:1969.
3.5 / The minimum heights of stacks X and Y (located as indicated in Appendix 2) shall not be less than 3m above roof ridge height of the main process building.
3.6 / The efflux velocity of gases from stacks X and Y (located as indicated in Appendix 2) shall not be less than 15 metres per second, and shall be vertically upwards with no restriction.
4 / Emissions Limits and Controls: Controlled Waters
4.1 /

The emissions limits specified in the following Table shall apply to releases to surface water and shall not be exceeded unless otherwise specified in this Permit:

Pollutant / Emission Limit / Frequency and Method of Monitoring / Applicable To *
Oil / 5 mg / litre / As requested by Regulator / Z
Suspended solids / 50 mg / litre / As requested by Regulator / Z
Zinc / 1 mg / litre / As requested by Regulator / Z
Ammoniacal nitrogen / 1 mg / litre / As requested by Regulator / Z
* located as indicated on the site layout shown in Appendix 2 to this Permit
4.2 / Runoff water from roofs and roadways shall be directed through the interceptor located at I on the plan in Appendix 2.
4.3 / Unless specified in condition 4.1 of this Permit, no emission from the installation shall give rise to the introduction into surface water of any substance at concentrations above the background concentration in the receiving water.
4.4 / There shall be no emissions to groundwater from the installation
5 / Emissions Limits and Controls: Sewer
5.1 / There shall be no emission to sewer from the permitted installation.
6 / Emissions Limits and Controls: Land
6.1 / There shall be no direct emission to land from the Permitted Installation.
7 / Emissions Monitoring
7.1 / Where they exist, MCerts standards shall be applicable to all monitoring exercises and instrumentation.
7.2 / Monitoring of emissions to air and groundwater shall be carried out for the parameters and at the frequencies specified in conditions 3.1 and 4.1 of this Permit.
7.3 / Calibration and compliance monitoring shall meet the following provisions as appropriate. No result shall exceed the emission concentration limits specified, except where either:
(a) data is obtained over at least 5 sampling hours in increments of 15 minutes or less; or
(b) at least 20 results are obtained where sampling time increments of more than 15 minute are involved;
AND in the case of (a) or (b)
(c) no daily mean of all 15-minute mean emission concentrations shall exceed the specified emission concentration limits during normal operation (excluding start-up and shut-down); and
(d) no 15-minute mean emission concentration shall exceed twice the specified emission concentration limits during normal operation (excluding start-up and shut-down).
7.4 / The Regulator shall be notified at least 7 days notice before any periodic monitoring to air is undertaken. The notification shall include: time and date of the monitoring, the organisation that will be undertaking it, the pollutants to be tested and the methods to be used.
7.5 / Results of all non-continuous monitoring shall be submitted to the Regulator within 8 weeks of the monitoring being undertaken.
7.6 / The introduction of dilution air or water to stacks to meet emissions limits shall not be permitted.
7.7 / The Operator shall undertake a visual assessment of emissions from the building at least once per day whilst fluxing is taking place and at least once per day whilst galvanizing is taking place.
7.8 / Emissions from the stacks serving the galvanising enclosure (located at X on the plan in Appendix 2 of this Permit) shall be continuously indicatively monitored for particulate matter.
7.9 / Readings from continuous monitors shall be on display to appropriately trained operating staff. The monitors shall be fitted with audible and visual alarms set at 75% of the emission limit. The activation of alarm events shall be automatically recorded. Alarm events shall be counted as abnormal emissions for the purposes of Section 8 of this Permit.

Environmental Protection Unit