-
Report of the Workshop on the Use of BAT-Conclusions in the
Cement Production Industry (IMPEL Project 2018-01)
held in Eisenstadt, Austria, on 04-05 October 2018
Chronology of events
• Adoption of the TOR at the IMPEL GA Meeting in Tallinn,
Estonia, on 06-07 December 2017
• Preparatory Meeting of the Workshop Project Team in Vienna,
Austria, on 13-14 March 2018
• On-line Survey on IED Implementation in Cement Installations,
June to September 2018
• Joint Inspection at Lafarge Cement Facility Mannersdorf,
Austria, on 03 October 2018
• Workshop in Eisenstadt, Austria, on 04-05 October 2018
(back-to-back with DTRT Meeting and along with IED Implementation
Meeting)
Background and Motivation
The Commission Implementing Decision of 26 March 2013
establishing the best available techniques (BAT) conclusions under
Directive 2010/75/EU on industrial emissions for the production of
cement, lime and magnesium oxide leads to intensive discussions
between clinker and cement producers and the competent authorities
in several European countries. So at the plenary meeting in
December 2017 IMPEL supported the proposal from the Industry and
Air Expert Team to organise a workshop to discuss various issues
concerning cement installations.
This workshop was the first of its kind to focus on an
industrial sector and held in the context of a joint
inspection.
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 2
Preparatory Meeting of the Project Team
The project team consisted of Günter Dussing, Robert Gross,
Angelika Brunner (Land Salzburg / AT), Gerhard Ederer (Lower
Austria / AT), Armin Heidler (Ministry for Environment / AT), Jaana
Leppänen (Tampere / FI), María Valero Gil (Galicia / ES), Ionel
Preda (Arges / RO) and Paul Stevens (Lancashire / UK). The team
developed a questionnaire to gather experience and knowledge from
participants and non-participants of the workshop, and discussed
the objectives of the workshop, in particular: sharing information
on best practice examples for updating permits (procedures,
preparation), new developments in cement and clinker production,
emission monitoring and emission trends, use of waste (as a
substitute for conventional fuels and as a secondary raw material)
and environmental inspections.
Preparatory Meeting of the Joint Inspection Team
In the morning before the site visit, the inspection team (with
members from AT, ES, RO, SK and UK, see the presentation sheet on
page 5 of this report) discussed and fixed the topics of the
inspection in view of limited time resources, using existing
documents of the competent authority and the operator. The
preparatory meeting was supported by Marnius Jordaan (NL),
coordinator of the joint inspections carried out as part of the IED
Implementation project.
Joint Inspection
The focus of the on-site inspection was on the use of waste
(used as raw materials and secondary fuels, including quality
control) and on air emissions (including relevant parameters,
abatement techniques, levels and trends of emissions). Following
the site visit, all important aspects and major findings were
summarised in a presentation, given in the workshop (see the
presentation sheets on page 5-21 of this report).
Terminology in cement installations
In order to ensure uniform usage of technical terms in workshop
discussions, a compilation of terms and definitions was prepared,
taking into account the BAT documents, the results of the IMPEL
sub-project "Terms and Definitions" and the INSPIRE Directive (see
the presentation sheets on page 22-25 of this report).
Use of Waste
As input for the workshop discussions, a presentation about
development and state of waste input in Austrian cement plants was
given, including the technical and legal framework conditions for
the waste usage concept, its implementation, quality control and
monitoring (see the presentation sheets on page 26-32 of this
report). The corresponding technical guideline of the Austrian
Federal Ministry (“Technische Grundlagen für den Einsatz von
Abfällen als Ersatzrohstoffe in Anlagen zur Zementerzeugung”, with
non-binding translation into English) is attached.
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 3
Results of the Survey
Finally, there had been 22 responses from 16 countries, though
only nine complete responses. Half of those who responded dealt
with inspections and half with permitting. Thirteen were at
national, ten were at regional and two were at a local level. Of
those who had responded, eight were not present at the meeting.
Others were encouraged to give their responses in the workshop
discussions of the interim results. The report attached (“Survey
Results on Cement Installations including Discussion Results of the
Cement Workshop in Eisenstadt, Austria, 04-05 October 2018”)
summarises the information gathered from both the survey and the
discussions.
Summary
The findings from the workshop can be summarised as follows:
• All the experts involved use the decisions on BAT conclusions
as a basis for assessing existing and planned techniques and their
performance data.
• In-depth discussions were held on the use of waste (as
secondary raw material and waste fuel) and the necessary framework
conditions therefor.
• The state of the art of air emission abatement techniques
depends on the type, quality and amount of the waste input.
• For most cement plants, a baseline report is required because
of the storage and use of mineral oils used as fuel or ammonia used
as reducing agents in SCR / SNCR systems, or because highly
alkaline water containing cement can drain into soil, groundwater
or nearby surface water.
• In general, the IED installation covers the entire cement
facility (plant, site) including the parts of installations for
cement production (such as clinker mills and cement storage
silos).
• The local circumstances of a production site are decisive in
drawing the boundaries of the installation and determining emission
limits.
Regarding the different legal and administrative systems in
Europe, workshops of this kind serve the common understanding of
experts and the gradual convergence of environmental performance
levels.
To avoid different interpretations of the scope of the IED
activities within and between Member States and to ensure a level
playing field for the operators across the EU, it is considered
necessary to improve the quality of the IED: Revision of Annex I
IED and alignment of the scope of the BAT documents to clarify and
define the scope of activities.
Salzburg, February 2019
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 4
Workshop Participants
Olympia Antoniou Greece Ivo Lemšs Latvia
Angelika Brunner Austria Jaana Leppänen Finland
Malgorzata Budzynska Poland Tony Liebregts The Netherlands
Horst Büther Germany Maria Jesus Mallada Spain
Cyril Burda Slovak Republic Jamie McGeachy United Kingdom
Eva Daňová Slovak Republic Martin O’Reilly Ireland
Elisabete Dias Ramos Portugal Deniss Pavlovs Latvia
Günter Dussing Austria Uzabela Tyrka Pettersson Sweden
Gerhard Ederer Austria Kara Pirkanniemi Finland
Maria Enrot Sweden Silva Prihodko Estonia
Simon Farrugia Malta Romano Ruggeri Italy
Robert Gross Austria John Seager UK (Consultant)
Csaba Hegedüš Slovak Republic Terence Shears UK (Consultant)
Armin Heidler Austria Paul Stevens United Kingdom
Florin Homorean Romania Enis Tela Albania
Preda Ionel Victor Romania Peter Valentovič Slovak Republic
Marinus Jordaan The Netherlands María Eulogia Valero Gil
Spain
Helena Kamenickova Czech Republic Jaakko Matias Vesivalo
Finland
Rob Kramers The Netherlands Boris Žbona Slovenia
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 5
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 6
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 7
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 8
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 9
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 10
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 11
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 12
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 13
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 14
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 15
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 16
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 17
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 18
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 19
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 20
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 21
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 22
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 23
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 24
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 25
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 26
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 27
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 28
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 29
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 30
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 31
-
IMPEL Workshop on IED/BAT in the Cement Industry – Eisenstadt,
Austria, October 2018 32
-
Austrian Technical Guideline for the Use of Waste as Substitute
(Secondary) Raw Materials Page 1
Original (BMLFUW, Wien, 18.12.2017) Translation – for your
information only, not binding/approved
TECHNISCHE GRUNDLAGEN FÜR DEN EINSATZ VON ABFÄLLEN ALS
ERSATZROHSTOFFE IN ANLAGEN ZUR ZEMENTERZEUGUNG
TECHNICAL GUIDELINE FOR THE USE OF WASTE AS SUBSTITUTE
(SECONDARY) RAW MATERIALS IN CEMENT MANUFACTURING INSTALLATIONS
Gemäß § 3 Z 20 Abfallverbrennungsverordnung - AVV, BGBl. II Nr.
389/2002, idgF sind Ersatzrohstoffe Abfälle, die die
Voraussetzungen einer stofflichen Verwertung gemäß § 2 Abs. 5 Z 2
AWG 2002 erfüllen.
Anmerkung: Abfälle, die verbrannt werden und damit den Vorgaben
der AVV unterliegen, sind vom Geltungsbereich der vorliegenden
technischen Grundlagen ausgenommen.
Gemäß § 2 Z 1 ZementV 2007, BGBl. II Nr. 60/2007, in der Fassung
BGBl. II Nr. 38/2010, sind Anlagen zur Zementerzeugung solche
Anlagen, in denen zumindest eine der folgenden der Zementerzeugung
dienenden Tätigkeiten durchgeführt wird:
a) Transport, Zerkleinern und Trocknen des Rohmaterials, der
Korrekturstoffe und des Brennmaterials,
b) Herstellung von Rohmehl,
c) Brennen von Zementklinker (Ofenanlage)
aa) in Drehrohröfen mit Rostvorwärmer (Lepolöfen),
bb) in Drehrohröfen mit Zyklonvorwärmer (mit oder ohne
Abgasverwertung) oder
cc) in Schachtöfen,
d) Weiterverarbeitung wie Mahlen von in der Anlage erzeugtem
oder von angeliefertem Zementklinker oder
e) Lagern und Fertigmachen des Zements zum Direktverkauf oder
Versand.
According to § 3 No. 20 Waste Incineration Ordinance - AVV,
Federal Law Gazette II No. 389/2002, in its current version
substitute raw materials are waste that meets the requirements for
recycling according to § 2 (5) No. 2 AWG 2002.
Note: Wastes that are incinerated and therefore subject to the
requirements of the AVV, are exempt from the scope of the
present
technical guidelines.
According to § 2 No. 1 Cement Ordinance 2007, Federal Law
Gazette II No. 60/2007, in the version of Federal Law Gazette II
No. 38/2010, plants for cement production are such installations in
which at least one of the following cement production activities
are carried out:
a) transport, crushing and drying of the raw material, the
correction substances and the fuel,
b) production of raw meal,
c) burning cement clinker (kiln installation)
aa) in rotary kilns with grate preheater (Lepol kilns),
bb) in rotary kilns with cyclone preheater (with or without
exhaust gas utilization) or
cc) in shaft furnaces,
d) further processing such as grinding of cement clinker
produced in the installation or delivered or
e) storing and finishing the cement for direct sale or
shipping.
-
Austrian Technical Guideline for the Use of Waste as Substitute
(Secondary) Raw Materials Page 2
1. ERSTUNTERSUCHUNG (1) Vor dem Einsatz von Ersatzrohstoffen in
Anlagen zur Zementerzeugung ist jeder Ersatzrohstoff – getrennt
nach Abfallart und Herkunft – einer Erstuntersuchung zu
unterziehen. Die Erstuntersuchung ist an einer gemäß dem Stand der
Technik repräsentativ beprobten Teilmenge (z. B. gemäß ÖNORM S 2127
„Grundlegende Charakterisierung von Abfallhaufen oder von festen
Abfällen aus Behältnissen und Transportfahrzeugen“, ausgegeben am
1. November 2011) durchzuführen. Im Rahmen dieser Erstuntersuchung
sind mindestens folgende Parameter zu untersuchen: Sb, As, Pb, Cd,
Cr, Co, Cu, Mn, Ni, Hg, Tl, V, Zn, Sn, Chlor und TOC. Besteht auf
Grund der Abfallart und Herkunft der Verdacht auf das Vorhandensein
zusätzlicher relevanter Parameter (z.B. (hoch-)toxische organische
Bestandteile wie z.B. PCDD/PCDF) ist der Untersuchungsumfang um
diese Parameter zu erweitern.
Bei Verdacht auf das Vorhandensein relevanter leichtflüchtiger
organischer Substanzen ist ein qualitatives Screening auf
leichtflüchtige organische Verbindungen mittels Headspace-
Gaschromatographie (GC-MS) durchzuführen. Flüchtige aromatische
Kohlenwasserstoffe, Halogenkohlenwasserstoffe und ausgewählte
aliphatische Ether werden im Methanolextrakt der Festproben gemäß
ÖNORM EN ISO 22155 „Bodenbeschaffenheit – Gaschromatographische
Bestimmung flüchtiger aromatischer Kohlenwasserstoffe,
Halogenkohlenwasserstoffe und ausgewählter Ether - Statisches
Dampfraum-Verfahren“, ausgegeben am 15. Juni 2016, mittels
Headspace-GC-MS im qualitativen (Scan-Modus) erfasst und durch
Vergleich mit der geräteinternen Spektrenbibliothek identifiziert.
Bei Bedarf wird die Quantifizierung der flüchtigen organischen
Substanzen in den Methanolextrakten gemäß ÖNORM EN ISO 22155
durchgeführt.
Bei Verdacht auf das Vorhandensein relevanter mittelflüchtiger
organischer Substanzen ist ein semiquantitatives Screening mittels
Gaschromatographie mit Massenspektrometrie (GC-MS) nach Extraktion
der Proben mittels organischem Lösungsmittel bei
1. INITIAL EXAMINATION
(1) Before substitute raw materials are used in cement
production installations, each substitute raw material - according
to the type of waste and its origin - has to undergo an initial
examination. The initial examination has to be applied on a subset,
which has been representatively sampled according to the BAT (e.g.
according to ÖNORM S 2127 "Basic characterization of waste piles or
solid waste from containers and transport vehicles ", issued on 1
November 2011). In the context of this initial examination, least
the following parameters should be investigated: Sb, As, Pb, Cd,
Cr, Co, Cu, Mn, Ni, Hg, Tl, V, Zn, Sn, chlorine and TOC. If -
judging by the type and origin of the waste - the presence of
additional relevant parameters (e.g. (highly) toxic organic
components such as PCDD / PCDF) is suspected the scope of research
shall be extended.
If the presence of relevant volatile organic substances is
suspected, a qualitative screening for volatile organic compounds
by means of headspace gas chromatography (GC-MS) shall be
performed. Volatile aromatic hydrocarbons, halogenated hydrocarbons
and selected aliphatic ethers are analysed in the methanol extract
of solid samples according to ÖNORM EN ISO 22155 "Soil quality -
Gas chromatographic determination of volatile aromatic and
halogenated hydrocarbons and selected ethers - Static headspace
method", issued on 15 June 2016, using Headspace GC-MS recorded in
qualitative (scan mode) and by comparison with the device's
internal spectrum library. If necessary, the quantification of the
volatile organic substances in the methanol extracts shall be
performed according to ÖNORM EN ISO 2215.
Upon suspicion of the presence of relevant medium volatile
organic substances, a semi quantitative screening by gas
chromatography with mass spectrometry (GC-MS) extraction of the
samples by means of organic solvents at different pH values shall
be performed. The basis for this is provided by the EPA method
3550C (Ultrasonic
-
Austrian Technical Guideline for the Use of Waste as Substitute
(Secondary) Raw Materials Page 3
Original (BMLFUW, Wien, 18.12.2017) Translation – for your
information only, not binding/approved
unterschiedlichen pH-Werten und Abgleich mit Datenbanken
durchzuführen. Als Grundlage dafür dienen die Verfahren EPA Methode
3550C (Ultraschall-Extraktion), Methode 3640a (Gel-Permeation
Cleanup), 3650B (Acid-Base Partition Cleanup) sowie Methode 8270
(GC-MS).
Extraction), Method 3640a (Gel Permeation Cleanup), 3650B
(Acid-Base Partition Cleanup) and Method 8270 (GC-MS).
2. ORGANISCHE SCHADSTOFFE (2) Der Einsatz von Ersatzrohstoffen,
die die in Anhang IV der Verordnung (EU) Nr. 850/2004 aufgelisteten
Stoffe enthalten oder durch sie verunreinigt sind und die ebendort
angeführten Konzentrationsgrenzen erreichen, ist verboten.
(3) Der Einsatz von Ersatzrohstoffen mit einem relevanten Gehalt
an flüchtigen organischen Verbindungen (VOC) hat so zu erfolgen,
dass die entstehenden Abgase kontrolliert, gleichmäßig und selbst
unter den ungünstigsten Bedingungen für mindestens zwei Sekunden
auf eine Temperatur von mindestens 850 °C erhitzt werden. Wenn
gefährliche Abfälle mit einem Gehalt von mehr als einem
Gewichtsprozent an halogenierten organischen Stoffen, berechnet als
Chloride, als Ersatzrohstoffe eingesetzt werden, muss die
Temperatur für mindestens zwei Sekunden auf 1.100 °C erhöht
werden.
Die Relevanz des VOC-Gehalts ist auf Grund der Ergebnisse der
Erstuntersuchung zu beurteilen, wobei durch den Einsatz eines
spezifischen Ersatzrohstoffes im Vergleich zur genehmigten
Rohmehlmischung (Rohstoffe und Ersatzrohstoffe, allerdings ohne den
spezifischen Ersatzrohstoff) keine Erhöhung des Emissionsniveaus
von relevanten organischen Schadstoffen stattfinden darf.
Erforderlichenfalls ist gemäß Punkt 6 vorzugehen.
Der Gehalt an flüchtigen organischen Verbindungen (VOC) kann
auch mit einem Ausgasungsversuch, der die bei der Vorwärmung des
Rohmehls ablaufenden Vorgänge simuliert, bestimmt werden. Für
diesen Ausgasungsversuch sind eine qualifizierte Stichprobe
heranzuziehen und eine Doppelbestimmung durchzuführen, wobei
2. ORGANIC POLLUTANTS
(2) The use of substitute raw materials which contain or are
contaminated by the substances listed in Annex IV to Regulation
(EU) No. 850/2004 and which reach the concentration limits
specified therein shall be prohibited.
(3) The use of substitute raw materials with a relevant content
of volatile organic compounds (VOC) shall be such that the
resulting exhaust gases are controlled, uniformly and even under
the conditions specified be heated to a temperature of at least 850
°C for at least two seconds. When hazardous wastes containing more
than one percent by weight of halogenated organic substances,
calculated as chlorides, are used as substitute raw materials, the
temperature must be increased to 1,100 °C for at least two
seconds.
The relevance of the VOC content shall be assessed based on the
results of the initial investigation, whereby the use of a specific
substitute raw material in relation to the authorized raw meal
mixture (raw materials and substitute raw materials, but excluding
the specific substitute raw material) shall not increase the
emission level of relevant organic pollutants. If necessary,
proceed according to item 6.
The content of volatile organic compounds (VOC) can also be
determined by means of an outgassing test, which simulates the
processes occurring during the preheating of the raw meal. For this
outgassing test, a qualified sample must be used and a duplicate
determination carried out according to the work instruction for the
execution of outgassing tests (Umweltbundesamt, 2017). The
results
-
Austrian Technical Guideline for the Use of Waste as Substitute
(Secondary) Raw Materials Page 4
Original (BMLFUW, Wien, 18.12.2017) Translation – for your
information only, not binding/approved
gemäß der Arbeitsanweisung zur Durchführung von
Ausgasungsversuchen (Umweltbundesamt, 2017)4 vorzugehen ist. Die
Ergebnisse geben Hinweise auf den geeigneten Aufgabeort des
Ersatzrohstoffes und die spezifische Emission im Abgas (in mg
VOC/Nm³).
(4) Der Einsatz von Ersatzrohstoffen, die auf Grund der Art oder
Herkunft einen relevanten Gehalt der in Anhang IV der Verordnung
(EU) Nr. 850/2004 aufgelisteten Stoffe aufweisen, hat so zu
erfolgen, dass die entstehenden Abgase kontrolliert, gleichmäßig
und selbst unter den ungünstigsten Bedingungen für mindestens zwei
Sekunden auf eine Temperatur von mindestens 1.100 °C erhitzt
werden. Die Relevanz des Gehalts der in Anhang IV der Verordnung
(EU) Nr. 850/2004 aufgelisteten Stoffe ist auf Grund von
Untersuchungsergebnissen (insbesondere der Ergebnisse der
Erstuntersuchung gemäß Punkt 1) zu beurteilen. Erforderlichenfalls
ist gemäß Punkt 6 vorzugehen.
Anmerkung: Darunter sind Ersatzrohstoffe zu verstehen, deren
Kontamination mit in Anhang IV der Verordnung (EU) Nr. 850/2004
aufgelisteten Stoffen (POP) auf Verunreinigungen, aber nicht auf
die ubiquitäre Verteilung von POP (Hintergrundbelastung)
zurückzuführen ist.
(5) Bei Einhaltung des Grenzwertes für den Tagesmittelwert für
die Emissionen von gas- und dampfförmigen organischen Stoffen in
die Luft gemäß Anlage 1 zur AVV ist eine Abweichung von den
Vorgaben gemäß Punkt 3 und 4 zulässig. Erforderlichenfalls ist
gemäß Punkt 6 vorzugehen.
(6) Auf Grund der Ergebnisse eines Probe- oder Versuchsbetriebs
oder von Forschungstätigkeiten, Entwicklungsmaßnahmen oder
Zukunftstechniken ist eine Abweichung von den Vorgaben gemäß Punkt
3 und 4 zulässig, sofern durch den Einsatz eines spezifischen
Ersatzrohstoffes im Vergleich zur genehmigten Rohmehlmischung
(Rohstoffe und Ersatzrohstoffe, allerdings ohne den
spezifischen
give indications of the suitable place of replacement of the
substitute raw material and the specific emission in the exhaust
gas (in mg/m³ VOC under standard conditions).
(4) The use of substitute raw materials which, by reason of
their nature or origin, have a relevant content of the substances
listed in Annex IV to Regulation (EU) No. 850/2004 shall be such
that the resulting waste gases are controlled, uniform and - even
under the least favourable conditions - are heated for a minimum of
two seconds to a temperature of at least 1,100 °C. The relevance of
the content of the substances listed in Annex IV to Regulation (EU)
No. 850/2004 is to be determined on the basis of the results of the
investigation (in particular the results of the initial
investigation referred to in item 1). If necessary, proceed
according to item 6.
Note: This refers to substitute raw materials whose
contamination
with substances listed in Annex IV of Regulation (EU) No.
850/2004 is due to impurities but not to the ubiquitous
distribution of POP
(background pollution).
(5) If the limit value for the daily average for the emissions
of gaseous and vaporous organic substances into the air is not
exceeded in accordance with Annex 1 of the AVV, a deviation from
the requirements according to items 3 and 4 is permissible. If
necessary, proceed according to item 6.
(6) Based on the results of a trial or trial operation or
research activities or development measures or future techniques, a
deviation from the requirements of items 3 and 4 is permissible,
provided that the use of a specific substitute raw material
compared to the approved raw meal mixture (raw materials and
substitute raw materials, but without the specific Substitute raw
material) does not cause an increase in the emission level of
relevant organic pollutants. During the trial or trial operation or
the Research activities, development measures or future
technologies, the relevant organic
-
Austrian Technical Guideline for the Use of Waste as Substitute
(Secondary) Raw Materials Page 5
Original (BMLFUW, Wien, 18.12.2017) Translation – for your
information only, not binding/approved
Ersatzrohstoff) keine Erhöhung des Emissionsniveaus von
relevanten organischen Schadstoffen stattfindet. Für diesen
Nachweis sind im Rahmen des Probe- oder Versuchsbetriebs oder der
Forschungstätigkeiten, Entwicklungsmaßnahmen oder Zukunftstechniken
die relevanten organischen Schadstoffe unter den für die
Luftreinhaltung voraussichtlich ungünstigsten Betriebsbedingungen
und unter schrittweiser Erhöhung der Einsatzmenge des spezifischen
Ersatzrohstoffes bis zur geplanten maximalen Menge im Abgas zu
messen. Eine Abweichung ist beispielsweise bei Vorliegen und
kontinuierlichem Betrieb einer Abgasreinigungsanlage (z. B. einer
thermischen Abgasreinigungsanlage), die geeignet ist, die
Emissionen von organischen Schadstoffen in die Luft zu verringern,
zulässig.
(7) Der genaue Einsatzort jedes Ersatzrohstoffes und die
einzuhaltende Temperatur sind festzulegen.
(8) Die Einhaltung der mindestens erforderlichen Temperatur
gemäß den Punkten 3 und 4 ist einmalig durch eine Netzmessung und
danach kontinuierlich an einer repräsentativen Stelle des
Brennraums
nachzuweisen.
(9) Die Verweilzeit ergibt sich als Quotient aus dem Volumen des
Reaktionsraums und dem Betriebsvolumenstrom im Reaktionsraum.
pollutants shall be monitored in the exhaust gas under the most
unfavourable operating conditions for air pollution control and
while incremental increase in the amount of the specific substitute
raw material up to the planned maximum amount. A deviation is
allowed, for example, in the presence and continuous operation of
an exhaust gas purification system (e.g., a thermal emission
control system), which is suitable to reduce emissions of organic
pollutants into the air.
(7) The exact place of use of each substitute raw material and
the temperature to be maintained shall be specified.
3. ANORGANISCHE SCHADSTOFFE
(10) Vor dem Einsatz von Ersatzrohstoffen in Anlagen zur
Zementerzeugung sind die Auswirkungen auf die Emissionen in die
Luft und auf die Zusammensetzung jeder hergestellten
Normalzementart gemäß ÖNORM EN 197-1 „Zement – Teil 1:
Zusammensetzung, Anforderungen und Konformitätskriterien von
Normalzement“, ausgegeben am 15. Oktober 2011, mit Hilfe einer
Stoffstromanalyse für jede spezifische Anlage zur Zementerzeugung
darzustellen. Anmerkung: Diese Stoffstromanalyse ist u.a. mit den
Ergebnissen der Erstuntersuchung gemäß Punkt 1
3. INORGANIC POLLUTANTS
(10) Before any use of substitute raw materials in cement
production installations, the effects on the emissions into the air
and to the composition of any common cement type produced in
accordance with ÖNORM EN 197-1 "Cement - Part 1: Composition,
specifications and conformity criteria for common cements", issued
on 15 October 2011, has to be shown using a mass flow analysis for
each specific installation for cement production.
Note: This material flow analysis shall be done inter alia with
the
results of the initial examination according to item 1
assuming
-
Austrian Technical Guideline for the Use of Waste as Substitute
(Secondary) Raw Materials Page 6
Original (BMLFUW, Wien, 18.12.2017) Translation – for your
information only, not binding/approved
unter Annahme realistischer Einsatzbedingungen durchzuführen.
Liefert die Stoffstromanalyse als Ergebnis eine Überschreitung der
Grenzwerte für die Emissionen in die Luft oder der
Vorsorge-Richtwerte im Zement gemäß Punkt 20, ist der Einsatz des
Ersatzrohstoffes nicht zulässig.
(11) Ersatzrohstoffe, die in Anlagen zur Herstellung von
Zementklinker eingesetzt werden, haben folgende Grenzwerte ab 1.
Juli 2018 einzuhalten:
Parameter Schadstoffgehalt in mg/kg TM
Sb 30
As 301
Pb 500
Cd 5
Cr 500
Co 250
Ni 500
Hg 0,72
Tl 3 1) Für geogen bedingte Gehalte gilt ein Grenzwert in der
Höhe von 200 mg/kg TM. 2) Die im Rahmen der Erstuntersuchung gemäß
Punkt 1 hergestellte Probe hat den Grenzwert in der Höhe von 0,7
mg/kg TM einzuhalten. Für die laufende Qualitätssicherung gelten
die Vorgaben gemäß Punkt 14.
Auf Grund der Art und Herkunft eines Ersatzrohstoffes kann es im
Einzelfall – beispielsweise bei Verdacht auf eine Kontamination –
erforderlich sein, weitere Parameter zu untersuchen und zu
begrenzen. Die Einhaltung der Grenzwerte ist im Rahmen der
Erstuntersuchung gemäß Punkt 1 nachzuweisen. In Abhängigkeit von
der Heterogenität des Ersatzrohstoffes bzw. bei Änderungen des
Herstellungsprozesses, aus
realistic conditions of use. If the mass flow analysis shows
that the
limit values for the emissions into the air or the
precautionary
values in cement according to item 20 could be exceeded, the use
of
substitute raw material is not permitted.
(11) Replacement raw materials used in cement clinker
installations have to comply with the following limit values from 1
July 2018 on:
Parameter Pollutant content in mg/kg DM
Sb 30
As 301
Pb 500
Cd 5
Cr 500
Co 250
Ni 500
Hg 0.72
Tl 3
1. For geogenic contents a limit value of 200 mg/kg DM applies.
2. The sample produced during the initial examination according
to
item 1 has the limit in the level of 0.7 mg/kg DM. For ongoing
quality assurance, the specifications according to item 14.
Due to the nature and origin of a substitute raw material, in
individual cases - for example suspicion of contamination - it may
be necessary to investigate and limit additional parameters.
Compliance with the limit values is part of the initial
investigation in accordance with item 1. Depending on the
heterogeneity of the substitute raw
-
Austrian Technical Guideline for the Use of Waste as Substitute
(Secondary) Raw Materials Page 7
Original (BMLFUW, Wien, 18.12.2017) Translation – for your
information only, not binding/approved
dem der Ersatzrohstoff stammt, können zusätzliche Untersuchungen
erforderlich sein.
(12) Kohlenasche, Holzasche sowie Flugaschen und -stäube aus
Mitverbrennungsanlagen sind von den Vorgaben gemäß Punkt 11
ausgenommen.
(13) Eine Abweichung von den Vorgaben gemäß Punkt 11 ist für
einen Ersatzrohstoff zulässig, sofern die Ergebnisse der
Stoffstromanalyse gemäß Punkt 10 belegen, dass die
Vorsorge-Richtwerte für den Zement gemäß Punkt 20 im
voraussichtlich ungünstigsten Fall nicht überschritten werden und
die Gesamtmenge der Ersatzrohstoffe, die eine Ausnahme gemäß diesem
Punkt beanspruchen, maximal 10 M.-% der Rohmehlmenge ausmacht.
(14) Ersatzrohstoffe, die in Anlagen zur Herstellung von
Zementklinker eingesetzt werden, haben ab 1. Juli 2018 für
Quecksilber den Grenzwert für den Median in der Höhe von 0,7 mg/kg
TM und den Grenzwert für das 80-er Perzentil in der Höhe von 1,4
mg/kg TM einzuhalten. Alle gemäß Punkt 17 hergestellten
qualifizierten Stichproben sind auf den Parameter Quecksilber zu
untersuchen. Die Einhaltung der Grenzwerte hat gemäß den Vorgaben
der Anlage 8 Kapitel 1.7 zur AVV zu erfolgen. Anmerkung: Diese
Vorgaben gelten für die laufende Qualitätssicherung und nicht für
die
Erstuntersuchung (siehe Fußnote 2 zur Tabelle in Punkt 11).
(15) Wenn auf Grund der Abfallart und Herkunft des
Ersatzrohstoffes sowie der Ergebnisse der Erstuntersuchung der
Quecksilber-Gehalt gesichert weniger als 0,35 mg/kg TM beträgt,
sind keine Untersuchungen gemäß Punkt 14 erforderlich.
(16) Werden Quecksilber und seine Verbindungen im Abgas durch
eine Abgasbehandlungsanlage verringert, ist eine Abweichung von den
Vorgaben gemäß Punkt 11 (hinsichtlich Quecksilber) und Punkt 14
zulässig, sofern im Vergleich zur Einhaltung der Vorgaben gemäß
Punkt 11 (hinsichtlich Quecksilber) und Punkt 14 keine höheren
Emissionen entstehen.
material or changes in the manufacturing process, from which the
substitute raw material originates, may require additional
testing.
(12) Coal ash, wood ash and fly ash and fly ash from
co-incineration plants shall be exempted from the requirements of
item 11.
(13) A derogation from the requirements under item 11 is
permitted for a substitute raw material, provided that the results
of the mass flow analysis according to item 10 proves that the
precautionary values for the cement under item 20 are not exceeded
in the worst case scenario and that the total quantity of
substitute raw materials which claim an exemption under this item
does not exceed 10 % by mass of the total quantity of raw meal.
(14) Substitute raw materials used in cement clinker
installations will be subject to the limit values for mercury as a
median of 0.7 mg/kg DM and as a 80th percentile of 1.4 mg/kg DM as
of 1 July 2018 on. All qualified samples produced in accordance
with item 17 shall be tested. The compliance with the limit values
must be carried out in accordance with the requirements of Annex 8
No. 1.7 of the AVV.
Note: These specifications apply to ongoing quality assurance
and
not to the initial examination (see footnote 2 to table in item
11).
(15) If, due to the nature of the waste and the source of the
substitute raw material, as well as the results of the initial
examination of the mercury content assured less than 0.35 mg/kg DM,
no studies according to item 14 are required.
(16) If mercury and its compounds in exhaust gas are reduced by
an exhaust gas treatment equipment, a deviation from the
requirements set out in item 11 (with regard to mercury) and item
14 is allowed, if no higher emissions arise in comparison to the
compliance with item 11 (with regard to mercury) and item 14.
(17) Substitute raw materials used in installations for the
production of cement clinker shall be sampled – separately
according to the type and origin of the waste – according to ÖNORM
S 2127. The maximum
-
Austrian Technical Guideline for the Use of Waste as Substitute
(Secondary) Raw Materials Page 8
Original (BMLFUW, Wien, 18.12.2017) Translation – for your
information only, not binding/approved
(17) Ersatzrohstoffe, die in Anlagen zur Herstellung von
Zementklinker eingesetzt werden, sind – getrennt nach Abfallart und
Herkunft – gemäß ÖNORM S 2127 zu beproben. Der maximale
Beurteilungsmaßstab beträgt 500 t, wobei mindestens eine
qualifizierte Stichprobe pro Kalenderjahr herzustellen ist.
Alternativ kann bei Abfallströmen gemäß Anhang 4 Teil 2 Kapitel 3
zur DVO 2008 vorgegangen werden.
(18) Von allen qualifizierten Stichproben gemäß Punkt 17 sind
Rückstellproben herzustellen und mindestens sechs Monate
aufzubewahren. Die Erfordernisse für die Mindestprobenmenge sind
dabei zu beachten.
(19) Die im Rahmen der Erstuntersuchung gemäß Punkt 1 beprobte
und untersuchte Teilmenge kann für die Verpflichtungen gemäß Punkt
14 und Punkt 17 verwendet werden.
(20) Um im Sinne eines vorsorgenden Umweltschutzes eine Erhöhung
der Umweltbelastung und des Umweltrisikos durch den Einsatz von
Ersatzrohstoffen zu vermeiden, sollten die folgenden
Vorsorge-Richtwerte im Zement nicht überschritten werden:
Parameter Vorsorge-Richtwerte in mg/kg TM
Sb 15
As 15
Pb 200
Cd 4
Cr 300
Co 50
Ni 200
Hg 0,5
Tl 2
assessment scale is 500 t, with at least one qualified sample
per calendar year. Alternatively, waste streams as defined in Annex
4 Part 2 No. 3 of the Landfill Ordinance of 2008 can be
addressed.
(18) All qualified samples according to item 17 shall be subject
to test samples and kept for at least six months. The requirements
for the minimum sample quantity must be fulfilled.
(19) The subset sampled and examined during the initial
investigation referred to in item 1 may be used for the obligations
set out in items 14 and 17.
(20) In order to avoid an increase in environmental impact and
environmental risk through the use of substitute raw materials in
the interests of preventive environmental protection, the following
precautionary values in cement should not be exceeded:
Parameter Precautionary values in mg/kg DM
Sb 15
As 15
Pb 200
Cd 4
Cr 300
Co 50
Ni 200
Hg 0,5
Tl 2
(21) For each type of cement, a sample taken during the internal
surveillance test to assess the conformity of the cement types
in
-
Austrian Technical Guideline for the Use of Waste as Substitute
(Secondary) Raw Materials Page 9
Original (BMLFUW, Wien, 18.12.2017) Translation – for your
information only, not binding/approved
(21) Pro Zementart ist pro Monat eine Probe, die im Rahmen der
internen Überwachungsprüfung zur Beurteilung der Konformität der
Zementarten gemäß ÖNORM EN 197-1 gezogen wurde, auf die Parameter
gemäß Punkt 20 zu untersuchen. Liegen die Ergebnisse für einen oder
mehrere Parameter im Bereich ≤ 80 % der Vorsorge-Richtwerte gemäß
Punkt 20, so ist ab dem zweiten Jahr die Untersuchung einer
Mischprobe, welche aus den im Rahmen der internen
Überwachungsprüfung zur Beurteilung der Konformität der Zementarten
gemäß ÖNORM EN 197-1 gezogenen Proben hergestellt wurde, auf diese
Parameter pro Zementart und pro Quartal ausreichend.
Bei nicht fortlaufend versandten Zementarten ist eine Mischprobe
pro Quartal zu untersuchen.
Eine Überschreitung der Vorsorge-Richtwerte gemäß Punkt 20 ist
der Behörde unverzüglich mitzuteilen, und in jeder Woche des
betroffenen Untersuchungszeitraums ist eine Mischprobe, welche aus
den im Rahmen der internen Überwachungsprüfung zur Beurteilung der
Konformität der Zementarten gemäß ÖNORM EN 197-1 gezogenen Proben
hergestellt wurde, auf jene Parameter zu untersuchen, bei denen
eine Überschreitung festgestellt wurde. Der Anlageninhaber hat die
Ergebnisse der Untersuchungen sowie eine Darstellung der
getroffenen und noch zu treffenden Maßnahmen zur Wiederherstellung
eines konsensmäßigen Betriebs der zuständigen Behörde zu
übermitteln. Dazu kann es erforderlich sein, die aus den
Ersatzrohstoffen gemäß Punkt 18 hergestellten Rückstellproben aus
dem betroffenen Zeitraum auf jene Parameter zu untersuchen, bei
denen eine Überschreitung der Vorsorge-Richtwerte festgestellt
wurde.
(22) Die Bestimmungsverfahren gemäß Anlage 8 Kapitel 2.10 und
2.11 zur AVV sind anzuwenden. Der Parameter Tl ist im Zement
ausschließlich im Rahmen der Fremdüberwachungsprüfung gemäß Punkt
26 zu untersuchen.
(23) Über die Untersuchungen gemäß Punkt 1 und Punkt 14 ist ein
Beurteilungsnachweis zu erstellen, wobei aus Gründen der
Zweckmäßigkeit auf die Inhalte gemäß Anlage 8 Kapitel 2.12 zur AVV
zurückgegriffen werden sollte.
accordance with ÖNORM EN 197-1 shall be tested for the
parameters referred to in item 20. If the results for one or more
parameters are in the range of ≤ 80 % of the precautionary values
in accordance with item 20, during the second year the examination
of a mixed sample consisting of samples within the framework of the
internal monitoring test to assess the conformity of the cement
types in accordance with ÖNORM EN 197 -1 is sufficient on these
parameters per cement type and per quarter of the year.
For non-continuously dispatched types of cement, a mixed sample
should be examined every quarter of a year.
When precautionary values referred to in item 20 are exceeded,
this shall be notified to the authority without delay and, in each
week of the investigation period concerned, a mixed sample
consisting of those used in the internal surveillance test prepared
to assess the conformity of cement species according to ÖNORM EN
197-1 shall be used to examine those parameters in which an
exceedance was detected. The operator of the installation shall
forward to the competent authority the results of the investigation
and a description of the measures taken and still to be taken to
restore compliance of the operation. Additionally it could be
necessary to examine the reference samples of the substitute raw
materials during the production period concerned referred to in
item 18 for those parameters which exceed the limit value of the
precautionary values.
(22) The determination procedures according to Annex 8 No. 2.10
and 2.11 of the AVV are to be applied. The parameter Tl in the
cement has only to be tested in the external monitoring test
according to item 26.
(23) An assessment report should be prepared on the
investigations referred to in items 1 and 14 and, for reasons of
expediency, the content should be used in accordance with Annex 8
No. 2.12 of the AVV.
-
Austrian Technical Guideline for the Use of Waste as Substitute
(Secondary) Raw Materials Page 10
Original (BMLFUW, Wien, 18.12.2017) Translation – for your
information only, not binding/approved
(24) In Anlagen zur Herstellung von Zementklinker sind die
Quecksilber-Emissionen in die Luft kontinuierlich zu messen.
(25) Im Rahmen der Zementherstellung ist neben anorganischen
mineralischen Stoffen, die aus der Klinkerherstellung stammen, und
sonstigen primären Zumahlstoffen der Einsatz von Ersatzrohstoffen
zulässig, die in Kapitel 5 der ÖNORM EN 197-1 angeführt sind. Das
sind Hochofenschlacke, Flugaschen5, Calciumsulfat6 und
Zusätze7.
(24) In installations for the production of cement clinker,
mercury emissions into the air are to be measured continuously.
(25) In addition to inorganic mineral substances originating
from clinker production and other primary additives, the use of
substitute raw materials which are listed in Chapter 5 of ÖNORM EN
197-1 is allowed in the production of cement. These are blast
furnace slag, fly ash, calcium sulphate and additives.
4. EXTERNE ÜBERWACHUNG
(26) Im Rahmen der Fremdüberwachungsprüfung gemäß ÖNORM EN 197-1
ist jährlich eine der pro Zementart entnommenen Proben zusätzlich
auf die Parameter gemäß Punkt 20 zu untersuchen. Vom Inhaber der
Anlage zur Zementerzeugung ist eine Überschreitung der
Vorsorge-Richtwerte gemäß Punkt 20 der Behörde unverzüglich
mitzuteilen und eine Darstellung der getroffenen und noch zu
treffenden Maßnahmen zur Wiederherstellung eines konsensmäßigen
Betriebs der zuständigen Behörde zu übermitteln.
(27) Im Rahmen der Prüfung gemäß § 15 AVV ist durch eine externe
befugte Fachperson oder Fachanstalt die Einhaltung der Vorgaben
hinsichtlich des Einsatzes von Ersatzrohstoffen zu kontrollieren.
Über jede Prüfung ist ein Bericht zu erstellen, aus dem
insbesondere der Umfang und der Inhalt der Prüfung hervorgehen.
Dieser Bericht ist vom Anlageninhaber mindestens sieben Jahre
aufzubewahren und auf Verlangen der Behörde vorzulegen. Werden im
Rahmen der Prüfung Mängel oder Abweichungen vom konsensgemäßen
Zustand festgestellt, hat der Bericht entsprechende Vorschläge samt
angemessenen Fristen für die Behebung der Mängel oder für die
Beseitigung der Abweichungen zu enthalten. Der Anlageninhaber hat
in diesem Fall unverzüglich eine Ausfertigung dieses Berichts sowie
eine diesbezügliche Darstellung der getroffenen und zu treffenden
Maßnahmen der zuständigen Behörde zu übermitteln.
4. EXTERNAL MONITORING
(26) Within the framework of the third-party surveillance test
in accordance with ÖNORM EN 197-1, one of the samples taken per
type of cement must also be examined annually for the parameters
according to item 20. The operator of the cement production
facility must notify the authority immediately of any exceedance of
the precautionary values referred to in item 20 and a description
of the measures taken and still to be taken to restore
consensus-based operation to the competent authority.
(27) Within the scope of the examination in accordance with § 15
AVV, the observance of the requirements regarding the use of
substitute raw materials must be checked by a third-party
authorized specialist or specialist institution. Each audit must be
accompanied by a report, covering in particular the scope and
content of the audit. This report must be kept by the operator for
at least seven years and be submitted to the authority upon
request. If deficiencies or non-compliances are detected during the
audit, the report has to include appropriate proposals and time
limits for remedying the deficiencies or eliminating the
non-compliances. In this case, the operator of the installation
must immediately issue a copy of this report as well as a report on
the measures taken and to be taken to the competent authority
-
Cement Industry - IED Implementation
Welcome to this questionnaire!
Survey Results on Cement Installations
including Discussion Results of the
Cement Workshop in Eisenstadt, Austria,
04-05 October 2018
Robert Gross, 13.11.2018
-
Survey Results on Cement Installations Page 2
1. Background of the respondents
Q1 Respondents contact details
• 22 responses from 16 countries
• 9 complete responses
Q2 Your field of work
Answer Choices Survey Responses
Permitting 15
Inspecting 17
Other (please specify) 3
Answered 25
Other:
• Policy, legislation and technical support
• Appeal body, BAT Center
• Expert
Q3 Your geographical coverage
Answer Choices Survey Responses
National 14
Regional 10
Local 2
Answered 25
-
Survey Results on Cement Installations Page 3
2. Definition and boundaries of a cement production
installation
Q4 If there is a mining activity (quarry) nearby, is it included
into the IED
installation? If not, where is the boundary between mining and
cement
production installations? If applicable, please upload a
map.
Answer Choices Survey Responses Workshop Discussion
Yes 7 2
No 6 8
Not applicable 2 0
Answered 15 10
Comments:
• In Latvia we have only 1 cement plant under IED, that called
"CEMEX". Interactive process animation on company WEB page (in
latvian):
http://www.cemex.lv/razosanas-process.aspx
Quarry is located 22 km away from plant and not included in
permit. They have specific
mining permit for this activity.
• the IED installation includes the transfer of the mining
materials from the quarry
• There needs to be a direct technical link between the quarry
and the clinker manufacturing for it to be included in the permit.
For example - if all of the limestone from
the quarry goes to make clinker the permit site boundary would
include the quarry but
the installation boundary could be only for the clinker
manufacture. Both boundaries are
included in the permit.
• There is a mining activity nearby (about 2 km); is not
included in the IED installation; limestone transport is done with
a conveyor belt not included in the IED installation.
• There are different permits
• If there is a clear technical connection between the activity
and the quarry.
• according to German regulations the quarry should be included
if the is a spatial and operational context (could be unclear in
many cases!)
Q5 If there is a landfill for production waste on-site or
nearby, is it included into the
IED installation?
Answer Choices Survey Responses
Yes 3
No 6
Not applicable 5
Answered 14
-
Survey Results on Cement Installations Page 4
Comments:
• Waste landfills are only included in the permit if there is a
direct technical link. For example if the waste is removed from the
installation by truck onto the public road then
the technical link would be broken - even if the landfill was
close to the installation.
• Landfill for waste (code 10 13 12*)
• In UK it is possible to include the waste landfill in the
permit. There are technical rules to follow. Most installations
have a separate
• from a technical viewpoint, yes. no known examples.
Q6 Is the access road to the site included in the IED
installation? Where is the
boundary of the IED installation in this respect?
If applicable, please upload a map.
Answer Choices Survey Responses
Yes 4
No 4
Not applicable 6
Answered 14
Comments:
• Roads not included in the IED permit.
• A site and installation boundary are defined in the permits
with different coloured lines. Where activities linked to the
installation such as a transport road for raw materials it is
included from the point it leave the public highway.
• Discussion result: Duty to clean the access road regardless of
street ownership
-
Survey Results on Cement Installations Page 5
Q7 Which material storage units, e.g. for raw materials, fuels,
intermediate
products, final products and waste produced (e.g. by-pass dust)
are included in
the IED installation?
Answer Choices Survey Responses Workshop Discussion
Tanks 11
Silos 13
Stockpiles 10
Day bins 7
Winter deposits 5
Other (please specify) 4
All storage units for raw materials and
products X
Answered 15
Other:
• storage building
• All. Storage of any materials used in the process is included
within the permit. The only time this is different is where another
operator, on the same site, is in charge of the
material. In this case we would have linked permits.
• All material storage units existing on-site are included in
the IED installation
Q8 Is the equipment for packaging and dispatch of the products
included in the IED
installation?
Answer Choices Survey Responses
Yes 10
No 3
Not applicable 0
Answered 13
Comments:
• Cement placed in railway carriage or trucks.
• UK legislation includes "Part A2 and Part B" processes that
are to be included within the IED (EPR) permit. this includes:
A(2)(a) grinding cement clinker, Part B(a) storing and
loading cement or clinker, (b) Blending and bagging cement.
• Activities carried out on site are
-
Survey Results on Cement Installations Page 6
• According to German regulations only the auxiliary parts are
only included if they are responsible for harmful environmental
impacts
• Discussion result: the equipment should be included
Q9 Is an on-site quality control lab (for input materials and
products) included in
the IED installation?
Answer Choices Survey Responses
Yes 7
No 4
Not applicable 3
Answered 14
Comments:
• Quality control lab is considered a fundamental part of the
clinker manufacturing process. If done off-site it is not included
in the permit as the technical link is broken
• According to German regulations only the auxiliary parts are
only included if they are responsible for harmful environmental
impacts
• In Estonia there is no QM-Lab (included), because the
installation for clinker production doesn't include a cement
production.
Q10 Is an on-site maintenance workshop for mobile machinery
included in the IED
installation?
Answer Choices Survey Responses
Yes 6
No 6
Not applicable 1
Answered 13
Comments:
• On-site maintenance is considered a fundamental part of the
clinker manufacturing process. If done off-site it is not included
in the permit as the technical link is broken.
• According to German regulations only the auxiliary parts are
only included if they are responsible for harmful environmental
impacts
• Latvia: yes for wastewater from the vehicle cleaning
-
Survey Results on Cement Installations Page 7
Q11 If there is a direct discharge of process water, cooling
water (used e.g. for the
rotary kiln drive) or surface water to a river or into ground
water, is this point of
discharge included in the IED Installation? If no, please
explain the reason.
Answer Choices Survey Responses
Yes 11
No 1
Not applicable 2
Answered 14
Comments.
• Consolidation of regulation under IED means a single permit is
issued to an installation that integrates relevant activities.
Where process water is discharged a discharge consent
is incorporated with conditions into the permit.
• Discussion result: direct discharges should be included, also
direct discharges to the sea
Q12 Is an on-site fueling station (also) for non-road mobile
machinery included in
the IED installation?
Answer Choices Survey Responses Workshop Discussion
Yes 7 Majority
No 6 Minority
Not applicable 0
Answered 13
Comments:
• As the activity is technically linked it is included within
the permit.
• could be harmful to the groundwater
-
Survey Results on Cement Installations Page 8
Q13 If there are production units for cement and lime on one
site, are they seen as a
single installation (covering several IED activities)?
Answer Choices Survey Responses
Yes 3
No 6
Not applicable 4
Answered 13
Comments:
• We can have a single permit with multiple activities
undertaken. One installation in the UK has two cement kilns and 5
Lime kilns. Each activity under IED and EPR regulations are
clearly defined in the permit.
• The locations of the lime and cement plants are neighbors; the
production units are operated by different operators;
authorizations are individual per unit
• Cement production only
Discussion topics:
• possibility of separate operation as a criterion
• comparison to a refinery with 17 IED installations
• former separate permits merged into one permit to comply with
European legislation
Q14 Is a concrete plant (producing ready-mix concrete or
concrete parts) at the
same site included in the IED Installation?
Answer Choices Survey Responses
Yes 2
No 6
Not applicable 5
Answered 13
Comments:
• Cement only
• England does not have any Cement installations producing
concrete. However, in theory there is no reason why an operator
could not start one and have it included within the
single IED permit.
• Discussion results: obviously a theoretical question
-
Survey Results on Cement Installations Page 9
Q15 Are there other facilities at the same site (e.g. an
electricity plant) included in
the IED installation?
Answer Choices Survey Responses
Yes 1
No 7
Not applicable 2
Answered 10
Other:
• This is an option. Examples include CCGT for electricity
production and Solar plant.
• There are thermal boilers for space heating and technological
steam with methane gas; these are included in the IED
installation
• Discussion results: obviously a theoretical question
Q16 If possible, please upload a map of a typical site.
Figure 1: Cauldon Cement Plant, Stoke-on-Trent, UK. Site
boundaries marked in red.
-
Survey Results on Cement Installations Page 10
Figure 2: Bunlicky, Co. Limerick, Ireland. Site boundary marked
in blue (above), Google Map (below).
-
Survey Results on Cement Installations Page 11
Figure 3: Cemex Cement Plant, Brocēni, Latvia
3. Permitting of existing installations and reconsideration and
updating of permit conditions
Q17 When reconsidering and updating permit conditions, how do
you (or does the
competent authority) get the information on BAT 1 to 29 (General
BAT
conclusions and BAT conclusions for the cement industry)?
Answer Choices Survey Responses
Offer a mandatory template for the
operator’s report (or application) to
streamline the information 2
Ask for a report (or application) by the
operator 8
Other (please specify) 4
Answered 14
Other:
• Operators are required (by legal notice) to describe how they
will meet the requirements of the BATC by the implementation date.
The EA will then vary the permit on the basis of
the response.
-
Survey Results on Cement Installations Page 12
• Ask a report to the operator; the report is drafted by units
approved by the Ministry of Environment
• legal requirement, no form prerequisit
• there is an information provided by the ministry
Q18 When reconsidering and updating permit conditions, which of
the BAT 1 to 29
causes problems or leads to derogations (according to Art. 15
(4) IED)? Please
comment.
BAT Responses Regarding Problems or Derogations
1 ―
2 Noise - some site specific upgrades needed.
3 ―
4 ―
5 Monitoring - some site specific upgrades needed (mainly
dust)
6 ―
7 ―
8 Deadline 31.12.2020
9 ―
10 ―
11 Waste quality - No major issues. Some debate on frequency of
sampling but
agreed by use of control charts
12 ―
13 ―
14 Diffuse dust - No major issues - industry standards generally
applied. Some site
specific issues needed addressing
Deadline 31.12.2020
15 Stockpile dust - No major issues - industry standards
generally applied. Some site
specific issues needed addressing
16 Channelled dust (non-kiln). Significant work needed to define
less than 10,000
Nm³ flows and testing programmes and monitoring arrangements
needed for
larger flows. Risk based approach taken. Larger the flow (and
risk) more
monitoring required.
-
Survey Results on Cement Installations Page 13
BAT Responses Regarding Problems or Derogations
17 Dust (kilns). Significant problems with a number of
derogations. EA applied ELV of
-
Survey Results on Cement Installations Page 14
Q19 Does the installation have a standardised Environmental
Management System
(EMS) like ISO 14001 or EMAS?
Answer Choices Survey Responses
Yes 11
No 3
Answered 14
Comments:
• They have ISO 9001:2015, ISO 14001:2015, OHSAS 18001:2007 and
ISO 50001:2011
• Discussion results: generally ISO 14001 is applied; in Ireland
also audit reports and measures are accepted
Q20 How do you (or does the competent authority) update the
permit?
Answer Yes No Answered
Is there a fixed procedure by legal
requirements? 10 4 14
Or is there a fixed procedure by an
internal instruction of the authority? 0 5 5
Is a public consultation necessary? 6 5 11
Comments:
• Permitting procedure in Latvia: Republic of Latvia Cabinet,
Regulation No. 1082 Adopted 30 November 201; Procedure by Which
Polluting Activities of Category A, B and C Shall Be
Declared and Permits for the Performance of Category A and B
Polluting Activities Shall Be
Issued
(https://likumi.lv/ta/en/en/id/222147-procedure-by-which-polluting-activities-of-
category-a-b-and-c-shall-be-declared-and-permits-for-the-performance-of-category-a-
and-b-polluting-activities-shall-be-issued)
• Variations can be requested by the operator or the regulator
can impose changes.
• It is a fixed procedure by legal requirements, supplemented by
internal instructions of the central authority
• legal requirement; no public consultation
• by administrative order
• Discussion results: the initial installation or renewal of
e.g. fuel stations usually classified as small changes
-
Survey Results on Cement Installations Page 15
Q21 Is remote emission monitoring by environmental quality
monitoring (ambient
air quality measurements and/or deposition monitoring) required
in IED
permits?
Answer Choices Survey Responses Workshop Discussion
Yes 8 +1
No 5 -1
Answered 13
Comments:
• In exceptional circumstances, ambient monitoring can be
required.
• Discussion results: odour immissions due to emissions of
sulphur compounds
Q22, Q23, Q24 and Q26 about environmental quality monitoring
These questions are not assessable because most of the answers
are related to emissions.
Q25 If environmental quality monitoring is required, what are
the required sampling
media and principles?
Answer Choices Survey Responses
Not applicable 2
Active air sampling 7
Passive air sampling 7
Soil sampling 5
Use of bioindicators 2
Other (please specify) 3
Answered 13
Other:
• In the past we have required the above sampling to address
local health concerns.
• Emissions to water
• authorised measurement equipments (Sick etc.)
-
Survey Results on Cement Installations Page 16
4. Permitting of largely rebuilt installations
Q27 Do you have exemplary cases of permitting of largely rebuilt
installations? What
is the reason for changing the permit?
Answer Choices Survey Responses
Yes 3
No 10
Answered 13
Comments:
• Latvia: Old soviet time cement plant was completely rebuilt
and modernized in 2011
• Greece: Titan S.A -Thessaloniki plant
• Romania: Is the case of a factory that has been
refurbished
5. Application of BAT
Q28 Do you have experience with the use of wet scrubbers to
reduce Sulphur
dioxide emissions?
Answer Choices Survey Responses
Yes 2
No 11
Answered 13
Comments:
• Hanson's Ribblesdale plant in North West England.
• Discussion topic: recycled waste water
Q29 Do you have experience with the use of selective catalytic
reduction (SCR)? Is
there any kiln with full-stream SCR?
Answer Choices Survey Responses
Yes 3
No 10
Answered 13
-
Survey Results on Cement Installations Page 17
Comments:
• SNCR technology is used
• Most English plant now use SNCR
• SNCR abatement used for NOx.
• Discussion results: according to BREF SCR is used in 2 EU MS
but actually at least in 3 MS; only cross-media effects discussed
in BREF, but not effects on energy efficiency
• Discussion results: a planned thermal oxidation in AT leads to
a temperature increase, which opens the option for an SCR
Q30 Do you have any experience with the use of thermal oxidation
due to high
organic emissions (e.g. due to the use of waste, alternative
fuels or secondary
raw materials)?
Answer Choices Survey Responses
Yes 0
No 13
Answered 13
Comments:
• Not required
• not yet, planned
• not yet, new Project
Q31 Is the amount of waste, alternative fuels or secondary raw
materials increasing?
Answer Choices Survey Responses
Yes, including hazardous waste 6
Yes, but not for hazardous waste 3
No 5
Answered 14
Comments:
• Not applicable
• alternative fuels have been increasing and are still; max
amount according to permit is not fully reached yet
• Discussion result: in UK no further increase expected for
alternative fuels, but for secondary raw materials
-
Survey Results on Cement Installations Page 18
Q32 Did problems (e.g. specific emissions) occur with increasing
amounts of waste
as secondary raw materials?
Answer Choices Survey Responses
Yes 2
No 8
Not applicable 3
Answered 13
Comments:
• Problems were mainly related to perception rather than
increases in emission. Generally we have seen NOx reduction
• Cl or generally, halogenides, caused installation of tertiary
air channelling; thermal treatment of waste gas is necessary; heavy
metals have been dominated by raw material
input, thus no change, esp. when dust filtering was upgraded; Hg
did not increase.
Q33 Are there compliance problems with the raw mill off versus
on and how do you
deal with them?
Answer Choices Survey Responses
Yes 1
No 11
Not applicable 0
Answered 12
Comments:
• Previously we had some installations with ELV for operation
with and without the mill on. The BATC removed this options and
operators have had the tighter limits applied.
Q34 Did problems occur with emissions of organic compounds
(TOC)?
Answer Choices Survey Responses
Yes 2
No 11
Answered 13
-
Survey Results on Cement Installations Page 19
Comments:
• TOC is reason for derogation
• Generally TOC levels are associated with the raw material.
Levels fluctuate but on a scale associated with different quarry
areas. As this is predictable raw meal preparation and
selective quarrying can reduce short term spikes.
Q35 Did problems occur with emissions of persistent
organochlorine compounds?
Answer Choices Survey Responses
Yes 0
No 10
Answered 10
Comments:
• Discussion topic: importance of appropriate waste quality
6. IED Baseline Report
Q36 Is a (full) baseline report required because of the
existence of hazardous
substances in the installation?
Answer Choices Survey Responses Workshop Discussion
Yes 0 +1
No 10 -1
Answered 10
Comments:
• Discussion results: Yes for UK (all), ES (all), RO (data
collection since the time of the IPPC directive); “baseline report”
is merely a new term for already existing documents
according to IPPC directive
Q37 If required, what are the relevant substances considered in
a baseline report for
cement production sites, other than conventional liquid fuels
and abatement
chemicals (e.g. ammonia)?
Responses:
• no baseline report has been submitted so far
• mineral oils
• Mineral oil, NH3-solution (for SNCR)
-
Survey Results on Cement Installations Page 20
• Discussion result: hazardous liquid waste used as a fuel
Q38 If required, does the baseline report cover the area of the
IED installation or a
larger area (e.g. site boundary)?
Answer Choices Survey Responses
The area of the IED installation 5
A larger area 1
A smaller area 0
Not applicable 4
Answered 10
Comments:
• We have a site boundary for technically connected activities
which will all be part of the baseline report.
• Discussion topic: extensions are under discussion with
competent authorities in AT and RO
7. Particular aspects of environmental inspections in cement
production installations
Q39 For cement sites, are there characteristic differences in
approach compared to
environmental inspections at other industries?
The question concerned the following aspects: Inspection team,
Time required for
preparation, Checklists, Preparation by the operator, Duration
of the site visit, Follow-up,
Outcome, Announced or unannounced inspections and Other
aspects.
Six respondents answered, in the sense of the question as
follows:
• No differences compared to other environmental inspections
• Are similar compared to other IED installation of the same
complexity and higher than non IED installations
• Other aspects : Dust issues for off site receptors and noise
issues/complaints from site operation.
Discussion result:
• in UK cement installations inspectors from 14 areas
periodically meet to exchange information on problem cases
-
Survey Results on Cement Installations Page 21
8. Special aspects and developments in cement production
Q40 Continuous dust monitoring of bag filters: do you have any
difficulties
concerning calibration techniques or do you know alternative
approaches?
Answer Choices Survey Responses
Yes 1
No 12
Not applicable 1
Answered 14
Comments:
• Since ELVs all reduced to
-
Survey Results on Cement Installations Page 22
Q42 Do you have experience with the use of pulverised fly ash
(PFA) to reduce
Sulphur dioxide emissions?
Answer Choices Survey Responses
Yes 1
No 10
Answered 11
Comment:
• one site in particular is experimenting with this approach as
opposed to installing a wet scrubber. limited success reported so
far.
Q43 Cement kiln dusts and bypass dusts: do you have experience
in minimising
production of excessive dusts and/or establishing uses of this
dusts offsite (e.g.
as a fertilizer)? How is waste dust utilised?
Answer Choices (one or more) Survey Responses
Reintroduce into process 8
Other on-site use 1
Off-site use 3
Landfill 1
Not applicable 2
Answered 11
Comments:
• There are only some researches about ash use in building
process.
• No CKD/Bypass dust is sent to landfill. All is either use for
land spreading (deployment process used) or mixed into blocks
• Bypass dust is applied during the cement grinding process
• Off site impact on residents - complaints.
• but not as a fertilizer!!
• Discussion results: as a by-product of clinker production,
used for soil improvement (not as a fertilizer)
-
Survey Results on Cement Installations Page 23
Q44 What are your methods for introducing and testing new waste
derived fuels
and waste derived alternative raw materials?
Responses:
• Methods specified by operator. Operators laboratory testing
waste derived fuel by moisture content, calorific value, ash,
sulphur, chlorine, VOC
• Quality acceptable procedures and specifications
• A pre-approved list of wastes for alternate raw materials or
fuel is now included in all permits (over 100 EWC code). A code of
practice has been established to minimise
variations but maintain environmental protection.
• - X-ray spectrometry, - X-ray Diffractometry, - Energy
dispersion spectrometry, - Calorimetry, - Infrared Combustion, -
Chromatography, - Mass spectrometry, - Karl-Fisher
titration
• Guideline by Federal Ministry, issued 2016; Limitation of
heavy metals etc, pretesting for volatile organic compounds.
• Discussion results: Code of practice in UK
Q45 Carbon capture trials: do you know possible future
development of cement
plants?
Answer Choices Survey Responses
Yes 2
No 9
Answered 11
Comment:
• research on going
• Very interested though
• Discussion topic: use of oxygen instead of air to get a CO2
rich flue gas
9. Uploaded files concerning environmental permits
• Keskkonnakompleksluba (Environmental Complex License, FI)
• Industrial Emissions Licence (EI)
• Summary of a Permit (RO)
• Review of an Environmental Permit (UK)
• Notice of Variation (UK)
• Atļauja A kategorijas piesārņojošai darbībai (Permission for
Category A Polluting Activity, LV)