3.

DESCRIPTION OF THE DEVELOPMENT

3.1

INTRODUCTION Lagan Cement Ltd intend to increase the processing capacity of the existing
cement manufacturing plant and to develop a concrete products
production area including a dry mortar plant, roof tile plant, concrete pavers
plant and administration building respectfully at the Lagan Cement Ltd. site in
Killaskillen, Kinnegad, Co.Meath.

Lagan Cement Ltd. are submitting two separate planning applications for the
proposed development. One application will deal solely with the cement
capacity increase while a second application will apply for the development
of the concrete products production area.

3.2

CEMENT CAPACITY INCREASE

3.2.1

The Cement ManufucturingProcess

There are four broad stages in the cement manufacturing process:

1) Preparation of raw materials

3) Clinkering
4) Finish mitliny

2) Raw milling

E a c h of these steps is summarised below.

Prersaration of Raw Materials

The cement manufacturing process begins when limestone and shale rock is
quarried and crushed. Precise proportions of the crushed rock ure then
blended with small amounts of sand, clay, bauxite, or iron ore to form U raw
mix.

Raw MIllfna

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lhe raw mix is milled (i.e. pulverised]into a fine powder. or ruw meal.

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Clinkering is the conversion process that takes place within the cement kiln
and associated equipment. It begins when the raw meal is pre-heated to
900 C in a pre-heating tower. After preheating, the raw meal passes into a
large kiln, where coal is burned to heat the raw meal to temperatures in
excess of 1400 C. The exposure to such intense heat transforms the raw meal
physically and chemically, creating a new material. clinker. Clinker
comprises hard nodules resembling grey pebbles about the size of marbles.

At the finish milling stage, the clinker is blended with small amounts of gypsum
(which ollows the setting time of the cement to be controlled). This mix is then
milled into a fine g r e y powder. When the manufacturing process is complete,

the final finished cement is stored in silos until its delivery to customers.
Cement is delivered via trucks, either in bulk or bagged (usually on pallets),
depending on use and type of cemerd.

Envlronmental Impact Ststement.

ILogan Cement I Id, Kinnegad, Co. Meath.

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3.2.2

Proposed Capacity Increase

The existing permitted output capacity of the facility is Mx),OOO tonnes of

cement per annum (tpa) and it is intended to increase this output capacity to
700,000 tonnes per annum. The existing Lagan Cement Works has received
Planning Permission from Meath County Council (Reg. Ref.: TA402281 and is an
PA Licenced Activity {IPC Licence Reg. No. PO-487-03).
The increase in cement production results from Lagan Cement Ltd.'s plans to
produce more 'Green' cement (CEM 2). This "green" cement has a clinker
content ofapprox. 80-9056 jlimestone 6-15%, Gypsum 4%) as opposed to the
present primary cement CEM 1 which has Q clinker content of 91% (limestone
5X,gypsum 4%). This meum that the productionof cement can be increased
with no increase in the production of clinker and thus no new construction is
required. The manufacture of clinker produces upprox 1t of CO2 per tonne of
clinker produced. Thus increased production of green CEM2 cement
effectivelyreduces the cement plants net CO2 emissions per tonne of cement
produced.
The ratio of CEM 2 cement to CEM 1 cement produced at the site will largely
be set by market demands, however the total maximum combined cement
production at the site will be 700,000 tpa. The proposed increase in
producfion rate will not require an increase or an alteration of t h e existing
permitted extractive areas. The overat1 site area will remain unchanged from
the original EIS and IPC Licence Application.
3.2.3

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New Raw Materials, Fuel Selection and Energy Efficiency

Row Materials

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Fuels and h e r q v Efficiency

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It is proposed to improve the sustainability of Lagan Cement's operation

through the use of alfernotive raw mafetials in the production process. These
alternative raw materials are recycled gypsums, ashes and, mineral rich
sludge with high alumina content from water treatment facilities. This
recycling of atfernative raw materialswill represent o significant improvement
in the environmental sustainability of Lagan Cement's operation, through the
reduction of dependency on non-renewableruw materials.

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Lagan Cement Itd has permission to burn cool, Pet Coke, fuel oil, Meat and
Bone meal and natural gos to provide the required heat in the kiln at the

Killaskilten Cement Plant.

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It is also intended to use ccrbon neutral biofuels such as waste construction

and demolition (C & D) wood, clean saw dusts derived from the sawmill and
forestry industry. Q dried biosludge derived from the water treatment industry
and biomass as fuel at thc cement manufacturing facility.
Lagan Cement sees this use of renewable energy as an essential step in
improving the sustainability of its cement manufacturing operation and
reducing its emissions of greenhouse gases.

It is proposed to use all possible and practicable means to use the cleunest
and most energy-efficientfuels in the manufacturing process.

Environmental Impact Statement.

Lagan Cement Ltd, Kinnegad,Co. Meath.

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-rCareful consideration hus been afforded to minimising emissions, especially

of greenhouse gases such as CO?, and to the minimisation of energy use. In
particular,selection of the optimum fuels for these purposes will be continualty
reviewed and UII possible options for misting the developer to achieve these
objectives will be explored. Wherever practicableoptions which contribute to
the achievement of the objectives of the Climate Change Strategy huve
been and will continue to be explored and selected.

The optimisation of energy use is being actively promoted by the developer's

plans to maximise the throughput of the kiln. The optimisation of the
throughput will contribute significantly to an enhanced utilization of energy for
this process.
Maximising energy efficiency and optimisation of fuel selection will also
minimize greenhuuse gas emissions. The developer is aware of Ireland's
commitments to meet Kyoto targets for CO2 emissions. The proposed
enhancement in energy efficiency will confribute to the national effort and
will be Q significant contribution to the National Climate Change Programme.
Lagan Cement Ftd is committed to continuously reviewing options for raw
material substitution andlor the use of cleaner, less polluting fuels which c a n
minimise COz emissions associated with the process.
3.3

CONCRETE PRODUCTS PRODUCTION AREA

3.3,l

Introduction

This proposed developrnenf will include Q concrete pavers plant, roof tile
plant, administration building, weighbridge, aggregate storage bays, outdoor
storage urea and a facility to produce dry mortar and cement based
products. These aspects are individually described below.

3.3.2

Dry Mortar Plant

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This plant will produce 70,000 tonnes of mortar producf per a n n u m . The dry
mortar plant end product will be split between bulk transport. IO tonne
trunsportable and reusable silos a n d bags.
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I he mortar plant is configured a s a high level mixing plunt (Mixing Tower) f o r

Dry Mortar and Plaster. The aggregates ore placed into the inlct funncl

(receiving hopper) by truck or front end loader. Materials are fransported from
the receiver hopper up to the Fluid Bed Dryer/Cooler, the Dryer is within a
building. and is fed by belt conveyors. The Fluid Bed DryerKooler is

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connected with (3 bucket elevator which charges the storage silos within the
mixing tower. The aggregates. binders and additives are weighed in a
weighing hopper and the whole batch is released into a mixer. Following the
batch time the homogenised material is distributed by Q belt conveyor either
to the packing plant, to the bulk loading or to the finished product silm.

Environmental Impact Stalenieril.

Lagan Cemenl Lld. Kinnegod. Co. Meath.

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TAn indicative diagrurn showing the dry mortar plant process is outlined in
Figure 1 below.

Figure 1: Indicative Dry Mortar Plonl Process

3.3.3

Source:TPA

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Concrete Puver Plant

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It is proposed to construct a concrete block pavers plan! with internal staff

facilities to produce up to 100,000 tonnes of concrete paving slabs per
annum. The main elements incfude the feed hopper for limestone and s a n d ,
the fluidised bed dryerjcooler, block forming machine, conveyors and silos for
storage of product.
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The paving block plant is a high volume production process and will produce
a variety of different paving block ranges. The entire mixing process is totully
automated to ensure consistency of manufacture and orderly storaye u r d
curing of the blocks.

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The aggregates for production are delivered b y truck from the on-sitequarry
into Q ground feed hopper from which each material is fed into covered
storage bins. A butching system dispenses the exact quantity of each
material by measuring the weight of the aggregate with loud cells beneath
the conveyor. The mixed aggregates ore transferred into a holding hopper
above the concrete mixer. Cement is fed to the mixer and water is added in
a carefully controlled way so that the resutting concrete hus the correct
moisture content and consistency. Pigment is udded to the mix during the
mixing process.

EnvironmentalImpact Statement.
Lagan Cement Ltd, Kinnegad,Co. Meath.

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At the start of the moulding process, a palette is moved into position in t h e

block press, the mould-boxis lowered onto the palette and the feed drawer
fills the mould box with mixed concrete. Flat compaction heuds are lowered
onto the mould and vibration is applied to compact the block to size. The
moutd is then lifted and the pulette containing the wet paving block moves
down the production line.

Palettes containing the formed paving blocks are moved to a storage

elevator. When the storage elevator is full, a finger car automatically lifts the
palettes and transfers them to one of the curing chambers. During the
following 24 hour period, the heat developed b y the hydration of the cement
cures the paving blocks. The curing chambers are highly insulated to contain
the heat and humidity produced during the curing cycle.

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After curing, the puving blocks sre transferred to areas where the product is
continually inspected and sampled for laboratory testing. Hydraulic grabs lift
the blocks from the palette and stack them into cubes which are strapped
and wrapped for protection during storage. Each cube is individually tagged
with both a tracking code and a product description prior to being moved
from the conveyor forstorage in the yard. The blocks are kept in storage until
the appropriate strengths Rave developed. An indicative diagram showing
the concrete pavers plant process is outlined in figure 2 below.

Figure 2 - lndicotive Concrete Fsver Plant Pmcery

Source.TPA

Environmental Impact Statement.

Luguri Cernenl Lld, Kinnegod. Co. Meath.

EPA Export 23-01-2007:02:17:11

3.3.4

Roof Tile Plant

It is proposed to construct a roof tile plant with internal staff facitities to
produce up to 50,000tonnes of roof tiles per annum. The main dements of
the plant are the screen, holding hopper & weighing system, concrete mixer
and the tile extruder. The aggregates for production are delivered b y truck
into a ground feed hopper from which each material is fed into covered
storage bins.

The aggregates then go through a screen and up to the Holding Hopper

where they are then weighed and blended together in the mixer. Cement is
brought up to the mixer by meum of a cement screw. The Cement is
discharged into the mixer and pigment is added. A hydronix system then
takes a moisture reading and water is then added to the settings required.
As the tile mould is fed towards the extruder fA tile extruder is a device that
pumps unset concrete hough a die. The type of die determines the size and
shape of the tile] it is sprayed with release oil. Over spray from the release oil is
filtered and put back into the release oil tank. The mix is then dropped into U
hopper above a conveyor and fed to the Tile Extruder. The tiles are then
loaded and pushed into the Rotary Carousel to cure. The Rotary is a insulated
chamber with a rotating chamber inside used for setting fhe concrete tiles.
The tiles are conveyed into the chamber where they are introduced to high
temperature steam. The tile then set very quickly in the presence of
temperature and steam.
Each ruck on the Rotary Carousel holds 200 tiles which, when cured, are then
gushed out by the Cured tite pusher onto U conveyor.

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The tiles are then fed towards the depalleter. The tile is split from the mould
and the mould is fed bock round to the Tile Extruder. The tiles ore then senf in
another direction to the Coating Booth before being stored for transport. An
indicative diagram showing the roof tile plant process is outlined in figure 3
below.

Environmental Impact Statement.

Lagan Cement Ltd, Kinnegad, Co. Meath.

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T-

Drying and Curing

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fiaure 3 - Indicative Roof Tile Plunt Process

3.3.5

Source: TPA

Admlnlsfratfon Building

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It is also proposed to construct a 348sq.m administration building thut will

include infernal sfaff facilities such as chunging rooms, toilets and a kitchen
area, staff offices, a laboratory for product testing and meeting worn$. This
administration building will cater for 011 the needs of employees of t h e
concrete products production area and ensures that the development will be
independent of the rest of the cement plant.
Aggrcgotc Storage Bays, Product Storage Area, Weighbridge, Car Parking and

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3.3.1

Amendments to Width of Permitted landscaping Barriers

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Aggregate materials are contained in storage buys at the site to minimire dcirt
generated in windy conditions. The development also proposes c. 6.85 ha of
product storage area which includes c. 2.7 ha of hardcore covered area os
overflow storage space, a weighbridge identical to the one already present
on the Lagon Cement Ltd. site and car parking tu cuter for Itie e x t m stuff
employed in the plants and administrotion building. It is also proposed to
amend part of the landscape barrier north of the Coricrele Products
Production Area. This amendment will not affect the height of the permitted
barrier. The earthen barrier is proposed to be made less wide but !his will nut
alter its effectiveness as a visual impact barrier.

Environmental Impact Statement.

Lagun Cement Itd. Kinnegad, Co. Meath.

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3.4

RAW MATERIAL REQUIREMENTS FOR THE PROPOSED DEVELOPMENT

The proposed increase in Cement production will require an increase in raw

material production rates from the permitted Limestone Quarry over that
stated in the 2004 Environmental Impact Statement {Meath County Council
Reg. Ref.: TA/40228 and IPC Licence Register No.: PO-487-03). The proposed
increase in annual raw rnateFialrequirements will be as futlows:
Increase In Cement plant Capaciiy

On Site Limestone
Aggregate

100,Ooo tpa

100,OOO tpa

TOTAL

3.5

Concrete Products Production Area

On Site Cement
I 37,000tpa
On Site Lime
8,000 tpa
On Site Limestone Aggregate
O n Site Limestone Sand
Imported Additives

Imported Piamenfs
TOTAL

CUMULATIVE TOTAL

320.000 h a

6 1,660 tpa
113,000 tpa
190 tpa
150 tpa
220.000tpa

I
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QUARRY DESIGN
The increased rate of production will not affect the location or final geometry
of the permitted Limestone Quarry. The overall permitted site layout and the
location of the Limestone Quarry during the eorly phases of operalions ore
shown in Figure 8.2 in chapter 8 of this EIS.
In effect, the variution from the currentty permitted development is the
increased rote production, arising from the improvement in capacity and
efficiency of the plant and t h e requirement jo provide raw rnoteriats for the
proposedconcrete products facilities.

3.5.1

Limestone Quarry

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The Limestone Quarry provides the principal raw material for cement
manufacture. The proposed increase in kiln output and production of
concrete products will require that the quarry production rate be increased
by one fhird.
The working limits and finat levels of the Limestone Quarry will be unchanged
from the permitted 2004 scheme. The increased productionrate of limestone
will have no adverse implications for sbps stability.

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Frequency of blasting wilt not increase. The rock take from each individual
blast will be increased in order lo meet the increased demand for
aggregates.Vibration and uir over pressure will be kept to within existing EPA
permitted limits. Noise and vibration issues relating to blasting and other
quarrying activities are discussed in Chapter 1 1 in this EIS.
Quarry uctivities will accommodate the increase in output by increasing the
size rather fhan the number of items of plant within the current operating
hours. A primary crusher will be located in the quarry floor, ond limestone will
be transported to the secondary crusher and plant area by a covered
conveyor. The primary crusher and conveyor system are already in ptoce ond
have sufficient capacity to accommodate the increused rate of production.
Envlroxental Impact Slafemcnt.
Logan Cernenl Lid. Kinnegad,CO.Meath.

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3.5.2

Quarry Reserve Life

The direction of working and phasing of excavation in the limestone quarry will
be unchanged from the 2004 EIS.

She life of the Reef Limestone reserves will decrease as a result of the
increased kiln production rates and concrete products production and
specificalty, as a consequence of the raw material requirement rates given in
Section 3.4. The permitted reserve life of the Limestone Quarry wilt be reduced
from 34.6 years with the permifted production rate, to 22.6 years at the
proposed increased rates of extraction.

It is important fo note that the reserve life of 22.6 years is only the reserve life of
the permitted extraction area. There is well in excess of 100 years reserve life
in the quarry and its immediate surroundings that has not been proposed for
extraction as yet and extensions to the permitted extraction area and the
depth will be the subject of future planning applicationswhen necessary.
3.5.3

Water Hundling Arrangements

These will be undertaken in the same fashion as proposed in the original EIS
and permitted in the original planning application for the whole cement works
project (Meoth County Council Reg. Ref. 98/2026. The workings will not be
deeper, or more extensive, ut full depth than in the original proposal.
Water will be pumped from quarry sumps directly to the settlement lagoon at
the northern end of the site for treatment (as previously permitted). In thc
event of storm flows etc., water would either be held in the quurry void(s) or
pumped to the attenuation pond for the controlled discharge into the
set Ilement fagoon.

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Groundwater monitoring will remain u s proposed und permitted for the

original mineral workings.

rnvironmental lrnpflct Statement.

logan Cemenl Ltd, Kinnegad,Co. Meath.

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