SI Group AEL Variance Application (May 2021) (Amended July 2021)

CITY OF EKURHULENI
HEALTH AND SOCIAL DEVELOPMENT DEPARTMENT
APPLICATION FORM FOR ATMOSPHERIC EMISSION LICENCE/PROVISIONAL

ATMOSPHERIC EMISSION LICENCE IN TERMS OF CHAPTER 5 OF THE NATIONAL
ENVIRONMENTAL MANAGEMENT: AIR QUALITY ACT, 2004 (ACT NO. 39 OF 2004) AS
AMENDED
Ekurhuleni Air Quality Officer Tel: (011) 999 2969/70

Health and Social Development Department Fax: (011) 999 2151
P O Box 4 Email: Jerry.Chaka@ekurhuleni.gov.za
Alberton
1450
APPLICATION FORM FOR ATMOSPHERIC EMISSION LICENCE / PROVISIONAL ATMOSPHERIC

EMISSION LICENCE IN TERMS OF CHAPTER 5 OF THE NATIONAL ENVIRONMENTAL
MANAGEMENT: AIR QUALITY ACT, 2004 (ACT NO. 39 OF 2004) AND AMENDED
Name of Enterprise: SI GROUP SOUTH AFRICA (PTY) Ltd
Declaration of accuracy of information provided:

Application for an atmospheric emission licence / provisional atmospheric emission licence as envisaged in
chapter 5 of the National Environmental Management: Air Quality Act, 2004 (Act No. 39 of 2004).
I, [delegated by the Accounting Officer],

declare that the information provided in this application or attached to the application is, to the best of my
knowledge, in all respects factually true and correct. I am aware that the supply of false or misleading information
in the application form is a criminal offence in terms of section 51(1)(f) of the Act.
Signed at on this day of
SIGNATURE
CAPACITY OF SIGNATORY
TABLE OF CONTENTS
1. TYPE OF APPLICATION
2. ENTERPRISE INFORMATION
3. SITUATION AND EXTENT OF THE PLANT
3.1. Location and extent of plant
3.2. Description of surrounding land use
4. NATURE OF PROCESS
4.1. Process description
4.2. Listed activity or activities
4.3. Unit process or processes
4.4. Hours of operation
4.5. Graphical process information
5. RAW MATERIALS AND PRODUCTS
5.1. Raw materials used
5.2. Production rates
5.3. Materials used in energy sources
5.4. Sources of atmospheric emission (including all tiers of greenhouse gasses)
6. APPLIANCES AND MEASURES TO PREVENT AIR POLLUTION
6.1. Appliances and control measures
6.2. Start-up, maintenance and shut down conditions
6.3. Routine reporting and record-keeping
7. DISPOSAL OF WASTE AND EFFLUENT ARISING FROM ABATEMENT EQUIPMENT CONTROL
TECHNOLOGY
8.
9.
10.
11.
12.
1
NB: PLEASE COMPLETE ALL SECTIONS. KINDLY MARK WITH AN X IN SPACES WHERE APPLICABLE. IF THE SPACE PROVIDED
IS INSUFFICIENT, THE REQUIRED INFORMATION MAY BE SUBMITTED IN THE FORM OF A MEMORANDUM. ATTACH REQUIRED
MAPS AND SKETCHES. GRAPHICS MUST BE CLEAR, LABELED AND, WHERE APPLICABLE.
13. TYPE OF APPLICATION

14.
15. 16. New Application 17. 18. Transfer 19. 20. Section 22A
21. 22. Renewal 23. X 24. Variation/Amendment/Review 25. 26.
27.
28. Current APPA Permit / Atmospheric Emission Licence 29. 14/1/1/7/6/106/SI GROUP/ALB
Number:
30.
31. ENTERPRISE INFORMATION
32.
33. Enterprise Name 34. SI Group South Africa (Pty) Ltd
35. Trading As 36. SI Group South Africa (Pty) Ltd
37. Type of Enterprise, e.g., Company/Close 38. (Pty) Ltd
Corporation/Trust, etc
39. Company/Close Corporation/Trust 40. 1967/001278/07
Registration Number (Registration Numbers if
Joint Venture)
41. Registered Address 42. 45 – 47 Potgieter Street, Alrode, Alberton, 1451
43. Postal Address 44. P.O. Box 124206, Alrode, Alberton, 1451
45. Telephone Number (General) 46. 011 – 389 8224
47. Fax Number (General) 48. 011 – 864 3174
49. Industry Type/Nature of Trade 50. Chemical Industry
51. Land Use Zoning as per Town Planning 52. Industrial
Scheme
53. Land Use Rights if outside Town Planning 54. -
Scheme
55.
56. Responsible Person Name or Emission
57. Ms. Lisa McKay
Control Officer (where appointed)
58. Telephone Number 59. 011 – 389 8215
60. Cell Phone Number 61. 083 564 5659
62. Fax Number 63. 011 – 864 3174
64. E-mail Address 65. Lisa.McKay@siigroup.com
66. After Hours Contact Details 67. 083 564 5659
68.
69.
70.
2
71.
72. SITUATION AND EXTENT OF PLANT
72.1. Location and extent of plant
73. Physical Address of the Plant 74. 45 – 47 Potgieter Street, Alrode, Alberton, 1451
75. Description of Site (Where No Street 76. ERF NO: A0800400000626 (45)
Address) 77. ERF NO: A0800400000625 (47)
78. Coordinates of Approximate Center 79. North-south: 26 ˚19’02.76’’ S, -26.317433
of Operations 80. East-west: 28 ˚07’59.26’’ E, 28.133128
81. Extent (km²) 82. 23 996m2
83. Elevation Above Mean Sea Level 84. 1570m
(m)
85. Province 86. Gauteng
87. Metropolitan/District Municipality 88. Ekurhuleni Metropolitan Municipality
89. Local Municipality 90. Ekurhuleni Metropolitan Municipality
91. Designated Priority Area 92. Highveld Priority Area
93.
93.1. Description of surrounding land use (within 5 km radius)
94. Provide a description of the surrounding land use within a 5 km radius, specifically noting the names and
proximity of residential and commercial areas in relation to the site of the works.
95. SI Group South Africa (Pty) Ltd is situated within the industrial area of Alrode within the Ekurhuleni
Metropolitan Municipality. Surrounding industries within a 5km radius include: Nadustria, Quality Coating,
Improfile 2000, Winplas, Flex Brake and Afrox. Surrounding residential areas, also within a 5km radius
include: Mayberry Park, Mapanga, Mpilisweni.
96. Attach map(s), satellite image(s) or aerial photograph(s) detailing location of premises in relation to
surrounding community.
3
97.
Figure 1: Map depicting the location of SI Group in relation to the surrounding community.
98. NATURE OF PROCESS

98.1. Process description
99. Please provide a detailed description of the entire production process including reference to the overall
balance sheet of inputs, outputs and emissions at the site of the works.
100.SI Group SA (Pty) Ltd is the world’s leading developer and manufacturer of chemical intermediates, phenolic
resins and alkylphenols. SI Group South Africa specialises in the manufacture of phenol-formaldehyde
resins, mainly for the timber, foundry and industrial resins markets. Major raw materials are phenol and
formaldehyde.
101.In total, SI Group South Africa has 5 stainless steel reaction kettles in use on the site for the manufacture of
these resins. There is one stainless steel reaction kettle previously used for sulphonation which is now a
discontinued process.
102.Resin Manufacturing
103.Resins are manufactured in specially designed reaction kettles. Resins are manufactured from varying
combinations of phenol, formaldehyde, furfuryl alcohol, sodium hydroxide, Cashew Nut Shell Liquid,
melamine, ethylene glycol, cresols and resorcinol. Not all materials are used in every product.
104.Adjustments are made with small amounts of butanol, methanol, ethanol, acids (not all are used in every
product).
105.Processes are catalysed with small quantities of sodium hydroxide, hexamine, triethylamine and
dimethylethanolamine.
106.The site currently has storage tanks for oleum, xylene and toluene, however, due to the ceasing of the
sulphonation process, these tanks and the respective materials will no longer be in use.
4
107.
108.Powder Plant
109.The raw materials are supplied in 25kg bags and loaded into the mixer. After mixing the product is packed
into bags via a screw feed. The unit is connected to a bag filter designed to capture fugitive particles from the
mixer. The pulse system on the bag-house allows the dust to be removed from the system into the baghouse
from where it is collected. The pH of the product is between 7 and 8. It is disposed of as hazardous waste by
EnviroServ, who provide safe disposal certificates.
110.Mixing Plant
111.Raw materials are added to the mixers with a pump or manually loaded. After mixing, the material is either
pumped through a pipe system to the resin plant (enclosed system) or packed into IBCs and drums using a
pump.
112.Coating Plant
113.Raw materials (liquid and powder) are pumped and manually loaded into the mixer. After mixing, the product
is packed into tins, drums and IBCs by gravity. The unit is connected to a bag filter designed to capture
fugitive particles from the mixer. The pulse system on the bag-house allows the dust to be removed from the
system into the baghouse from where it is collected. The pH of the product is between 7 and 8. It is disposed
of as hazardous waste by EnviroServ, who provide safe disposal certificates.
113.1. Listed activities
114.List all Listed Activities, as published in terms of section 21 of the National Environmental Management: Air
Quality Act, 2004 (Act No. 39 of 2004), proposed to be conducted at the premises in terms of this application:
115.Listed 116.Categor 117.Sub- 118.Name of 119.Description of the Listed Activity

Activity y of category the
Number Listed of the Listed
Activity Listed Activity
Activity
124.The production or use in production of organic
chemicals not specified elsewhere including
acetylene, acetic, maleic or phthalic anhydride
or their acids, carbon disulphide, pyridine,
formaldehyde, acetaldehyde, acrolein and its
derivatives, acrylonitrile, amines and synthetic
123.Organic rubber. The production of organometallic
Chemica compounds, organic dyes and pigments,
120.6 121.6 122.N/A surface-active agents.
ls
Industry 125.The polymerisation or co-polymerisation of any
unsaturated hydrocarbons substituted
hydrocarbon (including vinyl chloride). The
manufacture, recovery or purification of acrylic
acid or any ester of acrylic acid. The use of
toluene di-isocyanate or other di-isocyanate of
comparable volatility; or recovery of pyridine.
5
126.Despite the repeal of the Atmospheric Pollution Prevention Act, 1965 (Act No. 45 of 1965), list all Scheduled
Process(es), as was or were set out in the Second Schedule of the repealed Atmospheric Pollution
Prevention Act, 1965, currently conducted at the premises:
127.
128.
129.APPA 130.Date of 131.Scheduled 132.Scheduled Process Description

Registration Registration Process
Certificate Certificate Number
Number
133.N/A 134.N/A 135.N/A 136.N/A
136.1. Unit process
137.List all unit processes associated with the listed activities in operation at the premises by the atmospheric
emission licence holder, highlighting unit processes proposed in respect of this application:
138.Unit Process 139.Unit Process Function 140.Batch or

Continuous
Process
141.Process Reactor 1 142.Resin manufacture 143.Batch
159.Process Reactor 6 is still on site but is no longer used as the site no longer conducts a sulphonation process.
160.Tumbler 161.Powder Hardening Manufacture 162.Batch
163.Nautamixer 1 164.Powder Hardening Manufacture 165.Batch
166.Nautamixer 2 167.Powder Hardening Manufacture 168.Batch
169.Ribbon Blender 170.Powder Hardening Manufacture 171.Batch
172.Vollrath Mixer 173.Coatings Manufacture 174.Batch
175.Henschell Mixer 176.Coatings Manufacture 177.Batch
178.Potash Tank 179.Potash Manufacture 180.Batch
181.Ester Mixer 182.Ester Manufacture 183.Batch
184.Hot / Cold Mixer 185.Hot and cold blends 186.Batch
187.Activator Mixer 188.Activator Manufacture 189.Batch
190.Boiler 1 & 2 191.To supply a steam 192.Continuous
193.Steam Tray 194.Heats water to melt cresol 195.Batch
196.Nitrogen Generator 197.Nitrogen will be used to blanket tanks and reaction 198.Batch
vessels, if required
6
199. *Unit process means a single component (equipment) with identifiable inputs and outputs within a process flow. A series of
unit processes make up the full manufacturing process, for example, boiler, furnace, distillation column, etc.
200.
201.
202. Please provide any other unit processes currently conducted at the site of works.
203.Name of the Unit Process 204.Description of the Unit Process

205.Workshop 206.Maintenance.
207.Warehouse 1 208.Storage of tanks.
209.Warehouse 2 210.Flammable material.
211.Lab 212.Test raw materials and final products.
212.1. Hours of operation
213.Provide the hours of operation of all unit processes associated with the listed activities in operation at the
premises by the atmospheric emission licence holder, highlighting unit processes proposed in respect of this
application:
214.Unit Process 215.Operating Hours 216.Number of Days Operated per Year

217.Process Reactor 1 218.24 219.365 days
235.Tumbler 236.24 237.365 days
238.Nautamixer 1 239.24 240.365 days
241.Nautamixer 2 242.24 243.365 days
244.Ribbon Blender 245.24 246.365 days
247.Vollrath Mixer 248.24 249.365 days
250.Henschell Mixer 251.24 252.365 days
253.Potash Tank 254.24 255.365 days
256.Ester Mixer 257.24 258.365 days
259.Hot / Cold Mixer 260.24 261.365 days
262.Activator Mixer 263.24 264.365 days
265.Boilers 266.24 267.365 days
268.Steam Tray 269.24 270.365 days
271.Nitrogen Generator 272.24 273.365 days
7
273.1. Graphical process information
274.Attach the following for the entire operation being undertaken at the site of the works:
 Simplified block diagram with the name of each unit process in a block; showing links between all unit
processes or blocks.
 Process flow chart(s) clearly indicating inputs, outputs and emissions at the site of works, including points of
potential fugitive emissions and emergency releases.
 Site layout diagram (plan view and to scale) indicating location of unit processes, plants, buildings, stacks,
stockpiles and roads (include true north arrow and scale).
275.
276.NB: Indicate clearly on the above graphics the listed activity or activities applied for in this application.
Alternatively, provide additional graphics for the listed activity or activities applied for.
277.
278.
279. Figure 2: Powder Plant.

280.
8
281.
282. Figure 3: Resin Plant (Sulphonation process is no longer being conducted by the site).
283.
9
284.
285. Figure 4: Coating Plant.

286.
287.
Figure 5: Bulk Storage Tanks.

288.
10
289.
290. Figure 6: Resin Process.

291.
292.
11
293. Figure 7: Simplified block diagrams for the phenolic resin manufacturing process.
294.
295.
296. Figure 8: Generic process flow diagram for the phenolic resin manufacturing processes.
297.
12
298.
299. Figure 9: Aerial image depicting the infrastructure at SI Group – South Africa (Pty) Ltd.
300.
5 RAW MATERIALS AND PRODUCTS
6. Provide raw material information, production and by-production rates and emissions information.
6.1. Raw materials used
7. Regulated Raw Materials

9. Maximum Permitted 10. Actual
11. Units
8. Raw Material Type Consumption Rate Consumption Rate
(Quantity/Period)
(Quantity) (Quantity)
12. Maximum values are just double the actual consumption rates. The reason for this is just to ensure the
plant has some leeway, however, consumption rates should always be in line with the actual consumption
due to the plants operational limits.
13. formaldehyde 14. 48.8 15. 24.4 16. Tons per day
17. phenol 18. 37 19. 18.5 20. Tons per day
21. Furfuryl alcohol 22. 32 23. 16 24. Tons per day
25. Sodium hydroxide 26. 14 27. 7 28. Tons per day
29. Oleum – No longer 30. 0 31. 0 32. Tons per day
used
33. Toluene – No longer 34. 0 35. 0 36. Tons per day
used
13
37. Xylene – No longer 38. 0 39. 0 40. Tons per day
used
41. Sodium silicate 42. 6 43. 3 44. Tons per day
45. methanol 46. 14 47. 7 48. Tons per day
49. Propylol B 50. 3 51. 1.5 52. Tons per day
53. hexamine 54. 4 55. 2 56. Kg per day
57. triethylamine 58. 2 59. 1 60. Kg per day
61. Ethylene glycol 62. 60 63. 30 64. Kg per day
65. Cashew Nut Shell 66. 80 67. 40 68. Kg per day
Liquid
69. Meta/para cresol 70. 2.4 71. 1.2 72. Tons per month
73. Ortho cresol 74. 30 75. 15 76. Kg per day
77. melamine 78. < 10 79. < 5 80. Kg per day
81. resorcinol 82. 5 83. 2.5 84. Tons per month
85. Ethylol 86. 42 87. 21 88. Kg per day
89. n-butanol 90. 10 91. 5 92. Kg per day
93. Salicylic acid 94. 6 95. 3 96. Kg per day
97. Sulphuric acid 98. 4 99. 2 100.Kg per day
101.Raw Material Type 102.Maximum Permitted 103.Actual 104.Units
Consumption Rate Consumption Rate (Quantity/Period)
(Quantity) (Quantity)
105.Water 106.30 107.15.5 108.Ton/day
108.1. Production rates
109.Production Name 110.Maximum 111.Actual Production 113.Units

Production Capacity Capacity (Quantity/Period)
Permitted (Quantity) 112.(Quantity)
114.Resin manufacture 115.157 116.78.7 117.Ton/day
118.Maximum production rates are just double of the actual. The reason for this is just to ensure the plant has
some leeway in terms of compliance, however, consumption rates should always be in line with the actual
consumption due to the plants operational limits.
119.Sulphonation 120.0 121.0 122.Ton/day
123.Sulphonation process has been removed
124.
125.By-Product Name 126.Maximum 127.Actual Production 129.Units
Production Capacity Capacity (Quantity/Period)
Permitted (Quantity) 128.(Quantity)
130.Solvent distillate 131.2 132.1.4 133.Ton/day
134.Phenolic distillate 135.2 136.0.2 137.Ton/day
14
137.1. Materials used in energy sources
138. The applicant must specify the materials used in energy sources, namely, coal, oil, gas or
wood.
139.Materi 140.Sulphur 142.Ash Content 143.Maximum 144.Actual 146.Units

als for Content of of Material Permitted Consumption (Quantit
Energ the Material (%) Consumption Rate y/
y 141.(%) Rate 145.(Quantity) 147.Period)
(Quantity)
148.Natur 149.- 150.- 151.8000 152.4716 153.GJ/
al Gas annum
154.Diesel 155.0.5 156.- 157.36 000 158.18 000 159.L/annum
160.Electri 161.- 162.- 163.N/A 164.1 395 443 165.kWh/
city annum
166.
15
166.1. Sources of atmospheric emission (including all tiers of greenhouse gas)
167. Provide emissions averaging periods that correspond to the averaging periods as set out in the national ambient air quality standards published under Government Notice
No. 1210, Gazette No. 32816 dated 24 December 2009, and/or the minimum averaging periods of the relevant pollutant in relation to its health impact.
167.1.1. Point source parameters
168.Uniq 169.Source Name 170.Latitude 171.Longitude 172.Height of 173.Height 174.Diameter 175.Actual Gas 176.Actual Gas 177.Actual Gas
ue (decimal (decimal Release Above at Stack Exit Volumetric Exit
Stac degrees) degrees) Above Nearby Tip / Vent Temperatur Flow Velocity
k ID Ground Building Exit (m) e (°C) (m³/hr) (m/s)
(m) (m)
178.SIG 179.Scrubber Stack - MS 180.-26.316857 181.28.133153 182.3.5 183.0 184.0.26 185.15 186.157.29 187.0.82
001 (Adjacent)
188.Non-regulated point sources.
191.26º19'0.67" 192.26º19'0.67" 194.1 195.0.54 196.161.3 197.2 874.91 198.6.80
189.BS1 190.Boiler Stack One 193.4
S S
201.26º19'0.67" 202.26º19'0.67" 204.3 205.0.25 206.N/A(1) 207.N/A(1) 208.N/A(1)
199.BS2 200.Boiler Stack Two 203.6
S S
209.
210. (1) Boiler 2 is only used as a backup boiler and therefore no stack testing has been done.
211.
212. *Point source means a single identifiable source and fixed location of atmospheric pollution, e.g., stack, chimney, etc.
16
213. 5.4.2 Point Source Emissions
214. Provide emission values as being measured under normal conditions of 273 K, 101.3 kPa, specific oxygen percentage and dry gas.
215.As per 216.Pollutant 217.Maximum Release Rate 218.Emissions Hours 219.Type of Emissions
5.4.1 Name (Continuous /
222. 225. 228. 232.
ID Routine but
223. 226. 229. 233. Intermittent /
224.(mg/Nm³) 227.(mg/Am³) 230.g/s 234.Averaging period Emergency Only)
231.
238.Sulphur
Trioxide 239.0.19 240.0.15 241.0.000007 242.3 x 1 hour 243.24 244.Batch
(SO3)
246.Total Volatile
237.SIG00
Organic
1 247.16.54 248.13.15 249.0.0005 250.3 x 1 hour 251.24 252.Batch
Compounds
(TVOC’s)
254.Methylamines
255.0.16 256.0.13 257.0.0000054 258.3 x 1 hour 259.24 260.Batch
(CH3NH2)
263.CO 264.33.85 265.- 266.- 267.3 x 1 hour 268.24 269.Batch
262.BS1 271.NOx 272.81.88 273.- 274.- 275.3 x 1 hour 276.24 277.Batch
279.SO2 280.1.02 281.- 282.- 283.3 x 1 hour 284.24 285.Batch
286.BS2 287.N/A, Boiler 2 is only utilised as a backup for boiler 1.
17
287.1.3 Point source current emissions monitoring
288. Provide information on emission monitoring requirements.
289.As 290.Emission Sampling / Monitoring Method 291.Sampling Frequency 292.Sampling Duration 293.Measured Parameters
per
5.4.1
ID
295.US EPA Method 8 296.Annually 297.1 x 3 Hourly Tests 298.Sulphur Trioxide (SO3)
294.SIG0
300.US EPA Method 18 301.Annually 302.1 x 3 Hourly Tests 303.Total Volatile Organic Compounds (TVOC’s)
01
305.OSHA Method 40 306.Annually 307.1 x 3 Hourly Tests 308.Methylamines (CH3NH2)
311.US EPA Method 10 312.Annually 313.1 x 3 Hourly Tests 314.Carbon Monoxide
310.BS1 316.US EPA Method 6C 317.Annually 318.1 x 3 Hourly Tests 319.Sulphur Dioxide
321.US EPA Method 7E 322.Annually 323.1 x 3 Hourly Tests 324.Oxides of Nitrogen
(
325.BS2
2) 326.Boiler 2 is only utilised as a backup for boiler 1.
327. (2) The same parameters shall apply to BS2 should it be tested.
328.
328.1.1. Point source emission estimation information
329.As per 330.Basis for Emission Rates

5.4.1
ID
331.N/A 332.N/A
18
332.1.1. Area and/or line source parameters
333.Uni 334.Source Name 335.Source Description 336.Latitude 337.Longitude 338.Height of 339.Length of 340.Width of 341.Angle of
que (decimal (decimal Release Area (m) Area (m) Rotation
Are degrees) of degrees) of Above from True
a SW corner SW corner Ground (m) North (°)
So
urc
e
ID
342.TR 343.Tank 344.Phenol 345.-26.316711 346.28.133261 347.7.5 348.10 349.9 350.120°
1
351.TR 352.Tank 353.Phenol 354.-26.316711 355.28.133261 356.7.5 357.10 358.9 359.120°
2
360.TR 361.Tank 362.Formalin 363.-26.316711 364.28.133261 365.8 366.10 367.9 368.120°
3
369.TR 370.Tank 371.Formalin 372.-26.316711 373.28.133261 374.8 375.10 376.9 377.120°
4
378.TR 379.Tank 380.Furfuryl Alcohol 381.-26.316711 382.28.133261 383.9 384.10 385.9 386.120°
5
387.TR 388.Tank 389.Oleum 390.-26.316711 391.28.133261 392.7 393.10 394.5.6 395.120°
6
396.TR6 is still located on site but is no longer being used
397.TR 398.Tank 399.Xylene 400.-26.316711 401.28.133261 402.4 403.10 404.5.6 405.120°
7
407.TR 408.Tank 409.Toluene 410.-26.316711 411.28.133261 412.4 413.10 414.5.6 415.120°
8
19
So
urc
e
ID
417.TR 418.Tank 419.Sodium Silicate 420.-26.316711 421.28.133261 422.5 423.8 424.4.4 425.120°
9
426.TR 427.Tank 428.Sodium Silicate 429.-26.316711 430.28.133261 431.6.4 432.8 433.4.4 434.120°
10
435.TR 436.Tank 437.Methanol 438.-26.316711 439.28.133261 440.6.73 441.- 442.- 443.120°
11 (underground)
444.TR 445.Tank 446.Propylol B 447.-26.316711 448.28.133261 449.4 450.10 451.5.6 452.120°
12
453.TR 454.Tank 455.Sodium Hydroxide 456.-26.316711 457.28.133261 458.4.5 459.4.5 460.2.5 461.120°
13 (Caustic)
462.TF 463.Tank 464.Alkaline Phenolic Resole 465.-26.316711 466.28.133261 467.6 468.19 469.9.6 470.250°
1
2
3
4
498.GN 499.Generator 500.Diesel 501.-26.316711 502.28.133261 503.12 504.4 505.1.5 506.110°
507.VP 508.Vacuum pump 509.Resins 510.-26.316711 511.28.133261 512.10 513.20 514.12 515.90°
S1 system
20
So
urc
e
ID
516.VP 517.Vacuum pump 518.Acids / Sulphonation 519.-26.316711 520.28.133261 521.10 522.20 523.12 524.90°
S2 system
525.VPS2 was part of the sulphonation process which is no longer being done on the site.
526.CP 527.Coating Plant 528.Manufacture of resins for 529.-26.317011 530.28.132822
531.10 532.20 533.15 534.30°
coating applications.
535.PP 536.Powder Plant 537.Manufacture of powdered 538.-26.316678 539.28.132669
540.10 541.20 542.15 543.45°
phenolic resins.
*Area source means air pollution source from a specified area, e.g., pollution from a landfill site, fugitive dust from a process.
*Line source means a moving source of pollutants, e.g., motor vehicles.
543.1.1. Area and/or line source emissions
544.As 545.Pollutant Name 546.Maximum Release 547.Average Annual 548.Emission Hours 549.Type of Emission 550.Wind Dependent
per Rate (quantity per Release Rate (Continuous / (Yes / No)
5.4.5 period) (quantity per Intermittent)
ID period)
551.TR11 552.VOC 553.150mg/m3 (TVOC) 554.0.46 mg/m3 555. 24 Hours 556.Intermittent 557.Yes
558.TR21 559.VOC 560. 150mg/m3 561. 0.46 mg/m3 563.Intermittent 564.Yes
(TVOC)
562. 24 Hours

(TVOC)
569. 24 Hours

(TVOC)
576. 24 Hours
21
ID period)
583. 24 Hours
(TVOC)
588. 150mg/m3
586.TR61 587.VOC 589. 0.46 mg/m3 590. 24 Hours 591.Intermittent 592.Yes
(TVOC)
593.TR6 is no longer in use.
594.TR71 595.VOC 596. 150mg/m 3
597. 0.46 mg/m3 599.Intermittent 600.Yes
598. 24 Hours
(TVOC)
602.TR8 1
603.VOC 604. 150mg/m 3
606. 24 Hours
(TVOC)
610.TR91 611.VOC 612. 150mg/m 3
614. 24 Hours
(TVOC)
(TVOC)
621. 24 Hours

628. 24 Hours
(TVOC)
635. 24 Hours
(TVOC)
642. 24 Hours
(TVOC)
645.TF11 646.VOC 647.150mg/m3 (TVOC) 648. 0.46 mg/m3 649. 24 Hours 650.Intermittent 651.Yes
652.TF21 653.VOC 654. 150mg/m 3
655. 0.46 mg/m 3
657.Intermittent 658.Yes
(TVOC)
656. 24 Hours
659.TF31 660.VOC 661. 150mg/m3 662. 0.46 mg/m3 664.Intermittent 665.Yes

(TVOC)
663. 24 Hours
666.TF41 668. 150mg/m3 669. 0.46 mg/m3 671.Intermittent 672.Yes

667.VOC
(TVOC)
670. 24 Hours
22
ID period)
673.GN 675.0.05mg/m3 676.- 678.Intermittent 679.Yes
674.SO2 677. 24 Hours
(Sulphur Dioxide)
680.VPS1 681.VOC 682.150mg/m3 (TVOC) 683.0.46 mg/m3 685.Intermittent 686.Yes
1 684.24 Hours
689.100mg/m3
687.VPS2 688.SO3 (Acids/Sulphonatio 690.0.19mg/Nm3 691.24 Hours 692.Intermittent 693.Yes
n)
694.VPS2 was part of the sulphonation process which is no longer being done on the site.
695.CP 696.DUST/ VOC’s 697.Enclosed system 698.Enclosed system 699.Enclosed system 700.Enclosed system 701.Enclosed system
702.PP 703.DUST/VOC’s 704.Enclosed system 705.Enclosed system 706.Enclosed system 707.Enclosed system 708.Enclosed system
1
Passive sampling of the TVOC’s emissions is currently taking place on a quarterly basis at the fence line of the property. The combined TVOC concentrations, measured during 2020 revealed an overall TVOC average
concentration of 0.46 mg/m3.
709.
23
709.1.1. Area and/or line source – management and mitigation measures
Provide information on management and mitigation measures.
710.As per 5.4.5 711.Description of Specific Measures 712.Timeframe for 713.Method of Monitoring 714.Contingency Measure
ID Implementation of Measure Effectiveness
Specific Measures
715.TR1 (Phenol 716.Leak detection and VOC program. 717.Immediately 718.Visual inspection and 719.Repair and / or replace
Tank) fence line monitoring. defective tanks.
720.TR2 (Phenol 721.Leak detection and VOC program. 722.Immediately 723.Visual inspection and 724.Repair and / or replace
725.TR3 726.Leak detection and VOC program. 727.Immediately 728.Visual inspection and
729.Repair and / or replace
(Formalin fence line monitoring.
defective tanks.
Tank)
(Formalin fence line monitoring.
defective tanks.
Tank)
735.TR5 (Furfuryl 736.Leak detection and VOC program. 737.Immediately 738.Visual inspection and
Alcohol fence line monitoring.
defective tanks.
Tank)
740.TR6 (Oleum 741.Leak detection and VOC program. – Tank is no longer in use. 742.Immediately 743.Visual inspection and 744.Repair and / or replace
745.TR7 (Xylene 746.Leak detection and VOC program. – Tank is no longer in use. 747.Immediately 748.Visual inspection and 749.Repair and / or replace
750.TR8 751.Leak detection and VOC program. – Tank is no longer in use. 752.Immediately 753.Visual inspection and
(Toluene fence line monitoring.
defective tanks.
Tank)
755.TR9 (Sodium 756.Leak detection and VOC program. 757.Immediately 758.Visual inspection and 759.Repair and / or replace
Silicate) fence line monitoring. defective tanks.
24
Specific Measures
(Sodium fence line monitoring.
defective tanks.
Silicate)
(Methanol fence line monitoring.
defective tanks.
Tank)
(Propylol B fence line monitoring.
defective tanks.
Tank)
(Sodium fence line monitoring.
Hydroxide
defective tanks.
(Caustic
Tanks)
780.TF1 (Alkaline 781.Leak detection and VOC program. 782.Immediately 783.Visual inspection and
Phenolic fence line monitoring.
defective tanks.
Resole)
defective tanks.
Resole)
defective tanks.
Resole)
defective tanks.
Resole)
800.GN (Diesel 801.Leak detection and VOC program. 802.Immediately 803.Visual inspection and 804.Repair and / or replace
defective tanks.
25
Specific Measures
Tank) fence line monitoring.
805.VPS1 806.Leak detection and VOC program. 807.Immediately 808.Visual inspection and
(Resins fence line monitoring.
defective tanks.
Tank)
810.CP 811.Floors must be swept on a daily basis to keep it dust free. 812.Immediately 813.Visual Inspections 814.Regular replacement of
filter bags.
815.PP 816.Floors must be swept on a daily basis to keep it dust free. 817.Immediately 818.Visual Inspections 819.Regular replacement of
filter bags.
819.1.1. Area and/or line source emission estimation information
820.As per 5.4.5 ID 821.Basis for Emission Rates

822.TR1 823.Annual passive sampling on the fence line for TVOCs – averaged from four (4) monitoring periods conducted in 2020.
26
820.As per 5.4.5 ID 821.Basis for Emission Rates
848.TF1 849.Annual passive sampling on the fence line for TVOCs – averaged from four (4) monitoring periods conducted in 2020.
856.GN 857.Annual passive sampling on the fence line for TVOCs – averaged from four (4) monitoring periods conducted in 2020.
858.VPS1 859.Annual passive sampling on the fence line for TVOCs – averaged from four (4) monitoring periods conducted in 2020.
860.CP 861.N/A
862.PP 863.N/A
864.
865.APPLIANCES AND MEASURES TO PREVENT AIR POLLUTION
865.1. Appliances and control measures
866.Provide information on appliances and measures implemented to prevent air pollution for the entire operation at the site of the works, highlighting information for listed activity or
activities proposed in respect of this application.
867.Appliances 868.Abatement Equipment Control Technology

869.Associate 870.Appliance 871.Appliance 872.Appliance 873.Abatement 874.Abatem 875.Abatement 876.Commissi 877.Date of 878.Design 879.Minimum 881.Minimum
d Unique / Process Type / Serial Equipment ent Equipment on Date Significant Capacity Control Utilization
Stack ID Equipme Description Number Manufactu Equipme Technology Modificatio Efficiency 882.(%)
nt re Date nt Name Type n/ 880.(%)
Number and Upgrade
Model
885.Vacuum 887.2014-08- 888.FCS- 889.Wet 890.2017-08- 891.2017-08-
883.SIG001 884.SIG/001 886.SIG/N010 892.294m3/hr 893.99 894.100
System 13 1081 Scrubber 01 01
27
867.Appliances 868.Abatement Equipment Control Technology
869.Associate 870.Appliance 871.Appliance 872.Appliance 873.Abatement 874.Abatem 875.Abatement 876.Commissi 877.Date of 878.Design 879.Minimum 881.Minimum
d Unique / Process Type / Serial Equipment ent Equipment on Date Significant Capacity Control Utilization
Stack ID Equipme Description Number Manufactu Equipme Technology Modificatio Efficiency 882.(%)
nt re Date nt Name Type n/ 880.(%)
Number and Upgrade
Model
895.Non-point source abatement equipment.
898.Liquid 899.AE80445 900.2014-08-
902.Dry Bag 903.2017-08- 904.2017-08- 905.700 m2
896.N/A 897.DBF1 Coating CACFE10 13 901.DBF1 906.100 907.100
Filter 01 01 Air Flow
Plant 68
910.Powder 911.AE80334 912.2014-08-
914.Dry Bag 915.2017-08- 916.2017-08- 917.700 m2
908.N/A 909.DBF2 Blending CACFE10 13 913.DBF2 918.100 919.100
Filter 01 01 Air Flow
Plant 67
28
919.1. Start-up, maintenance and shut-down conditions
920.List potential start up, maintenance, shut down, upset conditions and associated responses related to the operations at the site of the works, highlight possible releases and responses
for the proposed listed activity or activities in respect of the current application.
921.Unit Process 922.Description of Occurrence of Potential 923.Pollutants and 924.Briefly Outline Back Up Plan
Releases associated amount of
emissions
925.Boiler 926.Water from boiler drainage for maintenance 927.SO2 928.Water released into effluent system and treated to fall within
purposes. municipal specifications.
929.Formaldehyde holding tank 930.Formaldehyde residue / build-up in holding 931.VOC’s 932.Tanks set at constant temperature and fitted with side agitators to
tanks. prevent build up.
934.Start-up - ensure water level is adequate 935.VOC’s
937.Check water level.
936.
939.Maintenance - ensure water level fall in 940.VOC’s 942.If water level is below low-level valve, top up. If above high -level
933.Reactor Scrubber between high- and low-level valves valve, drain out to correct level.
941.
944.Shut down - ensure water supply valve is 945.VOC’s
closed 947.Ensure water supply valve is functional and closed.
946.
29
947.1. Routine reporting and record-keeping
947.1.1. Complaints register
948.Is a complaints register maintained at the site works?
949. 950.Ye 951.

X s
952. 953.No 954.
955. 956.To be initiated, by date:
957.
958.Please provide a copy of complaints received and corrective actions taken over the past two years.
959.
960. 961.Nature of complaints 962.Actions taken to investigate 963.Causes of complaints 964.Measures taken to avoid
complaints identified reoccurrences in instances
where the plant’s operations
were found to be the cause
966.
965.Current
967.None 969.None 970.None 971.None
year
968.
973.
972.Previous
974.None 976.None 977.None 978.None
year
975.
979.
980.
981.
982.
30
983.
7. DISPOSAL OF WASTE AND EFFLUENTS ARISING FROM ABATEMENT EQUIPMENT CONTROL TECHNOLOGY
984.
985.Provide the following information for any waste and effluent arising from abatement equipment control technology that are currently in place at the site of the
works:
986.
987.Unique Stack or Area ID 989.Waste / Effluent Type 990.Hazardous Components Present 991.Method of Disposal
988.(As per 5.4.1 or 5.4.5
above)
992.SIG001 993.Sludge 994.None 995.Authorised waste landfill disposal.
996.DBF1 997.Dust 998.None 999.Recycled in process.
1000. DBF2 1001. Dust 1002. None 1003. Recycled in process.
31
1004.

SI Group AEL Variance Application (May 2021) (Amended July 2021)

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SI Group AEL Variance Application (May 2021) (Amended July 2021)

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CITY OF EKURHULENI

HEALTH AND SOCIAL DEVELOPMENT DEPARTMENT

APPLICATION FORM FOR ATMOSPHERIC EMISSION LICENCE/PROVISIONAL

Ekurhuleni Air Quality Officer Tel: (011) 999 2969/70

APPLICATION FORM FOR ATMOSPHERIC EMISSION LICENCE / PROVISIONAL ATMOSPHERIC

Name of Enterprise: SI GROUP SOUTH AFRICA (PTY) Ltd

Declaration of accuracy of information provided:

I, [delegated by the Accounting Officer],

Signed at on this day of

13. TYPE OF APPLICATION

93.1. Description of surrounding land use (within 5 km radius)

98. NATURE OF PROCESS

113.1. Listed activities

115.Listed 116.Categor 117.Sub- 118.Name of 119.Description of the Listed Activity

129.APPA 130.Date of 131.Scheduled 132.Scheduled Process Description

136.1. Unit process

138.Unit Process 139.Unit Process Function 140.Batch or

203.Name of the Unit Process 204.Description of the Unit Process

212.1. Hours of operation

214.Unit Process 215.Operating Hours 216.Number of Days Operated per Year

279. Figure 2: Powder Plant.

285. Figure 4: Coating Plant.

Figure 5: Bulk Storage Tanks.

290. Figure 6: Resin Process.

5 RAW MATERIALS AND PRODUCTS

6.1. Raw materials used

7. Regulated Raw Materials

108.1. Production rates

109.Production Name 110.Maximum 111.Actual Production 113.Units

139.Materi 140.Sulphur 142.Ash Content 143.Maximum 144.Actual 146.Units

167.1.1. Point source parameters

288. Provide information on emission monitoring requirements.

328.1.1. Point source emission estimation information

329.As per 330.Basis for Emission Rates

543.1.1. Area and/or line source emissions

565.TR31 566.VOC 567. 150mg/m3 568. 0.46 mg/m3 570.Intermittent 571.Yes

572.TR41 573.VOC 574. 150mg/m3 575. 0.46 mg/m3 577.Intermittent 578.Yes

624.TR111 625.VOC 626. 150mg/m3 627. 0.46 mg/m3 629.Intermittent 630.Yes

659.TF31 660.VOC 661. 150mg/m3 662. 0.46 mg/m3 664.Intermittent 665.Yes

666.TF41 668. 150mg/m3 669. 0.46 mg/m3 671.Intermittent 672.Yes

Provide information on management and mitigation measures.

819.1.1. Area and/or line source emission estimation information

820.As per 5.4.5 ID 821.Basis for Emission Rates

867.Appliances 868.Abatement Equipment Control Technology

948.Is a complaints register maintained at the site works?

949. 950.Ye 951.

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