Document 4JjogYaxn7akp5Vmp2xMqoN0R
DATE: SUBJECT: FROM:
THRU:
TO:
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY REGIONS
77 WEST JACKSON BOULEVARD CHICAGO, ILLINOIS 60604
MAR 1 9 2019
CLEAN AIR ACT INSPECTION REPORT IKO Midwest, Inc., Kankakee, Illinois
Dakota Prentice, Environmental Engineer AECAB (IL/IN)
Nathan Frank, Section Chief AECAB (IL/IN)
File
BASIC INFORMATION
Facility Name: IKO Midwest, Inc.
Facility Location: 235 West South Tee Drive, Kankakee, Illinois
Date of Inspection: March 12, 2019
EPA Inspector(s): 1. Dakota Prentice, Environmental Engineer
Other Attendees 1. Chad Hertz, Plant Engineer - IKO Midwest, Inc.
Contact Email Address: Chad Hertz - chad.hertz@iko.com
Purpose of Inspection: to determine compliance with the facility's Federally Enforceable State Operating Permit issued by Illinois EPA.
Facility Type: Asphalt Roofing Material Manufacturing Plant
Regulations Central to Inspection: The facility is subject to multiple federal rules, including the National Emission Standards for Hazardous Air Pollutants for Area Sources: Asphalt Processing and Asphalt Roofing Manufacturing at 40 C.F.R. Part.63, Subpart AAAAAAA (NESHAP AAAAAAA).
Arrival Time: 10:15 AM Departure Time: 11 :30 AM
Inspection Type: !SJ Unannounced Inspection
D Announced Inspection
OPENING CONFERENCE
!SJ Credentials Presented !SJ CBI warning to facility provided
The following information was obtained verbally from Mr. Hertz unless otherwise noted.
Process Description: The facility produces asphalt roofing material consisting of either an asphalt shingle underlayment product at the Mod Line or asphalt shingles at the Shingle Line.
Asphalt used in shingle production is first modified in blowing stills utilizing ferrous chloride catalyst. Asphalt used in underlayment production does not go to the blowing stills, but to separate tanks to allow for modification by adding other compounds such as rubber. The asphalt then moves to either the Shingle Line or the Mod Line where it is applied to a continuous fiberglass mat at a coater unit. The Shingle Line moves from the coater to granule application, cooling, final processing, cutting, and packaging for shipment. The Mod Line moves from the coater to limestone application, final processing, and packaging for shipment. Additional onsite processes include limestone crushing.
Staff Interview: Mr. Hertz stated that initially the facility had difficulties maintaining the temperature at the mist eliminators below the setpoint required for regulatory compliance. The mist eliminators were then modified to reduce the operating temperature by changing their color and adding a water spray system. Mr. Hertz also noted that the Mod Line is new to the facility and is not operating at full capacity.
TOUR INFORMATION
EPA toured the facility: Yes
Data Collected and Observations: EPA walked the Shingle Line and Mod Lines. At the Mod line, the capture hood at the coater was only partially installed. Mr. Hertz informed EPA that the hood would be completed in the future.
Photos: were taken during the inspection. See Appendix A - photographs claimed to be confidential business information
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Field Measurements: were not taken during this inspection.
CLOSING CONFERENCE
Requested documents: Most recent stack performance test at each air pollution control unit Ferrous chloride usage data: annual usage from last three years and batch addition rate over last three years
Compliance Assistance: EPA provided Mr. Hertz information regarding the applicability of NESHAP AAAAAAA and the NESHAP for Asphalt Processing and Asphalt Roofing Manufacturing (NESHAP LLLLL).
SIGNATURES
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Facility Name: IKO Midwest, Inc. Facility Location: 235 West South Tee Drive, Kankakee, Illinois Date of Inspection: March I2, 2019
APPENDICES AND ATTACHMENTS
Appendix A - Photographic Lob Attachment - Confidential Business Information
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Facility Name: IKO Midwest, Inc. Facility Location: 235 West South Tee Drive, Kankakee, Illinois Date of Inspection: March 12, 2019
APPENDIX A: DIGITAL IMAGE LOG
1. Inspector Name: D. Prentice
3. Company/Facility Name:
IKO Midwest, Inc.
5. Number of Images:
4
Image Number 1 2 3 4
File Name IMG 0001.JPG IMG 0002.JPG IMO 0003.JPO IMO 0004.JPG
2. Date(s) of Inspection:
March 12, 2019
4. Street Address, City, State:
235 West South Tee Drive, Kankakee, Illinois
6. Archival Record Location:
CD-R Labeled: IKO Inspection Photos 3/12/19 - CBI
Date 3/12/2019 3/12/2019 3/12/2019 3/12/2019
Description of Image Shingle Line Hood Adhesive Application Shingle Line Hood Coater Mod Line Coater Hood Blowing Stills
Appendices Page 1 of 1