Document 5DjjpEMwD44pKKM6xpbLxJOL5

UNITED STATES ENVIRONMENTAL PROTECTION AGENCY REGION 5 77 WEST JACKSON BOULEVARD CHICAGO, ILLINOIS 60604 SUBJECT: FROM: THRU: TO: CLEAN AIR ACT INSPECTION REPORT Grain Processing Corporation, Washington, Indiana Dakota Prentice, Environmental Engineer AECAB (IL/IN) Nathan Frank, Section Supervisor AECAB (IL/IN) File BASIC INFORMATION Facility Name: Grain Processing Corporation Facility Location: 1443 South Country Road 300 West, Washington, Indiana Date of Inspection: April 5, 2022 EPA Inspector(s): 1. Dakota Prentice, Environmental Engineer 2. Victoria Nelson, Environmental Engineer 3. Tess Russell, Environmental Engineer Other Attendees: 1. Tammy Haug, Senior Environmental Manager - IDEM 2. Wendy Bouvier, Environmental Services Manager - Grain Processing Corporation 3. Shannon Dalton, Production Manager - Grain Processing Corporation 4. John Dudenhoeffer, Plant Manager - Grain Processing Corporation 5. Dylan Madden, Steep Mill Feed Department Superintendent, Grain Processing Corporation Contact Email Address: Wendy Bouvier - wendy_bouvier@grainprocessing.com Purpose of Inspection: to determine compliance with the facility's operating permit issued by the Indiana Department of Environmental Management (IDEM) Facility Type: Corn Wet Mill Page 1 of 4 Arrival Time: 2:00PM Departure Time: 5:00PM Inspection Type: Unannounced Inspection Announced Inspection OPENING CONFERENCE Presented Credentials Stated authority and purpose of inspection Provided Small Business Resource Information Sheet Small Business Resource Information Sheet not provided. Provided CBI warning to facility The following information was obtained verbally from Grain Processing Corporation (GPC) representatives unless otherwise noted. Process Description: The facility is a corn wet mill, which operates by breaking a corn kernel into fiber, germ, gluten, and starch. These components are either dried and sold or further refined or modified to produce other products. Production begins with the delivery of corn to the facility, which is stored onsite in silos. The corn is then transferred to steeping to start the kernel separation process. At steeping, corn is soaked in water with sodium bisulfite. From steeping, the material moves through a grind mill and then through a series of hydroclones and centrifuges to produce the fiber, germ, gluten (protein), and starch (carbohydrate) streams. The fiber, germ, and gluten streams are dried without significant additional modification and sold as final products. Starch is sent on for additional processing. The starch stream is used to produce three main categories of products: 1. Industrial starches; 2. Maltodextrin; and 3. Alcohol. At industrial starch production, the starch is modified in one of eight reactors to produce various starch types including acid-modified and oxidized starches which are used for multiple purposes including as a binder or glue. The modified starch is dried and sent to storage prior to shipment. At maltodextrin, the starch is reacted with acid and an enzyme, then dried and packaged for shipment. At alcohol, the starch is used as the feedstock in a batch fermentation process to produce ethanol, a majority of which is classified as beverage alcohol. Wastewater is treated onsite prior to discharge. The facility operates two anaerobic digesters. Methane gas from the digesters is collected and scrubbed to remove hydrogen disulfide. This biogas is used to fuel the germ and gluten dryers and two RTOs controlling emissions from the wet mill. Excess biogas goes to the Biogas Flare. The Biogas Flare is not steam or air assisted. Page 2 of 4 Staff Interview: The facility is currently undergoing an expansion to approximately double maltodextrin production capacity. Gluten, fiber, and germ dryers are currently controlled by scrubbers and thermal oxidizers in series. The facility is adding a wet electrostatic precipitator (WESP) in line between the scrubbers and thermal oxidizers to reduce downtime at the thermal oxidizers. TOUR INFORMATION EPA Tour of the Facility: Yes Data Collected and Observations: EPA toured specific portions of the facility including steeping and ethanol fermentation operations. At ethanol fermentation, the manway hatch at Fermentation Tank No. 3 was audibly and visibly leaking. EPA observed visible emissions from the Biogas Flare. Photos and/or Videos: were taken during the inspection. Appendix A - Digital Photo Log Appendix B - Digital Video Log Field Measurements: were not taken during this inspection. CLOSING CONFERENCE Provided U.S. EPA point of contact to the facility Requested documents: The most recent performance test at each scrubber, thermal oxidizer, and WESP at the facility Compliance Assistance: EPA recommended GPC assess the Biogas Flare operation and determine the cause of visible emissions. Concerns: EPA noted that the manway at Fermentation Tank No. 3 appeared to be leaking. Additionally, visible emissions at the Biogas Flare demonstrated poor combustion. DIGITAL SIGNATURES DAKOTA Digitally signed by DAKOTA PRENTICE Report Author: _P_R__E_N_T__IC__E___1_0_:31_:3_2_-0_5'0_0_' ____________ Date: 2022.05.03 Section Supervisor: Frank, Digitally signed by Frank, Nathan Nathan Date: 2022.05.04 16:04:50 -05'00' __________________________________ Page 3 of 4 Facility Name: Grain Processing Corporation Facility Location: 1443 South Country Road 300 West, Washington, Indiana Date of Inspection: April 5, 2022 APPENDICES AND ATTACHMENTS Appendix A - Digital Photo Log Appendix B - Digital Video Log Page 4 of 4 Facility Name: Grain Processing Corporation Facility Location: 1443 South Country Road 300 West, Washington, Indiana Date of Inspection: April 5, 2022 APPENDIX A: DIGITAL IMAGE LOG 1. Inspector Name: D. Prentice 2. Archival Record Location: Region 5 Electronic Records Center Image Number 1 2 3 4 5 6 7 File Name IMG_0031.JPG IMG_0032.JPG IMG_0033.JPG Date and Time (incl. Time zone and DST) 2022:04:05 13:17:46 2022:04:05 13:30:34 2022:04:05 13:34:01 Latitude and Longitude Not Available Not Available Not Available IMG_0034.JPG IMG_0035.JPG IMG_0036.JPG IMG_0037.JPG 2022:04:05 13:47:43 2022:04:05 14:11:17 2022:04:05 14:20:25 2022:04:05 14:30:58 Not Available Not Available Not Available Not Available Description of Image Steep Tank Steephouse Scrubber Stack Millhouse Scrubber (right), Feedhouse Scrubber (left), Thermal Oxidizer (right background) Fiber Transfer Conveyer Fermentation Tanks Fermentation Tank No. 3 Manway Biogas Flare Appendices Page 1 of 2 Facility Name: Grain Processing Corporation Facility Location: 1443 South Country Road 300 West, Washington, Indiana Date of Inspection: April 5, 2022 APPENDIX B: DIGITAL VIDEO LOG 1. Inspector Name: T. Russell (Numbers 1-13); D. Prentice (Number 14) 2. Archival Record Location: Region 5 Electronic Records Center Video Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 File Name MOV_2630.mp4 MOV_2631.mp4 MOV_2632.mp4 MOV_2633.mp4 MOV_2634.mp4 MOV_2635.mp4 MOV_2636.mp4 Date and Time (incl. Time zone and DST) 4/5/2022 4/5/2022 4/5/2022 Latitude and Longitude Not Available Not Available Not Available Not Available 4/5/2022 4/5/2022 4/5/2022 4/5/2022 Not Available Not Available Not Available Not Available MOV_2637.mp4 4/5/2022 Not Available MOV_2638.mp4 MOV_2639.mp4 MOV_2640.mp4 MOV_2641.mp4 MOV_2642.mp4 MVI_0038.MP4 4/5/2022 4/5/2022 4/5/2022 4/5/2022 4/5/2022 4/5/2022 Not Available Not Available Not Available Not Available Not Available Description of Image Steep Tank #1 Steeping Scrubber Stack Millhouse Scrubber Stack Feedhouse Scrubber Stack with RTO Stack in background RTO Stack Feedhouse Scrubber Stack, alternate perspective Outdoor roof vent Fiber Line Conveyor before and after steepwater "syrup" addition from evaporator and condenser Fiber Line Conveyor before and after steepwater "syrup" addition from evaporator and condenser Fiber Line Conveyor before steepwater "syrup" addition RTO Stack near the Ethanol Plant Manway on Fermenter #3 Manway on Fermenter #3 Biogas Flare Appendices Page 2 of 2