Document Ex37zvq6dyedpzLEyp4vVNR7V

DATE: UNITED STATES ENVIRONMENTAL PROTECTION AGENCY REGIONS 77 WEST JACKSON BOULEVARD CHICAGO, IL 60604 OCT 1 8 2019 SUBJECT: FROM: CLEAN AIR ACT INSPECTION REPORT Brampton Brick, Inc., Farmersburg, Indiana Charles Hall, Environmental Engineer L.~1J AECAB (MN/OH) THRU: Brian Dickens, Section Chief AECAB (MN/OH) TO: File, Brampton Brick, Inc., Farmersburg, Indiana BASIC INFORMATION Facility Name: Brampton Brick, Inc. Facility Location: 1256 East County Road 950 North, Farmersburg, Indiana Date of Inspection: 23 September 2019 EPA Inspector: l. Charles Hall, Environmental Engineer Other Attendees: 1. Daniel Roos, Air Compliance Manager, Indiana Department of Environmental Management 2. Mike Rixner, U.S. Technical Services Manager, Brampton Brick, Inc. 3. Chris Egge, Plant Manager, Brampton Brick, Inc. 4. Jared Epple, Staff Scientist, Patriot Engineering and Environmental, Inc. Contact Email Address: mrixner@bramptonbrick.com Purpose of Inspection: Inspection of brick manufacturer Facility Type: clay brick manufacturer Arrival Time: I 300 hours EDT Departure Time: 1515 hours EDT 1 of 3 Inspection Type: 0 Unannounced Inspection Announced Inspection OPENING CONFERENCE ~ Credentials Presented 0 CBI warning to facility provided The following information was obtained verbally from Rixner, Egge, and Epple unless otherwise noted, Process Description: Brampton's process has four basic steps: quarrying clay and shale; primary processing operations; secondary processing operations; and brick manufacturing. Brampton's qnaJTy is on-site. The primary processing operations consist of primary crushing of the shale and clay. The secondary processing operations include secondary grinding and screening of the shale and clay. Brampton uses numerous conveyor belts to move material between the crushing and screening operations. Brampton then mixes water with the processed shale and clay, and it is mixed in a pug mill. Depending on the product, Brampton may add a colorant before the raw materials enter the pug mill. Brampton then puts the mixture through a final pug mill, and removes the air from the mix, and extrudes the mixture to form a continuous column of bricks, coats the colunm with a thin layer of silica sand which prevents bricks from sticking together in the kiln, and detennines whether the slug has the desired hardness. If the brick slug has the coJTect hardness, the slug is cut into individual bricks. The bricks are loaded onto a refractory kiln car, and the cars are rolled into a holding room heated vvith waste heat fron1 the kiln for pre-drying. After pre-drying, the bricks continue through a tunnel dryer, and the car is then transported to fire in a natural gas-fired tunnel kiln. A copy of the process flow diagram is attached. TOUR INFORMATION EPA toured the facility: Yes Photos and/or Videos: were not taken during this inspection. Field Measurements: were not taken during this inspection. RECORDS REVIEW During the inspection, I reviewed an example of: Opacity records for each stack; Pressure'drop records for the combined dry lime injector and baghouse; Daily records for the dry lime feed system; Monthly records of control device bypass; and Records of the location of the origin of the clay/shale used during bypass periods. 2 of3 CLOSING CONFERENCE Requested Documents: " Process flow diagram Results section of the most recent performance tests for hydrogen chloride, hydrogen fluoride, and particulate matter ATTACHMENT Process flow diagram SIGNATURES Lead Inspector: Section Chief: CRk ~ -~~~~=-~~~------ Date ---~O~c:-{-~. l-, .-,,.,-2-0-'l-4- 10 _ __:/J3-=,Wt,::o1::.:''----'D""'-""'ceil~l""0J'-"iLl-___ _ _ _ Date: _ __ _/~9I"-'(1._~ , ' - - - - - - - - - 3 of3