Document JzbaDGqZ62x8v48808pV8Q0B

DATE: SUBJECT: FROM: THRU: TO: UNITED STATES ENVIRONMENTAL PROTECTION AGENCY REGIONS 77 WEST JACKSON BOULEVARD CHICAGO, ILLINOIS 60604 OCT O2 2019 CLEAN AIR ACT INSPECTION REPORT EDCO Products Inc., Hopkins, MN Luke Hullinger, Enviromnental Engineer AECAB (MI/WI) Ethan Chatfield, Acting Section Chief AECAB (MI/WI) File BASIC INFORMATION Facility Name: EDCO Producrs Inc. Facility Location: 8700 Excelsior Blvd, Hopkins. MN Date of Inspection: 8/12/2019 EPA Inspector(s): 1. Luke Hullinger, Environmental Engineer 2. Kenneth Ruffatto, Environmental Engineer Other Attendees 1. Mike DiSimone, EHS Facilities Specialist, EDCO Products Inc. 2. Jeffrey Williams. VP of Manufacturing, EDCO Products Inc. Contact Email Address: mdesimone@edcoproducts.com and jwillian1s(a)edcoat.com Purpose of Inspection: Clean Air Act Inspection Facility Type: Coating applicator for roof a11d siding panels Regulations Central to Inspection: NESHAP MlvlMM and NESHAP SSSS Arrival Time: 2:00 PM Departure Time: 4:00 P'l/i. Page 1 of3 Inspection Type: lg) Unannounced Inspection D Announced Inspection OPENING CONFERENCE CxJ Credentials Presented CxJ CBI warning to facility provided The following infonnation was obtained verbally from Mike DeSimone and Jeffery A. Williams unless otherwise noted. Process Description: EDCO Products Inc. is a metal siding and roofing coating facility located in Hopkins, MN. Steel and aluminum coils are brought in on trucks and then used to produce painted parts for siding or roofing. The metal coils are unrolled, cleaned, and coated with pretreatment, which is a polyester coating. Next, the pretreated metal is cured in an infrared oven and is coated with the top coat. Then, the metal is cured in a natural gas oven, quenched in a water bath, and either sold to a customer for siding use or sent to the roofing area of the plant for further processing. The metal coils that are used for roofing go through the same process except there is no pretreatment process, and the metal is pressed into a roofing shape after the water quench. Staff Interview: There is a fume hood over both paint application lines. The paint lines. infrared oven, and curing oven are vented to a thermal oxidizer. Air flow is continuously monitored into the coating room. Quarterly inspections are conducted for the air flow sensors. A monthly visual inspection is conducted on the duct work conveying emissions to the thermal oxidizer. TOUR INFORNIATJON EPA toured the facility: Yes Data Collected and Observations: The facility was not running during the inspection. Photos and/or Videos: were not taken during the inspection. Field Measurements: were not taken during this inspection. RECORDS REVIEW 1. 2018 compliance summary CLOSING CONFERENCE Requested documents: Page 2 of3  2016 thermal oxidizer stack test Last 2 years of deviation reports 2019 emissions swnmary report with calculations SIGNATURES Report Author: Section Chief: Paob e 3 of3 Attachment B-1 MACT Compliance Spreadsheet Summary, 2018 Coil lb hac uncontrolled lb har laallons li::ial solids lb hao/aal sollds lb hap/qal solids Shin~ le lb hac laallons loal solids lb hap/aal solids lb hao/aal solids Limit lb HAP/aallan solids) Limit (kq HAP/liter solids) Manthlv Value /lb HAP/aallon solids: Monthly Value (kq HAP/liter solids) Meet limit? Jan-19 Feb-19 Mar-19 2108.21 105.41 3344.00 1435.74 0.07342 0.07342 1422.53 71.13 2674.00 1126.63 0.06313 0.06313 2340.61 117.03 3661.00 1305.14 0.08967 0.08967 An-19 Ma~-19 Jun-19 Jul-19 Aur-19 Ser-19 Oct-19 Nov-19 Dec-19 2829.17 141.46 5587.00 2707.99 0.05224 0.05224 2868.35 143.42 4603.00 1946.57 0.07368 0.07368 2343.00 117.15 4483.00 2070.45 0.05658 0.05658 2267.30 113.36 3845.00 1564.98 0.07244 0.07244 0.00 0.00 0.00 0.00 0.00000 0.00 0.00 0.00 0.00 0.00000 0.00 0.00 0.00 0.00 0.00000 0.00 0.00 0.00 0.00 0.00000 0.00 0.00 0.00 0.00 0.00000 2019 16179 809 28197 12158 0.06654 0.06654 114.66 137.00 16.16 7.10 7.10 0.401 0.048 0.152 0.018 YES 85.87 96.50 12.13 7.08 7.08 0.400 0.048 0.138 0.017 YES 107,85 129.55 15.20 7.09 7.09 0.401 0.048 0.170 0.020 YES 124.04 139.75 17.54 7.07 7.07 0.394 0.047 0.097 0.012 YES 141.62 163.00 20.20 7.01 7.01 0.400 0.048 0.145 0.017 YES 84.17 95.00 11.83 7.12 7.12 0.393 0.047 0.097 0.012 YES 127.25 143.50 17.98 7.08 7.08 0.401 0.048 0.152 0.018 YES 0.00 0.00 0.00 0.00 0.384 0.046 NA NA NA 0.00 0.00 0.00 0.00 0.384 0.046 NA NA NA 0.00 0.00 0.00 0.00 0.384 0.046 NA NA NA 0.00 0.00 0.00 0.00 0.384 0.046 NA NA NA 0.00 0.00 0.00 0.00 0.384 0.046 NA NA NA 785 904 111 7.1 7.1 0.398 0.048 0.130 0.016 YES Example Calculation (January 2019) Total Coil Controlled HAP (MACT SSSS) Total Coil Gallon Solids 105.41 lb HAP 1435.74 Gallon Solids Total Shingle HAP (MACT MMMM) Total Shingle Gallon Solids 114.66 lb HAP 16.16 Gallon Solids Calculated Limit Formula (lb HAP/gallon solids)= (Total Coil HAP+ Total Shingle HAP)/(Total Coil Gallon Solids+ Total Shingle Gallon Solids) = (105.41+114.66)/(1435.74+16.16) 0.152 lb HAP/gallon solids Conversion Factor lb HAP/gallon solids~ (453.6 glib~ kg/1000 g) * (7.481 gallon/28.32 liters) 0.1515757 lb HAP/gallon solids* Conversion Factor 0.018 kg HAP/liter solids EDCO Products Inc. Jan19 Jun19 Jul19-Dec19 13912 696 24352 10593 0.066 0.066 2267 113 3845 1565 0.072 0.072 2019 16179 809 28197 12158 0.067 0.067 658 761 93 71 7.1 0.397 0.048 0.127 0.015 YES 127 144 18 7.1 7.1 0.401 0.048 0.152 0.018 YES 785 904 111 7.1 7.1 0.398 0.048 0.130 0.016 YES Total HAP Total HAP 1594 0.80 lb/ r ton/ r S\Engineering\Environmental\2019 Emissions Data\July 2019\MMMM Verification Cales July 2019