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DATE: SUBJECT: FROM: THRU: TO: UNITED STATES ENVIRONMENTAL PROTECTION AGENCY REGIONS 77 WEST JACKSON BOULEVARD CHICAGO, ILLINOIS 60604 APR 1~ tin~ CLEAN AIR ACT INSPECTION REPORT FXI Inc., Fort Wayne, Indiana Jason Schenandoah, Environmental Engineer AECAB (IL/IN) Nathan Frank, Section Chief AECAB (IL/IN) File BASIC INFORMATION Facility Name: FXI Inc. Facility Location: 3005 Commercial Rd., Fort Wayne, Indiana Date of Inspection: March 19, 2019 EPA Inspector(s): I. Jason Schenandoah, Environmental Engineer 2. Linda Rosen, Environmental Engineer Other Attendees I. Justin Bruce, Engineering and Maintenance Manager, FXI Inc. 2. Lee McHaney, Maintenance Supervisor, FXI Inc. 3. Joseph A. Cichy, Plant Manager, FXI Inc. 4. Chris Webb, Regional Manager, FXI Inc. Contact Email Address: cwebb@fxi.com; jbruce@fxi.com; scarlson@fxi.com Purpose of Inspection: To determine compliance with the Clean Air Act Facility Type: Polyurethane foam production Arrival Time: 9:00 am Departure Time: 12:15 pm Inspection Type: ~ Unannounced Inspection D Announced Inspection OPENING CONFERENCE ~ Credentials Presented ~ CBI warning to facility provided The following information was obtained verbally from FXI Inc. (FXI) personnel unless otherwise noted. Process Description: Raw materials at the facility are brought in by rail and tanker truck and pumped to storage tanks throughout the facility. Raw materials consist of polyols, diisocyanates, amines, water, dyes, and other additives. Raw materials are pumped to an emulsifier and blended right before depositing into a trough. The foam moves down the trough as the foam forms. Sections of the foam are cut off by specifications determined by final product or customer demand. The foam can be then further processed depending on the final product to be achieved. Foam may be sent to a flame laminator in which substrates such as vinyl, aluminum, and woven nets can be melted to the foam. Foam can also be sent to a skinner in which nip rollers heated with hot oil will heat the foam and a laminate is then adhered to the foam. Foam may also be sent to felt presses. At the felt presses, heat and pressure are applied to the foam to make the foam more adsorbent. The foam may go to zappers as well. In the zapper process, mini explosions blow out the cell walls of the foam, called reticulation, to make filters. The foam can also go to quench reticulation which uses a caustic bath to reticulate the foam and make the foam softer. Lastly, the final process that the foam can undergo is at a looper. The looper will connect the two ends of 200 ft rolls and slice it to create thin foam sheet rolls. Finished product is then packaged and shipped out via truck. Staff Interview: Process heat is used at the railcar and trucker unloading stations to prevent freezing of certain raw materials. A nitrogen blanket is pumped on top of tanker car to push product out. Most storage tanks vent to atmosphere with the exception of tanks containing Toluene Diisocyanate (TDI) which are controlled by carbon beds. Pumps for the TDI tanks are sealed and magnetically driven. TOUR INFORMATION EPA toured the facility: Yes Data Collected and Observations: Gas vapor was seen to rise from the hoses and the ground when a tanker truck and railcar were being unloaded. FXI personnel said the vapor seen was process steam. Photos and/or Videos: were taken during the inspection. Page 2 of 4 Appendix A contains the log of photos taken at the facility. Field Measurements: were not taken during this inspection. RECORDS REVIEW 1. Checklist form for FXI's internal inspection checks on pumps used for TDI. ~d~~~~~2~~;~> =-- Date : --'-..,__-,C.........- -'..--- - -.,.-----,,,<~:.-+~:..__,L__ - - = ~- - - - Date: --'-J....--'-....,__,---''--- Page 3 of 4 Facility Name: FXI Inc. Facility Location: 3005 Commercial Rd., Fort Wayne, Indiana Date of Inspection: March 19, 2019 APPENDICES AND ATTACHMENTS 1. Appendix A: Digital Image Log Page 4 of 4 Facility Name: FXI Inc. Facility Location: 3005 Commercial Rd., Fort Wayne, Indiana Date ofJnspection: March 19, 2019 APPENDIX A: DIGITAL IMAGE LOG 1. Inspector Name: Linda Rosen 3. Company/Facility Name: FXI Inc. 5. Number of Images: 17 2. Date(s) oflnspection: March 19, 2019 4. Street Address, City, State: 3005 Commercial Rd., Fort Wayne, Indiana 6. Archival Record Location: CD-R labeled as "FXI, Inc. Inspection photos; 3/19/2019; 3005 Commercial Rd; Fort Wayne, IN" Image Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 File Name P3190001.JPG P3190002.JPG P3190003.JPG P3190004.JPG P3190005.JPG P3190006.JPG P3190007.JPG P3190008.JPG P3190009.JPG P3190010.JPG P3190011.JPG P3190012.JPG P3190013.JPG P3190014.JPG P3190015.JPG P3190016.JPG P3190017.JPG Date and Time (incl. time zone and DST) 3/19/2019 8:57 3/19/2019 8:58 3/19/2019 9:04 3/19/2019 9:06 3/19/2019 10:27 3/19/2019 10:29 3/19/2019 10:35 3/19/2019 10:38 3/19/2019 10:41 3/19/2019 10:47 3/19/2019 10:47 3/19/2019 11:09 3/19/2019 11:13 3/19/2019 11:24 3/19/2019 11:24 3/19/2019 11:33 3/19/2019 11:36 Latitude and Longitude Description of Image Vapors from railcar unloading station Vapors from tanker truck unloading station Tanker truck unloading Vapors from tanker truck and railcar unloading station Foam testing stations Foam cutter Methylene diphenyl storage tank TDI Tank Run tanks Emulsifier and dispenser TDI monitor Flame laminator Mentor cleaning solvent label Carbon bed canister Date of change on carbon bed canister Foam coming out of trough to cutter Foam mixture pouring from emulsifier into the trough before curing Appendices Page 1 of 1