Document N22onow1RD0kOZV6OwRvbGX6R

UNITED STATES ENVIRONMENTAL PROTECTION AGENCY REGION 5 77 WEST JACKSON BOULEVARD CHICAGO, ILLINOIS 60604 SUBJECT: FROM: THRU: TO: CLEAN AIR ACT INSPECTION REPORT American Axel & Manufacturing (AAM), previously Metaldyne Ethan Chatfield, Environmental Engineer AECAB (IL/IN) Nathan Frank, Section Supervisor AECAB (IL/IN) File BASIC INFORMATION Facility Name: American Axel & Manufacturing (AAM), aka Metaldyne Facility Location: 8001 Bavaria Rd, Twinsburg, Ohio 44087 Date of Inspection: April 24, 2023 EPA Inspector(s): 1. Ethan Chatfield, Environmental Engineer 2. Brianna Fenzl, Environmental Engineer Other Attendees: 1. Alexander Chrustic, EHS Representative 2. Jeffery Nutter - Plant Maintenance Manager Contact Email Address: alexander.chrustic@aam.com Purpose of Inspection: Clean Air Act Inspection, including but not limited to compliance with any lead emission limits and associated health impacts. Facility Type: Foundry Arrival Time: 11:22 am (ET) Departure Time: 1:15 pm (ET) Inspection Type: Unannounced Inspection Announced Inspection Facility Name: AAM/Metaldyne Facility Location: Twinsburg, Ohio Date of Inspection: April 24, 2023 OPENING CONFERENCE Presented Credentials Stated authority and purpose of inspection Provided Small Business Resource Information Sheet Check the box if you provided during the inspection, or emailed after return to the office. If you are unsure whether the company is small, simply provide it. Small Business Resource Information Sheet not provided. Reason: does not appear to fit criteria as small business Provided CBI warning to facility The following information was obtained verbally from Alex Chrustic unless otherwise noted. Company Ownership: American Axel purchased Metaldyne Performance Group Inc. in or around 2017. The company continues to use the name Metaldyne as well as AAM. Process Description: The company has roughly 170 employees in the Twinsburg, Ohio location and operates 3 shifts, 24 hr/7 days: 7am-3pm, 3pm-11pm and 11pm-7am. Mr. Chrustic provided a map of the facility. The company uses aluminum alloys to make die cast parts for Ford and GM vehicles. There are four melting furnaces; two on the north end (referred to as Phase 1 furnaces) and two on the south end (Phase 2 furnaces). Generally, only one furnace on each end operates at any given time. Raw aluminum alloy, clean scrap material and some power `flux' material (as needed) is fed into each of the furnaces and the melted alloy is used in a series of die casting machines at high pressure (12 on Phase 1 and 12 on Phase 2 for a total of 24 die casting machines). The die cast parts are further processed (as needed) in one of two Shot Blasts (Phase 1 shot blast is controlled with a baghouse, but Phase 2 is not). None of the furnaces have PM controls. Two of the Die Cast machines have some internal emission controls, no details provided. All emissions from the die cast machines are exhausted directly into the Phase 1 (north) and Phase 2 (south) die casting machine rooms, respectively, and all fumes are evacuated to and through a series of roof vents. There is also closed loop water processing done onsite. The company makes approximately 17,000 parts per day. Any wet, oily scrap is sent offsite and any non-oily scrap is fed back into the furnaces. There is a "stack inspection" completed each day on the roof stacks to check for any opacity; with a simple `yes' or `no' on opacity logged. Page 2 of 5 TOUR INFORMATION Facility Name: AAM/Metaldyne Facility Location: Twinsburg, Ohio Date of Inspection: April 24, 2023 EPA Tour of the Facility: Yes Data Collected and Observations: EPA inspectors walked through each of the Phases production lines and noted high opacity inside each of the die casting rooms. Furnace 1 was in the process of being rebuilt during the inspection, but Furnaces 2, 3, and 4 were operating. The facility noted that they were getting ready to rebuild Furnace 4. Die casting machines 42 and 43 that make vehicle differential covers have been recently upgraded to newer machines with some internal PM controls. EPA noticed that these newer machines were significantly less emissive. The shot blast machines were not operating during the inspection. EPA then climbed a ladder to the roof to observe the roof exhaust vents. No visible emissions readings were taken. Photos and/or Videos: were taken during the inspection. CLOSING CONFERENCE Provided U.S. EPA point of contact to the facility Requested documents: Estimate of aluminum alloy usage (tons per month) past year. Specification of aluminum alloy. Specification of flux material used. Estimate of air emissions for PM, HAPs, Lead, etc. for 2022. Most recent air operating permit for the facility. Copies of any PM and/or lead stack tests (especially on any of the furnaces) Copy of the opacity check logs for past month. DIGITAL SIGNATURES Chatfield, Digitally signed by Chatfield, Ethan Report Author: _E_th__a_n________0_7:_23_:5_3 -_05_'0_0'_____________ Date: 2023.05.24 Section Supervisor: Frank, Digitally signed by Frank, Nathan N__a_t_h_a_n_______1_5:4_1_:11_-_05_'0_0'______________ Date: 2023.05.24 Page 3 of 5 APPENDICES AND ATTACHMENTS 1. Appendix A: Digital Media Log Facility Name: AAM/Metaldyne Facility Location: Twinsburg, Ohio Date of Inspection: April 24, 2023 Page 4 of 5 Facility Name: AAM/Metaldyne Facility Location: Twinsburg, Ohio Date of Inspection: April 24, 2023 APPENDIX A: DIGITAL IMAGE LOG 1. Inspector Name: Ethan Chatfield 2. Archival Record Location: Region 5 Electronic Records Center Image Number File Name Date and Time (incl. Time zone and DST) Description of Image 1 P4240047.JPG 2023:04:24 10:16:03 Alloy melt Furnace #1 and 2 2 P4240048.JPG 2023:04:24 10:16:09 Scrap material to be melted flux in front of bars of aluminum 3 P4240049.JPG 2023:04:24 10:16:37 alloy for melting 4 P4240050.JPG 2023:04:24 10:16:40 Alloy melt Furnace #1 and 2 5 P4240051.JPG 2023:04:24 10:22:26 Foundry Casting Unit 11 6 P4240052.JPG 2023:04:24 10:22:30 Opacity in foundry 7 P4240053.JPG 2023:04:24 10:23:31 Casting unit from back 8 P4240054.JPG 2023:04:24 10:34:03 9 P4240055.JPG 2023:04:24 10:34:12 Opacity in second foundry area 10 P4240056.JPG 2023:04:24 10:39:13 Alloy melt Furnace #3 11 P4240057.JPG 2023:04:24 10:39:17 Alloy melt Furnace #3 and 4 12 P4240058.JPG 2023:04:24 10:50:36 Roof vents 13 P4240059.JPG 2023:04:24 10:50:43 Roof vents 14 P4240060.JPG 2023:04:24 10:51:17 Roof vents 15 P4240061.JPG 2023:04:24 10:54:08 Roof vents 16 P4240062.JPG 2023:04:24 10:54:30 Roof vents 17 P4240063.JPG 2023:04:24 10:54:32 Roof vents 18 P4240064.JPG 2023:04:24 10:54:33 Roof vents Page 5 of 5