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DATE: UNITED STATES ENVIRONMENTAL PROTECTION AGENCY REGIONS 77 WEST JACKSON BOULEVARD CHICAGO, IL 60604 SEP 1 O 2019 SUBJECT: FROM: CLEAil\J AIR ACT INSPECTION REPORT Columbia Forest Products, Mellen, Wisconsin Charles Hall, Environmental EngineeC: ~ AECAB (MN/OH) THRU: Brian Dickens, Section Chief AECAB (MN/OH) TO: File, Columbia Forest Products, Mellen, Wisconsin BASIC INFORMATION Facility Name: Columbia Forest Products Facility Location: 606 Wilderness Drive, Mellen, Wisconsin Date of Inspection: 28 August 2019 EPA Inspector(s): 1. Charles Hall, Environmental Engineer Other Attendees: 1. Jim Mattson, Safety Coordinator 2. Bruce Rebella, Plant Engineer 3. John Scheufeli, Iv1aintenance Supervisor 4. Dwayne Watson, Plant Manager (opening and closing conferences only) Contact Email Address: jmattson@cfpwood.com Purpose of Inspection: Composite Wood Products/Wood Veneer Inspection Facility Type: wood veneer manufacturer Regulations Central to Inspection: Columbia Forest Products (Columbia) is an area source under the National Emission Standards for Hazardous Air Pollutants: Plywood and Composite Wood Products, 40 C.F.R. Part 63, Subpart DDDD. The Wisconsin Department of Natural 1 of 3 Resources issued Synthetic minor, non-Part 70 Operation Permit No. 802033540-F31 to Columbia on Augnst 24, 2016. Arrival Time: 8:50 a.m. CDT Departure Time: J 1:20 am. CDT Inspection Type: IZI Unannounced Inspection D Announced Inspection OPENING CONFERENCE ~ Credentials Presented IZI CBI warning to facility provided The following infom1ation was obtained verbally from Mattson, Rebella, and Schenfeli nnless otherwise noted. Process Description: Columbia prodnces hardwood veneers that start with one of two process lines. On one process line, Colnmbia turns 8-foot long logs on a lathe to shave a sheet of wood of the desired thickness. The sheet is collected on a reel which is moved to the front end of the Babcock dryer. The sheet is cnt to the desired width as it is fed into the dryer. On the second process line, Colnmbia feeds pre-cut hardwood veneers into the Coe dryer. Inside each dryer, the moisture content of the wood veneer is rednced to the range of 8 to 10%. Both dryers are steam-heated and vent directly to the atmosphere. To control the emission of volatile organic componnds and hazardons air pollntants inclnding formaldehyde, the pennit limits the nwnber of sqnare feet of veneer that each dryer can process per month. Colnmbia applies glue on the thin edge of the veneer from both process lines, aligns the veneer sheet along the thin edge, and presses them together to form a sheet that is 50 inches wide and 99 inches long. Bark, cuttings and other scrap wood is collected from multiple points in the manufacturing process, shreds them, and then uses the shredded wood in a 42.0 million British thermal unit per hour heat input boiler. A multi-cyclone removes particulate matter from the boiler's exhaust gas. As required by its permit, Columbia continuously measures and manually records the pressure drop across the multi-cyclone, the amount of wood fuel burned, the flue gas temperature, the oxygen concentration, and the carbon monoxide concentration. TOUR INFORMATION EPA toured the facility: Yes Photos and/or Videos: were not taken during this inspection. 2 of3 Field Measurements: were not taken during this inspection. RECORDS REVIEW The inspector reviewed examples of the daily records of data for pressure drop across the multi-cyclone, the amount of wood fuel burned, the flue gas temperature, the oxygen concentration, and the carbon monoxide concentration collected between January I, 2018, and August 27, 2019. CLOSING CONFERENCE Requested Documents: Boiler Tune Up Report required by the National Emission Standards for Hazardous Air Pollutants for Industrial, Commercial, and Institutional Boilers Area Sources, 40 C.F.R. Part 63, Subpart JJ.J.JJJ; and Report for the most recent performance test on each boiler. SIGNATURES Lead Inspector: , , ,0 , f ( ! 1 Section Chief: ---~/2/=A).u/~;-,,<-'"-'"'="~,.,-1~"=,.,~~~------ Date: - -'l1~c11~<i - - - - - - - - 3 of 3