Document jy0LVRaEGxkdqgR7YeqaVXQq9

DATE: SUBJECT: FROM: THRU: TO: UNITED STATES ENVIRONMENTAL PROTECTION AGENCY REGIONS 77 WEST JACKSON BOULEYARD CIDCAGO, ILLINOIS 60604 AUG 1 6 2019 CLEAN AIR ACT INSPECTION REPORT Skana Aluminum Co., Manitowoc, Wisconsin Jason Schenandoah, Environmental Engineer AECAB (IL/IN) Nathan Frank, Section Chief AECAB (IL/IN) File BASIC INFORMATION Facility Name: Skana Aluminum Co. Facility Location: 2009 Mirro Drive, Manitowoc, Wisconsin Date of Inspection: July 2, 2019 EPA Inspector(s): 1. Jason Schenandoah, Environmental Engineer 2. Linda Rosen, Environmental Engineer Other Attendees 1. Dave Houser, VP manufacturing 2. Daniel Todd, Director of engineering Contact Email Address: dave.hauser@skanaaluminum.com Purpose of Inspection: To ensure compliance with the Clean Air Act Facility Type: Aluminum manufacturing facility Arrival Time: 9:00 am Departure Time: 11 :30 am Inspection Type: C><;I Unannounced Inspection Announced Inspection C><;I Credentials Presented C><;I CBI warning to facility provided The following information was obtained verbally from Skana Aluminum Co. (Skana) personnel unless otherwise noted. Process Description: The facility is undergoing a transition in its furnace infrastructure. The old set up involves two sets of furnaces, each set consists of a melting furnace and a holding furnace. The holding furnaces then empty into a casting pit. One new style furnace completed installation by March 2018, while an additional new style furnace and casting pit were under construction at the time of the inspection. The installed new style furnace has a temporary trough that feeds to one of the holding furnaces of the old set up. When the new set up is complete, the new style furnaces will act as a melting and holding furnace in one unit and empty to the new casting pit. To start, aluminum ingot, "run-around" scrap, and hardeners are added to the melting furnace or the new style furnace to initiate the melting process. Run-around scrap is scrap aluminum that is created as a result of other finishing processes throughout the facility. When the molten aluminum reaches the proper temperature, it is transferred to the holding furnaces to maintain temperature. In the holding furnace, argon is injected into the molten aluminum to help remove impurities and samples are taken to test for the required specifications of the batch. The molten aluminum is then poured into a mold to form a slab. Cooling water is pumped through the mold to quench the aluminum as its poured; the cooling water is in a closed loop system with evaporative cooling towers. As the aluminum is poured through the mold a slab forms on the other side. The slabs will be 11-13 inches thick, 36, 42, or 47 inches wide, and 12 feet long. The slabs are then sent to homogenization furnaces to be reheated. The reheating will help to bring impurities toward the edges of the slab. The slab is then shaved on all sides and cut in half. Shavings from this area are air ducted to a briquetting machine to be reintroduced to the melting process. The slabs are then sent through a preheater to bring the slab to approximately I 000 F. The heated slab is set onto a hot rolling process to be rolled out to a thickness of inch and extruded from 69 inches out to 400 feet long. After the extrusion process, the sheet will be sent to a coiler to be rolled up into a coil. The rolls are then sent to the cold mill to be processed to customer specifications; multiple passes through the cold mill may occur. Next, the coil is sent to a slitter to cut the coil to the required width. At this point, some of the coils are sent to a stamping process to produce stamped aluminum for a specific end use. Scrap from the stamping and slitting processes are air ducted to the aluminum briquetting machine. Lastly, if required, coils will be sent to annealing furnaces to soften the aluminum. The aluminum is packaged as coiled sheets to be sold to customers. Staff Interview: The new furnaces are engineered to reduce gas usage by 25% and reduce NOx emissions by 36%, when both are operational, and the old melting and holding furnaces are shut Page 2 of 4 down. The new style furnaces will fully empty out molten aluminum after each batch. The oldstyle furnaces always need a pool of molten aluminum in them to remain functional. The hot mill uses a lubricant to process the aluminum. TOUR INFORMATION EPA toured the facility: Yes Photos and/or Videos: were taken during the inspection. See Appendix A: Digital Image Log Field Measurements: were not taken during this inspection. CLOSING CONFERENCE Requested documents: Safety data sheets and usage for two years for hot mill lubricant Safety data sheets for fluxes Information on how emission factors were created and what the emission factors are 2 annual emission reports with supporting calculations Entire month of method 9 visible emissions observation records for the entire months of April 2018 and May 2019. 2 years of compliance reports (if not included in annual emissions reports). Safety data sheets for water treatment chemicals used in the cooling towers. SIGNATURES Page 3 of 4 Facility Name: Skana Aluminum Co. Facility Location: 2009 Mirro Drive, Manitowoc, Wisconsin Date of Inspection: July 2, 2019 APPENDICES AND ATTACHMENTS I. Appendix A: Digital Image Log Page 4 of 4 Facility Name: Skana Aluminum Co. Facility Location: 2009 Mirro Drive, Manitowoc, Wisconsin Date of Inspection: July 2, 2019 CONFIDENTIAL BUSINESS INFORMATION ATTACHMENT APPENDIX A: DIGITAL IMAGE LOG 1. Inspector Name: Linda Rosen 3. Company/Facility Name: Skana Aluminum Co. 5. Number oflmages: 16 2. Date(s) of Inspection: July 2, 2019 4. Street Address, City, State: 2009 Mirro Drive, Manitowoc, Wisconsin 6. Archival Record Location: CD-R labeled "Skana Aluminum; Manitowoc, WI; Inspection photos; 7/2/2019" Image Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 File Name P7020029.JPG P7020030.JPG P7020031.JPG P7020032.JPG P7020033.JPG P7020034.JPG P7020035.JPG P7020036.JPG P7020037.JPG P7020038.JPG P7020039.JPG P7020040.JPG P7020041.JPG P7020042.JPG Date and Time (incl. time zone and DST) 2019:07:02 10:14:11 2019:07:02 10:15:40 2019:07:02 10:19:13 2019:07:02 10:26:51 2019:07:02 10:27:20 2019:07:02 10:28:11 2019:07:02 10:30:37 2019:07:02 10:31:47 2019:07:02 10:32:57 2019:07:02 10:33:10 2019:07:02 10:34:37 2019:07:02 10:40:26 2019:07:02 10:44:06 2019:07:02 10:50:39 Latitude and Longitude 44.130278, -87.6275 44.130512, -87.626887 44.129722, -87.626944 44.130278, -87.626667 44.13056, -87.626645 44.13056, -87.626645 44.130627, -87.626682 44.13061, -87.62645 44.130778, -87.626425 44.13078, -87.626425 44.130812, -87.626447 44.130556, -87.626389 44.130788, -87.626818 44.130792, -87.627432 Description of Image New casting pit construction Run around scrap pile Aluminum ingot label Old melting furnace, not operational Old melting furnace, operational New style furnace Stacks from new style furnace Stacks from furnaces Argon refrigeration unit Evaporative cooling towers Vapor from argon chiller heat exchanger Holding furnace Casting pit Hot mill Appendices Page 1 of 2 Facility Name: Skana Aluminum Co. Facility Location: 2009 Mirro Drive, Manitowoc, Wisconsin Date of Inspection: July 2, 2019 15 P7020043.JPG 2019:07:02 10:51:34 16 P7020044.JPG 2019:07:02 10:57:51 44.130843, -87.627502 44.13064, -87.627995 Hot mill, closer Annealing furnace Appendices Page 2 of 2