Document zQ95YrRMD5GydLVNn1JvX4yV3

DATE: S~JECT: FROM: THRU: TO: UNITED STATES ENVIRONMENTAL PROTECTION AGENCY REGIONS 77 WEST JACKSON BOULEVARD CIDCAGO, ILLINOIS 60604 OCT 3 0 %019 CLEAN AIR ACT INSPECTION REPORT Vulcan Global Manufacturing Solutions Inc., Milwaukee, Wisconsin David Sutlin, Environmental Engineer AECAB (MN/OH) Brian Dickens, Section Chief AECAB (MN/OH) File BASIC INFORMATION Facility Name: Vulcan Global Manufacturing Solutions Inc. Facility Location: 1400 Pierce Street, Milwaukee, Wisconsin Date of Inspection: October 15, 2018 EPA Inspector(s): 1. David Sutlin, Environmental Engineer 2. Dakota Prentice, Environmental Engineer Other Attendees 1. Fred Krablean, Vulcan, EHS Manager 2. David De Jesus, Vulcan, Vice President of Operations/General Manager Contact Email Address: fkrablean@vulcangms.com Purpose of Inspection: To determine compliance with Vulcan's operating permit and applicable federal regulations Facility Type: Lead Foundry Regulations Central to Inspection: 40 CFR Part 63, Subpart ZZZZZZ - National Emission Standards for Hazardous Air Pollutants: Area Source Standards for Aluminum, Copper, and Other Nonferrous Foundries Arrival Time: 10:00 AM Departure Time: 12:15 PM Inspection Type: iZI Unannounced Inspection D Announced Inspection OPENING CONFERENCE iZI Credentials Presented iZI CBI warning to facility provided The following information was obtained verbally from Mr. Krablean and Mr. De Jesus unless otherwise noted. Process Description: The facility produces various lead parts used in radiation shielding applications for medical and security equipment, as well as lead parts used as counter weights in various applications. Lead ingots, and reclaimed lead chips from Vulcan's machining operations are continuously charged into natural gas fired pots and melted at 800F. Small amounts of antimony, bismuth, and zinc are added to the melt to meet certain lead alloy specifications. Melt pot dross is skimmed off the top of the molten lead with a rake, and the purified lead or lead alloy is then either hand-ladled and poured into steel molds to produce castings of various shapes, or pumped to extrusion or injection molding processes. The cooled pieces are then transferred to onsite machining centers or shipped out. Staff Interview: The facility's output consists of roughly 70% castings and 30% extrusions. Melting, casting/diecasting, extruding, and machining operations take place at each of the facility's two buildings one at 1400 Pierce Street (Building #1) and the other across the street at 1517 Pierce Street (Building #2). Building #1 houses eight melt pots, including five each with a capacity of I0,000 lbs. and three smaller pots. Emissions from the pots are exhausted to a Torit 72-cartridge dust collector with a rating of24,249 ACFM, installed in 1992. Building #2 houses four melt pots, including two which are integrated into injection molding units. Emissions from the pots are exhausted to a Torit 24-cartridge dust collector with a rating of 6,607 ACFM, installed in 2002. Each dust collector's differential pressure is monitored and recorded once per shift and leak tested with florescent dye annually. Less than a single 55-gallon drum of dust is collected annually from each baghouse. TOUR INFORMATION EPA toured the facility: Yes Page 2 of 4 Data Collected and Observations: At Building# 1, EPA observed lead melt being ladled from one of the pots and poured into molds. No activity was occurring at several other pots though these were either unenclosed or partially enclosed. Visible emissions were observed being drawn into the overhead hood at one pot. At Building #2, the differential pressure meter for the dust collector read 3" of water column. At each building, EPA observed a roof opening with an exhaust fan. Photos and/or Videos: were taken during the inspection. Field Measurements: were not taken during this inspection. CLOSING CONFERENCE Requested documents: 2009 Stack tests of both dust collectors Capacity and age of each dust collector Page 3 of 4 Facility Name: Vulcan Global Manufacturing Solutions Inc. Facility Location: 1400 Pierce Street, Milwaukee, Wisconsin Date of Inspection: October 15, 2018 APPENDICES AND ATTACHMENTS Appendix A: Digital Image Log Page 4 of 4 Contains Items Claimed as CBI - Non-Releasable Facility Name: Vulcan Global Manufacturing Solutions Inc. Facility Location: 1400 Pierce Street, Milwaukee, Wisconsin Date of Inspection: October 15, 2018 CONFIDENTIAL BUSINESS INFORMATION ATTACHMENT Facility Name: Vulcan Global Manufacturing Solutions Inc. Facility Location: 1400 Pierce Street, Milwaukee, Wisconsin Date of Inspection: October 15, 2018 The written inspection notes contain CBI. CBI Page 1 of 1 Facility Name: Vulcan Global Manufacturing Solutions Inc. Facility Location: 1400 Pierce Street, Milwaukee, Wisconsin Date of Inspection: October 15, 2018 APPENDIX A: DIGITAL IMAGE LOG 1. Inspector Name: David Sutlin ,.;..;.. Company/.Facmty Name: Vulcan Global Manufacturing Solutions Inc. 5. Number of Images: 6 2. Date(s) of Inspection: October 15, 2018 4 Stn~et Address, City;State: 1400 Pierce Street, Milwaukee, Wisconsin 6. Archival Record Location: CD-R Labeled as "10-15-18 Inspection; Vulcan Global Solutions; Milwaukee, WI; Photos" Image Number 1 2 3 4 5 6 File Name PA150001.JPG PA150002.JPG PA150003.JPG PA150004JPG PA150005.JPG PA150006.JPG Date and Time (incl. time zone and DST} 10/15/2018 12:31 10/15/2018 12:32 10/15/2018 12:32 10/15/2018 12:35 10/15/2018 12:43 10/15/2018 12:52 Description of Image 3% Antimony Lead Pot 6% Antimony Lead Pot Partially closed lead pot Roof exhaust at 1400 W Pierce building Splatter marks on ceiling above pot with melt pump Roof exhaust at 1517 W Pierce building Appendices Page 1 of 1