AQ_F_0900063_20180124_CMPL_InspRpt

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NORTH CAROLINA DIVISION OF Fayetteville Regional Office
AIR QUALITY Peanut Processors Inc.-Plant 1
NC Facility ID 0900063
Inspection Report County/FIPS:Bladen/017
Date: 01/26/2018
Facility Data Permit Data
Peanut Processors Inc.-Plant 1 Permit 08005/R09
7329 Albert Street Issued 7/22/2014
Dublin,NC 28332 Expires 6/30/2022
Lat: 34d 39.4840m Long: 78d 43.5440m Classification Small
SIC: 2099/Food Preparations Nec Permit Status Active
NAICS: 311911 /Roasted Nuts and Peanut Butter Manufacturing Current Permit Application(s)None
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact S1P
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Brian Tart Houston Brisson Brian Tart
h Regulatory Manager President/CEO Regulatory Manager
[phone] [phone] [phone]
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Compliance Data
Comments:
Inspection Date 01/24/2018
Inspector's Name Stephen Allen
Inspector's Signature: -` e�� Operating Status Operating
-� Compliance Code Compliance-inspection
Action Code FCE
Date of Signature: i ���(S On-Site Inspection Result Compliance
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Total Actual emissions in TONS/YEAR:
- - TSP S02 NOX VOC CO PM10 *HAP
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2013 2.17 - 0.5000 0.1900 0.4000 2.17 18.00
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2008 0.9300 --- 0.2400 0.0200 0.2000 0.7000 85.80
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*Highest HAP Emitted inpounds)
Five Year Violation History:
Date Letter Type Rule Violated Violation Resolution Date
04/11/2014 NOV Permit Permit Condition 05/28/2014
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Performed Stack Tests since last FCE:None
Date Test Results Test Method(s) Source(s)Tested
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I.DIRECTIONS
From FRO take Highway 87 South and travel about 20 miles to Dublin. The facility is on the right after
passing the Highway 410 intersection.

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H. SAFETY CONSIDERATIONS
All standard DAQ FRO safety gear is required. Be aware of hot surfaces due to high temperatures used
during facility processes as well as fork lifts.
III.FACILITY/PROCESS DESCRIPTION
Shelled peanuts are loaded from a hopper onto a conveyor and passed through the natural gas fired pre-
heater at—180 degrees F in hot chambers and later finished with cooling chambers that drop the
temperature down to—155 F. The purpose of this pre-heater is simply to warm the peanuts up. The
peanuts are then blanched with dry heat at—190 degrees F in 5 electric dry blanching units. The
blanching process swells the nut,cracks the skin,and allows for easy removal of the skin.After
blanching,the peanuts are roasted submerged in peanut oil at—355 degrees F. The product is then stored
for packaging.
Peanut Oil Roasting Process
Peanut oil in the oil roaster is circulated out to a heat exchanger tank at—330 degrees F. The oil leaving 1
the heat exchanger feeds into a filtering machine that removes any particles and debris before the oil is
recycled back to the roaster. The recycling process helps maintain a consistent roasting temperature in 9
the oil roaster. The peanuts reabsorb some of this recycled oil. There is no fan used in the process.
About 60 gallons of oil are added from the roasting peanuts to this recycling system each day. About 4 to j
5 gallons of oil each day are lost during.fltering.
Air Emissions Description and Controls
Particulate emissions from the pre-heater are controlled by a cyclone. The two smog hogs that used to
operate in series with the cyclone are no longer in use. The exhaust from the cyclone simply passes
through the smog hog ductwork to the atmosphere. Peanut skin particles from the 5 blanchers are
vacuumed into another outside cyclone and the air is circulated back inside the building with no release to
the outside. Emissions from the oil roaster are uncontrolled and are released through two cool zone stacks
outside of the building. One of these stacks sits on top of the building near the cyclones and the other is
toward the ground at the middle of the building. The peanut oil heat exchanger tank vapors vent
uncontrolled through a stack outside of the building.
IV.EQUIPMENT LIST
Permitted Sources
Emission b e \� \�"���ira�Syste
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Natural gas fired peanut roaster(2.8 mm Btu per hour
ES 1 heat input rate and 4,500 lb.per hour peanut process CD 13 Cyclone(96 inches in dia.)
rate)
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-Not operating during inspection.
........................................... ....................................... ... . ................ .................................................. ........ ..........
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Natural Gas Fired Heat Exchanger and Oil Roaster
ES7 (2 mm Btu per hour heat input and 5,500 lb.per hour
peanut processing rate)
-Not operating during inspection. N/A N/A
Five Blanchers(6,000 lbs per hour)
ES8
-Operating at 0%opacity.
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V.INSPECTION SUMMARY
On 24 January 2018 I, Stephen Allen with FRO DAQ arrived at the facility to conduct a compliance
inspection. I drove by the facility and observed 0%opacity from the control devices and the facility roof.
I met with Mr. Brian Tart,the facility contact and he escorted me on a tour of the facility and provided me
with the inspection and maintenance records.Mr. Tart reviewed the FacFinder information and did not
note any changes. Mr.Tart stated they have not added any new equipment at the facility and there have
been no changes in the manufacturing process. The facility receives—500 lb bags of sized peanuts from
local farmers. I arrived just after they finished roasting a batch of peanuts. The natural gas fired peanut
roaster and the natural gas fired heat exchanger were not operating during the inspection. We began the
_ tour at the back of the facility to view the control devices that were still on while the roasters were being
cooled down. We then toured the inside of the facility where some of the peanuts were being put through
the blanching process to remove the redskins from the peanuts. No visible emissions were observed
during any of the processes. The duct work for the cyclone appeared to be well maintained and in
working order with no apparent holes or leaks. Most of the workers were cleaning the production area.
There was little accumulation of dust or peanut skins in the facility or around the control devices. Mr.
Tart stated there had been no excess emissions events since the last inspection and was aware of the
notification requirement.
Mr.Tart stated the facility has 6 employees and operates 2-3 days per week depending on demand. Mr.
Tart had a copy of the air permit in his Air Quality notebooks for Plant 1 and for Plant 2 the salt plant.
During the previous inspection the I/M logs for the cyclones were an item of concern after the previous
facility contact left the company. Mr. Tart had an up-to-date logbook that documented weekly
inspections for cyclones and listed any necessary repairs. The logbook is kept electronically and the Mr.
Tart stated he'd recently printed the 2017 log and added it to the Air Quality notebook he keeps. The log
showed the last inspection was on 12/29/2017.The last noted repair was on 3/24/2017 when the fan was
balanced.
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THROUGHPUTS
E W. anufs:Proeesse a' iG ..ombue ,DekaTherms -
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2017 3300.58 4917.8
2016 2821.85 3447.7
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2015 4161 4272
2014 2,608 Unknown
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2013 1,790 Unknown
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k VI.PERMIT STIPULATIONS
i A.2 2D.0202—PERMIT RENEWAL AND EMISSION INVENTORY REQUIREMENT—At least
I 90 days prior to the expiration date of this permit,the Permittee shall submit the permit renewal
application and air pollution emission inventory.
APPEARED IN COMPLIANCE—The recent permit renewal was due by 2 June 2014 and was received
on 28 May 2014. The next renewal is due in March 2022.
r A.3 2D.0503 PARTICULATES FROM FUEL BURNING INDIRECT HEAT EXCHANGERS-
PM emissions from the fuel burning Natural Gas fired indirect heat exchanger,ES7 shall not exceed 0.91
lbs/mmBtu/hr.
APPEARED IN COMPLIANCE—The AP-42 particulate emissions factor for natural gas is 0.007
lbs/mmBtu.
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AA 2D.0515 PARTICULATES FROM MISCELLANEOUS INDUSTRIAL PROCESSES-
particulate matter emissions from the emission sources shall not exceed allowable emission rates.
APPEARED IN COMPLIANCE—The last permit review indicated compliance based on the sources
being operated as permitted. There have been no changes since the last review.
A.5 2D.0516 SULFUR DIOXIDE CONTROL REQUIREMENTS- Shall not exceed 2.3 pounds per
million Btu heat input.
APPEARED IN COMPLL4,NCE The facility combusts only natural gas and AP-42 EF for sulfur
dioxide is 0.0006 lb/mmBtu
A.6 2D .0521 VISIBLE EMISSIONS CONTROL Requirement—Visible emissions from the emission
sources,manufactured after July 1, 1971, shall not be more than 20 percent opacity when averaged over a
six-minute period.
APPEARED IN COMPLIANCE Roasters were not operating during this inspection.No visible
emissions observed. Nothing indicated VE issues. Mr. Tart stated the change in the roasting process has
resulted in lower visible emissions.
A.7 2D .0535 NOTIFICATION REQUIREMENT-Facility is required to notify the DAQ of excess
emissions that last for more than four hours.
APPERARED IN COMPLIANCE—Mr.Tart stated there have been no occurrences of excessive
emissions since the last inspection and he is aware,of the reporting requirement. -
A.8 2D .0540 PARTICULATES FROM FUGITIVE DUST EMISSION SOURCES: - Shall not
ocause or allow fugitive dust emissions to cause or contribute to substantive complaints or excess visible
emissions beyond the property boundary.
APPEARED IN COMPLL4,NCE-No fugitive dust was observed beyond the property boundaries and
Mr.Tart stated they have not received any complaints.
A.9 2D.0611 CYCLONE REQUIREMENTS—(CD-13)-Particulate matter emissions from sources
shall be controlled as described in the permitted equipment list, including annual inspections recorded in
logbook and all maintenance activities recorded in logbook.
APPEARED IN COMPLIANCE—The facility provided records indicating the last I/M occurred on 29
December 2017. Inspection and Maintenance logbook documents weekly inspections and notes any
repairs made. The last repair noted was balancing of the fan on 24 March 2017.
VII. 112R STATUS
The facility does not store any of the listed chemicals at or above the 112(r)thresholds and is not required
to maintain a written Risk Management Plan.
VIII.NON-COMPLIANCE HISTORY SINCE CY2010
• On 10 November 2010,higher opacity readings than usual were observed by Pam Vivian while
driving by the facility doing other work at another location. She stopped in and notified Mr. Bud
Lotz,Facility Contact, about this problem. She later returned that same day and the problem had
been corrected by cleaning the ESP control devices and lowering the facility processing
temperature. Follow Up: During this inspection,visible emissions from the oil roaster stack
outside were at—15%opacity. No other visible emissions were observed. k
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• Issued NOV on 11 April 2014 for B.5 violation of changing control devices without a permit
modification. Follow Up: During this inspection,the previously permitted smog hogs were still
connected in series with the permitted cyclone CD 13 but were no longer operating.

IX.COMMENTS/COMPLIANCE STATEMENT
Peanut Processors Inc. - Plant 1 appeared to be operating in compliance with the current air permit on
24 January 2018.
PINK SHEET
y None as of this inspection.
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