AQ_F_0900063_20160610_CMPL_InspRpt

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: 06/28/2016
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 Nee 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 SIP
Brian Tart,Regulatory Houston Brisson,Jr Brian Tart,Regulatory
Manager President/CEO Manager
[phone] [phone] [phone]
(910)-876-5568 cell (910)-876-5568 cell
Compliance Data
Comments:
Inspection Date 06/10/2016
ff Inspector's Name Pam Vivian
Inspector's Signature: f 4, Operating Status Operating
Compliance Code Compliance-inspection
u Action Code FCE
Date of Signature: (e /Z �/ Z 0�6 On-Site Inspection Result Compliance
Total Actual emissions in TONS/YEAR:
TSP S02 NOX VOC CO PM10 *HAP
2013 2.17 --- 0.5000 0.1900 0.4000 2.17 18.00
2008 0.9300 --- 0.2400 0.0200 0.2000 0.7000 85.80
*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
Performed Stack Tests since last FCE:None
Date Test Results Test Method(s) Source(s)Tested

1)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.
2) 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.
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3)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
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
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
5 gallons of oil each day are lost during filtering.
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.
4)Equipment List:
Permitted Sources:
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(� Natural gas fired peanut roaster(2.8 mm Btu per hour i� Cyclone(96 inches in dia.)
� ES 1 heat input rate and 4,500]b.per hour peanut process rate) CD 13
Operating at--4,5001b.per hour;—0%opacity.
j 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) -
-Operating at--4,500 lbs per hour; 0%.opacity. N/A N/A
Five Blanchers(6,000 lbs per hour)
i 7ES ..
Operating at--4,5001bs per hour;—0%opacity.

5)Inspection Summary:
On 10 June 2016,I, Pam Vivian with FRO DAQ arrived at the facility and observed while driving down a
side roadway, zero opacity from the control devices and roof top. I met with Mr. Brian Tart,
Administrative Accounts Payable who informed me that Mr. Daniel Peterson, former facility/permit
contacts was no longer with Peanuts Processors, and has not been since January 2016. He said as of now,
no one has been appointed to that position. I informed him I was there to do a compliance inspection. He
said the facility was preparing to shut down for the day. He told me the facility receives Grade A peanuts
and are brought into the plant, dumped, and then further processed. I told him I would prefer to inspect
the facility first and then review the records. Mr. Tart guided me during this inspection.
Entering into the operations area, I observed 6 employees cleaning the floors, loading peanuts into large
500 plus pound sacks on wood pallets, and a fork lift operator loading the pallets onto a transport truck. I
heard equipment operating but it did appear production was ending for the day. I did not observe any of
the temperature gauges during this inspection. I did not observe any accumulated particulates at the
ductwork from the outside cyclone that waste the peanut skins into a drum.
Mr. Tart took me outside where I observed 0% opacity from ES that was operating. I observed the
cyclone which collects the peanut skins waste into a container below but vents inside the facility. The
areas around both cyclones were clean with no particle accumulations. The duct work leading to both
units appeared to be well-maintained with no apparent holes/leaks. I observed 0% opacity from ES7
associated stacks.
He reviewed the FACFINDER and said the facility and technical contacts would be announced at a later
date. He gave me his cell number to call for future information that he would acquire from Southern
Peanuts in Elizabethtown. He stated that as far as he knew, there had been no complaints received
regarding air quality and no changes had been made to the processes. He provided I/M records as well as
a copy of the current air permits for Plant 1 and Plant 2 that he found in Mr. Peterson's former office. I
reviewed the records and noted that the last entries for both facilities were dated 24 December 2015. I
showed him how the previous dates indicated more weekly type entries but suddenly stopped. He said he
was not sure why except for Mr. Peterson having left in January. He said he did not know who did the
UM activities nowadays. As we were talking, Mr. Tart was making notes. He said that possibly someone
was doing these I/M activities but entries had not been transferred and printed into the records. He said
the facility employees 6 workers and operates for 8 hrs per day two, sometimes three days per week,
depending on customer orders.
I asked him for facility throughputs for peanuts processed and natural gas combusted in 2015 and as of
this inspection. He said he did not know these throughputs and would have to contact others at the
Elizabethtown facility for this information and again made notes of it.
I told Mr. Tart a letter from this office would be sent to Mr. Brisson to request facility/permit contacts,
I/M records, and the throughput information for the facility.
Throu h uts:
Year Peanuts Processed,Tons/Yr NG Combusted,DekaTherms
2016—As of this inspection 740 1314
2015 4161 4272
2014 2,608 Unknown
2013 1,790 Unknown

6)Permit Stipulations:
A.2 2D .0202—"Permit Renewal and Emission Inventory Requirement"—At least 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 should be due in March 2022.
A.3 2D.0503 "Particulates from Fuel Burning Indirect Heat Exchangers," PM emissions from the
fuef 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.
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 COMPLIANCE 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 I observed 0%opacity during this inspection.
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.
A.8 2D .0540 "Particulates from Fugitive Dust Emission Sources: - Shall not cause or allow fugitive
dust emissions to cause or contribute to substantive complaints or excess visible emissions beyond the
property boundary.
APPEARED IN COMPLIANCE-No fugitive dust was observed beyond the property boundaries.
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 BUT WITH CONCERNS—The facility provided records indicating
the last I/M occurred on 24 December 2015. Previous annual was done on 2 April 2015. Historically,
records indicated weekly I&M activities. Concern was expressed to Mr. Tart that records now indicate no
routine I&M is occurring.
7) 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.

8)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.
• 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 CD13 but were no longer operating.
9)Comments/Compliance Statement:
With the former facility and permit contact no longer at this facility and no one having been identified in
these positions, and the lack of production information, as well as I/M records,there are concerns. Send a
CAI letter to Houston Brisson, Jr. requesting information to update this information. This facility
appeared to be operating in compliance with the current air permit but with concerns.
Pink Sheet:
None as of this inspection.
/pcv
Update: On 20 July 2016 Mr. Tart called and provided information stating the 2015 and 2016 peanut
production and NG usage for this facility. He said he has been trying to put together an I&M log through
the workers who generally do these actions and hoped to get it to me soon. Mr. Brisson also called and
stated that Mr. Tart is the Regulatory Manager as facility and technical contacts.
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