AQ_F_0400034_20140605_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Fayetteville Regional Office
AIR QUALITY Valley Protein Inc-Wadesboro Div
NC Facility ID 0400034
Inspection Report County/FIPS:Anson/007
Date: 06/10/2014
Facility Data Permit Data
Valley Protein Inc-Wadesboro Div Permit 06467/T18
Little Duncan Road Issued 10/3/2011
Wadesboro,NC 28170 Expires 9/30/2016
Lat: 35d 2.1192m Long: 80d 4.9683m Classification Title V
SIC: 2077/Animal And Marine Fats And Oil Permit Status Active
NAICS: 311613/Rendering and Meat Byproduct Processing Current Permit Application(s)None
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact SIP/Title V
James Hodges Chris Bivans Van Jones MACT Part Subpart 6J
Environmental Manager General Manager Corporate Environmental NSPS: Subpart
Dc
[phone] [phone] Manager
[phone]
Compliance Data
Comments:
Inspection Date 06/05/2014
Inspector's Name Robert Hayden
Inspector's Signature: Operating Status Operating
Compliance Code Compliance-inspection
Action Code FCE
Date of Signature: ' ) � U Q vj On-Site Inspection Result Compliance
Total Actual emissions in TONSIYEAR:
TSP S02 NOX VOC CO PM10 *HAP
2012 1.87 3.75 23.25 13.25 18.99 1.83 808.55
2011 2.07 3.39 23.66 13.27 17.92 2.02 762.68
2010 1.82 3.38 21.10 13.05 16.33 1.58 697.00
*Highest HAP Emitted in ounds)
Five Year Violation History:None
Date Letter Tyne Rule Violated Violation Resolution Date
Performed Stack Tests since last FCE:None
Date Test Results Test Method(s) Source(s)Tested

Two natural gas/No.2 fuel oil*/No. 6 fuel
oil/On Specification recycled No.4
B-1 and equivalent fuel oil/saleable fat-fired N/A N/A
B-2* boilers(33.0 million Btu per hour heat
input rate each)
Operating on NG—zero opacity.
One natural gas/No.2 fuel oil/saleable fat
B-3 -fired boiler(48.4 million Btu per hour N/A N/A
NSPS heat input)
Operating on NG-zero opacity.
One natural gas/No.2 fuel oil/No. 6 fuel
oil/On Specification recycled No.4
B-4 equivalent fuel oil/saleable fat-fired boiler N/A N/A
(33.5 million Btu per hour heat input)
Operating on NG—zero o acity
One natural gas/No.2 fuel oiUNo. 6 fuel
oil/On Specification recycled No.4
B-5** equivalent fuel oil/saleable fat-fired boiler N/A N/A
(29.3 million Btu per hour heat input)
Operating on NG—zero opacity
C-5 One air cooled condenser
in series with
Feather and Blood Rendering process C-1 One venturi scrubber(minimum scrubber
liquid inlet pressure 9 psig)with a
E2,E3,E4- consisting of.,
Mist eliminator
a,E4-b,
E4-c,E5-a, C-2 venting to One cyclone(60 inch diameter)with a
E5-b,and a) Seven batch cookers either Mist eliminator in series with a
E6 CY-1 combination of three natural gas/fuel oil
E9**** b)One rotary steam tube dryer
CM-1 /saleable fat-fired boilers
c One feather h drol ser B-1 to B-3 or One packed tower scrubber(minimum
y y C-4***, **** scrubber liquid inlet pressure 3 psig)
d)One feather press C-3**** One venturi scrubber(minimum scrubber
Operating no abnormalities noted. liquid inlet pressure 5 psig)in series with
B10**** P g C-4***, **** One packed tower scrubber(minimum
scrubber liquid inlet pressure 3 psig)
C-6 One air cooled condenser
in series with
El Rendering process consisting of: C-1 One venturi scrubber(minimum scrubber
One three stage slurry system evaporative liquid inlet pressure 9 psig)with a
condenser cooker with post heater forced Mist eliminator
circulation chamber on 1s`stage
C-2 venting to One cyclone(60 inch diameter)with a
either Mist eliminator in series with a
Operating—no abnormalities noted CY-1 combination of three(3)natural gas/fuel
CM-1 oil/saleable fat-fired boilers
B-1 to B-3 or One packed tower scrubber(minimum
C-4***,**** scrubber liquid inlet pressure 3 psig)
E18 One fluidizer tank C-3**** One venturi scrubber(minimum scrubber
liquid inlet pressure 5 psig)in series with
C-4***,**** One packed tower scrubber(minimum

visible emissions from the boilers firing on No. 6 fuel oil,recycled No. 4 fuel oil,No. 2 fuel oil and
animal fat oil daily against"normal." Record keeping and semiannual summary reporting.
APPEARED IN COMPLIANCE—B-1,B-2, B-3 and B4 were operating on natural gas,with zero
visible emissions. While on No. 6 oil in November, daily VE checks were recorded. There were no
abnormal readings recorded. While firing NG,facility checks VE daily anyway; VE log is well
organized and showed no exceedences. The last report was received on time(23 Jan 14),was
complete and appeared legitimate.
4. 15A NCAC 2D .0524 NSPS 40 PART 60 SUBPART Dc—The maximum sulfur content of any
_ oil combusted in boiler B-3 shall not exceed 0.5%, and the maximum VE shall be 20%. The
Permittee shall record and maintain records of the amounts of No. 2 fuel oil combusted during each
month and of the sulfur content through fuel supplier certifications. Semiannual reporting.
APPEARED IN COMPLIANCE—No oil has been combusted since the last inspection. The last report
was received on time (23 Jan 14), was complete and appeared legitimate.
5. 15A NCAC 2Q.0317 AVOIDANCE OF PREVENTION OF SIGNIFICANT
DETERIORATION for S02 and CO—Boilers B-1,B-2,B-3 and B-4 shall discharge less than 250
tons of sulfur dioxide and carbon monoxide per consecutive twelve-month period. The Permittee
shall record the amounts of natural gas,No. 2 fuel oil,No.6 fuel oil,On Specification No. 4 recycled
fuel oil, and animal fat oil combusted in the boilers each month;the Permittee shall also calculate the
amounts of carbon monoxide and sulfur dioxide emitted each month.
APPEARED IN COMPLIANCE—The monthly records are complete, and the format is improved
and more readable than prior. S02 emission under NG are inconsequential(1.3 tons for 12-month
perion ending in May 2014; CO was 12.6 tons. The last report was received on time(23 Jan 14),was
complete and appeared legitimate.
6. 15A NCAC 2D .0501 EMISSION CONTROL STANDARD—The daily emission of sulfur
dioxide from boilers B-1,B-2, B-3,B-4 and B-5 shall not exceed 3,644.49 pounds per day. The
permit allows calculations based on the PSD avoidance(monthly)calculations, divided by 30.
APPEARED IN COMPLIANCE—NG combustion generates S02 levels generally less than 1
lb/day.
B. One feather and blood rendering process consisting of one feather hydrolyser(E9)and seven batch
cookers (E2,E3,E4-a,E4-b,E4-c,E5-a and E5-b)and one rotary steam tube dryer(E6) controlled by
one air cooled condenser(C5) in series with one 50 gpm venturi scrubber(Cl)with a mist eliminator
(C2)in series with one 60-inch diameter cyclone(CYI)with a mist eliminator(CM I)in series with
three boilers(B-1,B-2, and B-3)or packed tower scrubber(C4),and one feather press (E10)
controlled by venturi scrubber(0) in series with packed bed scrubber(C4).
One rendering process consisting of one three stage slurry system evaporative condenser cooker(El)
controlled by one air cooled condenser(C6)in series with one 50 gpm venturi scrubber(Cl)with a
mist eliminator(C2) in series with one 60-inch cyclone(CYl)with a mist eliminator(CMl)in series
with three boilers(B-1,B-2, and B-3)or a packed tower scrubber(C-4),
One fluidizer tank(E18)controlled by venturi scrubber(0)in series with packed bed scrubber(C4).
One 320U cooker(E7)controlled by one air cooled condenser(C7)in series with one 50 gpm venturi
scrubber(Cl)with a mist eliminator(C2)in series with one 60-inch cyclone(CYI)with a mist
eliminator(CMl)in series with three boilers(B-1, B-2, and B-3)or a packed tower scrubber(C-4),
and
One centrifuge press(E8)controlled by venturi scrubber(0)in series with packed bed scrubber
(C4).

The area needing improvement from the last inspection has been addressed. The permit requires an
operator's log for checking high fire status when the boilers are used for odor control. The facility
now checks(and records)"pin" location,which is the vane/damper indicating firing rate. Pin
locations above 3 indicate high fire. These times were cross-checked against the VE logs and both
'Jived"and the system appears adequate for the intent.
2. 15A NCAC 2Q.03T7 AVOIDANCE CONDITION FOR 15 A NCAC 2D .1100: CONTROL
OF TOXIC AIR POLLUTANTS (State Only Requirement)—The Permittee shall only combust
recycled No. 4 fuel oil that meets the specifications listed in the permit. The Permittee shall record
the amount of recycled No.4 delivered to and combusted at the facility and retain the results of
analytical testing.
APPEARED IN COMPLIANCE—Zero recycled No. 4 has been purchased or combusted since
2005. The last report was received on time(23 Jan 14),was complete and appeared legitimate. The
need for a negative report was emphasized.
VI. CHEMICAL ACCIDENT PREVENTION/Sec 112r: The facility does not use or store any subject
chemical compounds in a quantity that would require a written Risk Management Program.
VH. PERMIT EXEMPT EMISSION SOURCES:
A. One loadout operation, 11321.1, 11321.2, and IE21.3, consisting of two bays in a building open on two
ends and one railcar loadout,
B. One grinding operation IE24.1, 11324.2, and IE24.2, consisting of three hammermill/shaker screen
systems.
VH. FIVE YEAR COMPLIANCE HISTORY: No adverse compliance actions in last 5 years.
VHI. CONCLUSIONS AND RECOMMENDATIONS:
A. At the time of the inspection,Valley Protein appeared to be operating in compliance with all air
permit stipulations.
B. Next inspection should include a check of the energy assessment record.
C. PINK SHEET ADDITIONS: None required.