AQ_F_0400009_20110525_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Fayetteville Regional Office
AIR QUALITY Hornwood Inc
NC Facility ID 0400009
Inspection Report County/FIPS: Anson/007
Date: 05/25/2011
Facility Data Compliance Data
Hornwood Inc Inspection Date 05/25/2011
766 Bailey's Ferry Road hnspector's Name Robert Hayden
Lilesville,NC 28091 Operating Status Operating
Lat:34d 57.2115m Long:79d 57.6182m Compliance Code Compliance-inspection
SIC: 2258/Warp Knit Fabric Mills Action Code FCE
NAICS: 313312/Textile and Fabric Finishing(except Broadwoven Fabric)Mills On-Site Inspection Result Compliance
Contact Data Permit Data
Facility Contact Authorized Contact Technical Contact Permit 04888/R13
Kenneth Horne Jr Kenneth Horne Jr Kenneth Horne Jr Issued 10/12/2009
Executive Vice President Executive Vice President Executive Vice President Expires 9/30/2014
[phone] [phone] [phone] Classification Synthetic Minor
Permit Status Active
Alternate: Benny Burr
Inspector's Signature Comments:
�- n
Date of Signature: �^ ri-t�
MACT/GACT: There are not applicable MACT/GACT at this time. The facility has no generators or fire
pumps.
Location: Hornwood, Inc is located at Pit Road, SR 1812 in Lilesville, NC. Anson County.
Directions: From downtown Fayetteville, take Highway 74 west past Rockingham 5 miles to Hailey's
Ferry Rd/SR 1801 /Pit Road on the left. WR Bonsal is on the left. Go for— IA miles to Hornwood on
the right.
Safety: Standard FRO safety equipment required. Plant personnel do not wear helmets. Boilers, high
pressure steam leaks, and associated hot piping are the principal hazards.
Description: Hornwood, Inc is a textile company that warps, weaves, dyes yarn, and heat-sets (tenter
frame finishes) and doffs (textures) nylon and polyester knit fabrics. They produce baseball uniforms,
automible seat fabric, cloth for reverse osmosis, gauze, liners for tennis shoes, and cowboy shirts to name
a faw. Last compliance inspection conducted on 15 July 2010 by Maureen("Mad Dog")Matroni-Rakes.
Current throughputs: There facility employs about 360 people and operates 24 hrs/day,5 or 6 days/wk,
50 wks/yr.

Permitted Sources are:
Emission Emission Source Control Control System j
Source ID Description System ID Description
Boiler Operation,including:
O1 natural gas/No.2 fuel oil-fired oil boiler(9.06 mmBtu/hi
maximum permitted heat input) N/A N/A
Main-031 (NSPS) natural gas/No.2 fuel oil-fired boiler(44.398 mmBtu/hi N/A N/A
'maximum permitted heat input)
Main-032(NSPS) natural gas/No.2 fuel oil-fired boiler(15.7mmBtu/hr N/A N/A
maximum permitted heat input)
03 natural gas/No.2 fuel oil-fired boiler(22.65 mmBtu/hr
N/A N/A
maximum permitted heat input)
Textile Operation,including:
05-tentecno.1 textile tenter frame(1,500 lbs of cloth per hour maximum,
capacity)consisting of the following:
a) pad-applied finishing station,and CD-2 ! Condenser/Mist '
b) natural gas fired four zone thermonol (hot oil) Eliminator
heated oven(4.8 million Btu per hour maximum
heat input) ii
07.tenter.no.2 textile tenter frame(2,300 lbs of cloth per hour maximum i
;capacity)consisting of the following:
a) pad-applied finishing station,and CD-2 Condenser/Mist
b) natural gas fired six zone thermonol(hot oil) i Eliminator
heated oven(9.0 million Btu per hour maximum j
heat input)
06.tenter.no.3 textile tenter frame(2,000 lbs of cloth per hour maximum
;capacity)consisting of the following:
a) pad-applied finishing station,and j
b) natural gas fired four zone thermonol (hot oil)
heated oven(7.2 million Btu per hour maximum
heat input) CD-1 ; Condenser/Mist
10 textile tenter frame(2,100 lbs of cloth per hour maximum Eliminator
;capacity)consisting of the following:
a) pad-applied finishing station,and
b) natural gas fired six zone thermonol(hot oil) j
heated oven(6 million Btu per hour maximum j
heat input)
Insignificant/Exempt Activities
Source Date of Exemption Source of {Source of Title V j
Application Regulation TAPS? i Pollutants?
I-ES 11 - Surface Finishing 05/30/2006 2Q .0102 (c)(2)(E)(i) l Yes Yes
Operation

Preinspection Conference: On 25 May 2011, I, Robert Hayden, FRO DAQ, met with Mr. Kenneth
Horne Jr. We verified all FacFinder information. Mr. Horne said that there had been no changes in
processes, equipment or formulations since the last inspection. Business is relatively good, thanks to the
steady Japanese auto sales and demand for polyester seats. Mr Horne said that Mr. Benny Burr the
wastewater manager is gradually assuming more environmental roles and could be listed as an alternate
contact. Mr. Wayne Martin provided the condenser maintenance logs.
Process Description: This process may be divided into several distinct operations and are discussed as
follows:
a. Warping: Yarn is spun onto a single spool for processing in the knitting room. Yarn may also
be draw warped which draws the diameter of the yarn down by heat and tension. Draw warping
effectively reduces the size of the yarn.
b. Knitting Room: Spools go onto a mandrel that feeds the knitting machines.
c. Middle Warehouse: This is where both finished and unfinished fabric is stored until either
future processing is done or shipped to the customer.
d. Dye House: Dye is added to the fabric in one of two processes, beam or jet dying. In beam
dying,fabric is wound onto a beam with holes that allow the dye to pass through. The dye
solution is pumped from the rear of the chamber and passes through holes in the beam and out
through the fabric. In jet dying, the cloth is pulled through a tube in the top of the dye chamber
by means of a roller and dye water and is constantly in motion through a solution in the bottom of
the chamber. They are now adding fire retardant here to reduce VE in the tenter frame.
e. Finishing: Here, cloth is passed through one of four tenter frames which heat sets the fabric to
reduce shrinking and stretching, and add chemicals which stiffen or coat the material.
f. Napping: One of three things may be performed on the material during this process. The
fabric will be napped which gives it the appearance of fleece, or shearing which cuts off the top
of the fleece, or sueded which sands the fabric.
g. Mist Eliminators: The exhaust air from the tenter frames flows through a pre-filter that takes
out some of the dry particles with a one inch fiberglass mesh using two trays to pass the air
through. They change these daily. Next, the air passes over six cold water coils that helps
condense the vapor and send it through the mist eliminator. The coils are washed daily and taken
out quarterly for washing. They discovered a problem with the pipes leading to the coils that had
to do with pipe threads. They have ordered new pipes so that the coils won't have to be replaced.
The mist eliminator houses 18 two-inch fiberglass cylinders that are surrounded by a wire mesh.
The condensed vapor passes through the center of the filter then proceeds out the stack. The
filters have to be cleaned during a shut down. They have had to replace the filters once already
because of epoxy buildup. A different surfactant is being used now that helps cut through the
epoxy, but they must first soak the filters weekly. Jet nozzles are located at the bottom center of
each filter tube and spray wash water into each. The rinse water is collected at the bottom of the
collector unit and sent through a trap to a holding tank for collection and disposal. They have not
collected enough material yet to weigh.
Inspection Summary: We discussed the letter Mr Horne had just received regarding new NSPS Do
opacity monitoring requirements. I assured him we would be in contact more as the DAQ action plan
firmed up. I checked VE from the two condenser and four boiler stacks prior to entering the plant. We
toured the plant and confirmed the accuracy of the permit and that there were no unpermitted sources.
Only one boiler(Main 031) has a legible data plate. Two boilers were operating onNG. Both
tenter/condenser stacks were emitting something, but the sun position, complexity of the emission stream
(vapor percentage) and poor background all complicate a valid VEE. Mr Horne said he would research
recommended temperature and throughput rates to possible reduce opacities. The condenser maintenance
logs were very good.

Stipulation Review:
2D.503 Particulate from combustion.
Compliance Indicated. The boilers have been operating on natural gas for the last year and AP-42
emission factors indicate compliance.
2D.0515 Particulate control from miscellaneous processes(tenters, presumably).
Compliance Indicated. Determined at initial permit review. Should have improved with installation of
condensers.
2D..0516 Sulfur Dioxide control.
Compliance Indicated. The boilers were operating on natural gas on the day of the inspection. When
fuel oil is combusted, NSPS Dc requires sulfur content no greater than 0.5%.
2D.0521 Visible Emissions control.
Compliance Indicated. No VE was noticed on the day of inspection, although there have been concerns
in the past.
2D.0524 NSPS fuel cert reporting.
In Compliance. No oil combusted since last inspection.
2D.0611 —Condenser/Mist Eliminator Requirements. Elements of the logbook include:
a) Amoral internal inspection - looking for structural integrity, coolant leakage,pressure
checks, presence of coolant in condensate. The checklist is good, with standards,
names of checkers, itemized things to check, dates and remarks. While frequent
maintenance was recorded (2 or 3 checks during each day of operation), there was no
listed annual, comprehensive inspection. Mr Martin said he would begin designating
an annual inspection.
b) Inspect and maintain structural integrity of duct work and piping leading to and
coming from condenser/mist eliminator.
c) Change pre-filter once per week.
d) Implement wash procedure when the pressure drop across the fiberglass Mist
Eliminator increases to 7.5 to 8.0 inches of water.
e) Implement wash procedure when pressure drop across water coils increases to 3.0
inches of water.
f) Weight of both the oil and particulate material collected in the condenser/mist
eliminator weekly.
Compliance Indicated. Maintenance checks are done daily on the condenser/mist eliminators. Twice
yearly they are internally checked for problems. The filters are changed weekly.The facility has not had
the any problems will pressure drops on the fiberglass mist eliminator but one is washed daily and the
other weekly just to make sure.
2D.0958(c) Work Practices.

Compliance Indicated. No rags, buckets or containers with VOC containing materials were left open or
unsealed. Very little solvent in use.
21).1806 Control and Prohibition of Odorous Emissions.
Compliance Indicated. No offensive odors were noticed on either side of the property.
2D.0540 Dust Control
Compliance Indicated. No dust was seen on the entrance of the facility or in the roadway. Most surfaces
are paved.
2Q.0711 Toxic Air Pollutant Emission Limit.
Compliance Indicated. No applicable changes in operating rate or formulations since last permit review.
Therefore they are incompliance from review done during their permit application process.
112R Status: Hornwood does not store any regulated chemicals in amounts that would make them
subject.
Compliance History: None in last 5 years. VE and reporting violations 1999-2005
Comments and Recommendations:
1. Plant should research tenter operating parameters to maybe reduce opacity; condenser vents are
difficult to read, but may exceed limits. Perhaps inspect early or late in the day to attempt better VE
read.
2. Boilers should be labeled as to ID, size and mfg date (at least ID). We researched past permit reviews
and found that the boilers from left to right, as observed from outside, are 01, Main 032, Main 031 and
03.
3. When the DAQ actions resulting from the changes to NSPS De, inform Mr Horne.
4. Hornwood appeared to be in compliance during this inspection.