AQ_F_0400005_20110824_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Fayetteville Regional Office
AIR QUALITY Bonsai American
NC Facility ID 0400005
Inspection Report County/FIPS: Anson/007
Date: 08/25/2011
Facility Data Compliance Data
Bonsal American Lrspection Date 08/24/2011
351 Hailey's Ferry Road Inspector's Name Cindy Grimes
Lilesville,NC 28091 Operating Status Operating
Lat: 34d 57.5360m Long: 79d 57.4490m Compliance Code Compliance -inspection
SIC: 3272/Concrete Products,Nee Action Code FCE
NAICS: 32739/Other Concrete Product Manufacturing On-Site Inspection Result Compliance
Contact Data Permit Data
Facility Contact Authorized Contact Technical Contact Permit 01759/R19
Charles Knight Frank Ketchum Ken Brown Issued 10/3/2007
Safety,Health,and Regional Plant Manager EHS Director Expires 3/31/2012
Environmental Rep. [phone] [phone] Classification Synthetic Minor
[phone] Permit Status Active
Inspector's Signature: Comments:
Date of Signature:
MACT/GACT Applicability: None(There are no emergency generators on site).
1) Location
Bonsal American is located at 351 Hailey's Ferry Road, outside of Lilesville,NC, Anson County.
Directions
From FRO,take Hwy 401 South to Wagram.Turn right onto Old Wire Road (1-Iwy 144)and go— 11 %miles
to Laurel Hill. Turn right onto US 74 West and continue for—25 miles until you enter Anson County,just
after crossing the Pee Dee River. Go— 5 more miles to Hailey's Ferry Road (crossroads SR 1801), where
there is a large antique cart in a yard on the right and a sign for Welika Fish Camp on the left. Turn left, go
almost .2 mile, and then just before the railroad tracks,take a left onto facility's dirt drive. Main office is on
the right.
Safety Considerations: Standard DAQ safety equipment, including vest. Watch for forldifts and truck traffic
throughout the whole facility during inspection.
2) Facility and Process Description
W R. Bonsal, Inc. is a mineral mixing and packaging facility that primarily manufactures bagged concrete. It
also produces play sand, all-purpose sand,and mortar.The processing plant is on contiguous property with
the W. R. Bonsal mine.This facility is permitted under Air Permit No. 17591119, effective from 3 October
2007 until31 March 2012. Cindy Grimes conducted the last compliance inspection on 29 July 2010.
Raw materials are delivered on site, processed and dried through the sand and gravel dryer and stored in
designated silos. They are then blended and packaged/bagged according to the specified concrete mix and
customer.

a) Current Throughputs for2010
Employees: 26 (including drivers)(21 in 2009)
Hours: 6AM—2:30PM Mon-Fri, 40 hrs/wk, 52 wks/yr(same in 2009)
Material received: Portland Cement 23,156,750 lbs in 2009
Masonry 4,136,754 lbs in 2009
Fly Ash 4,056,782 lbs in 2009
Units Produced: 1,967,691 Bags in 2009
b) .Permitted Sources
Emission Emission Source Control Control System
Source ID Description System ID -- Description
Drying Operation, consisting of:
ES30 Natural gas/No. 2 fuel oil-fired(15 BHIA Bagfilter(3,825 square feet of filter area)
mmBui max heat input)sand and
gravel dryer(50 tons per hour
maximum capacity)
Production Line 1,consisting of:
SF22 IPortland cement silo,Line 1 BH22 IBagfilter(156 square feet of filter area)
SF23 Recycled cement silo,Line 1 BH23 Bagfilter(156 square feet of filter area)
SF24 IFly ash silo,Line l F B2424 Ifiagifilter(156 square feet of filter area)
SF25 INomix cement silo, Line l F BH25 Bagfilter(156 square feet of filter area)
ES03 FRockaudand bucket conveyor BH1A Bagfilter(3,825 square feet of filter area)
cludin a rock silo and a
g
ESOl Cement handling operation(bagging, BH01 Bagfilter(3,840 square feet of filter area)
weighing,mixing),Line 1
Production Line 2,consisting of:
SF40 IPortland cement silo, Line 2 r BH40 IBagfilter(156 square feet of filter area)
SF41 IRock silo,Line 2 BH41 Bagfilter(156 square feet of filter area)
SF42 Sand silo split,Line 2 134142 113agfilter(156 square feet of filter area)
SF43 IFly ash silo,Line 2 B1443 lBagfilter(156 square feet of filter area)
SF44 Type S cement silo, Line 2 BH44 IBagfitter(156 square feet of filter area)
SFS2 IRecycled cement silo, Line 2 F 111152 , IBagfitter(156 square feet of filter area)
El Rock screen from sand, Line 2 BH13 Bagfilter(1,200 square feet of filter area)
ES02 Dement handling operation (bagging, BH02 Bagfilter(1,900 square feet of filter are)
weighing, mixing),Line 2
3) Inspection Conference
On 24 August 2011, I(Cindy Grimes)met with Jeff Horne (Plant Manager). Charles Knight, the Facility
Contact, was on extended sick leave and not available.Mr. Horne and I discussed the following:
a) Verified the FACFINDER information.
b) There have been no changes since last year's compliance inspection. Mr. Horne told me there have
been no problems with any of the permitted equipment.
c) I told Mr. Horne that I would be returning for the permit renewal inspection—November of this year,
and I can assist them with the emissions inventory and application forms at that time.

d) I inspected the logbooks, of which separate ones are kept for each bagfilter: The lead maintenance
technician or Mr.Knight usually performs the inspections,which includes inspections of the bags,
blower, ductwork, and observation of visible emissions. The results are all noted in the logbooks. These
inspections used to be done weekly but are now clone every 3 weeks. There is also an annual inspection
done on the system, usually toward the beginning of each year. This year's was performed in January.
4) Inspection Summary
Mr. Horne led me on an inspection of the facility, which was operating at the time. The results are as follows:
a) There was no unloading of products that occurred during the inspection.Drivers are told to unload at 10-l 5
psi, with their trucks being set at the maximum pressure of 15 psi before a relief valve on the trucks is
kicked off.
b) SF-22,23,24,25,40,41,42,43,44,and 52(all silos): I observed no excess build up of materials on any of
the silos,which might indicate any compromises.I observed 0%VE from all of these sources.
c) ES-03 (rock& sand conveyor operation), ES-18 (rock screen from sand): All conveyors and screens
appeared to be operating properly.
d) ES-01,ES-02(cement handling operations): Both of these lines operate inside a warehouse and appeared
to be working properly.
e) ES-30 (sand and gravel(fryer): Even though this dryer is old, it appears to function well. The input
temperature range for the sand is usually between 300-325 degrees F, and for the gravel, 225-250
degrees F. I saw no obvious problems,with VE being 0% in opacity. There is a magnehelic manometer
on the dryer to record the various drops of pressure within the bag house. Maintenance checks the
readings regularly and then records them into the logbooks.
f) I saw no excess dust from any trucks entering or leaving the facility.
5) Permit Stipulations
a) A.3 2D .0515 PARTICULATE CONTROL REQUIREMENT—Particulate matter emissions from
sources shall not exceed the allowable rates.
In Compliance—Latest permit review indicates compliance.
b) A.4 2D .0516 SULFUR DIOXIDE CONTROL REQUIREMENT—SO2 emissions from the combustion
sources shall not exceed 2.3 Ibs/mm BTU.
In Compliance—The AP-42 emissions factor for No. 2 fuel oil is 0.507 lbshnmBtu; natural gas is
0.001 Ibs/mmBtu.Facility is only burning natural gas at this time.
c) A.5 2D .0521 VISIBLE EMISSIONS CONTROL REQUIREMENT—Visible emissions from the
emission sources shall not exceed 20% opacity.
In Compliance—All visible emissions observed were 0% in opacity.
d) A.7 2D .0540 FUGITIVE CONTROL REQUIREMENT-The Permittee shall not allow fugitive
lion-process dust emissions to contribute to substantive complaints.
In Compliance—I saw no excess fugitive dust emissions during my inspection. The haul roads are
gravel/sand,and Mr.Horne said that he has not received any complaints.He uses water from a watering
truck if dust becomes a problem during a dry spell.
e) A.8 2D .0611 BAGFILTER REQUIREMENTS—Particulate matter emissions shall be controlled by
the permitted equipment list,with periodic/annual inspections performed and records kept in a logbook.
Irr Compliance—Separate logbooks are kept for each bagfilter, and regular and annual inspection
records are kept current.

6) Reporting Requirements
There are no reporting requirements for this facility in their current permit.
7) 112R Status
This facility neither uses nor stores chemical compounds that require a written risk management plan
under the Clean Air Act, Section I I2R.
8) DAQ Compliance History
a) 9 November 2005—NOWNRE for B6,Improper Operation and Maintenance and 2D.0535, Failure to
Report Malfunction.
b) 30 September 2003—NOV/NRE for 2D .0521,Excessive Visible Emissions.
c) 6 September 2000—NOWNRE for Operating Without an Air Permit and 136, Improper Operation and
Maintenance
d) 15 June 1999-Warning Letter,excess dust from play sand silo.
9) Comments and Compliance Statement
Mr. Horne verified that all drivers here know the procedure policy for the unloading of a product, in regards to
excess VE and pressure.
Note: The question had come up in the past concerning if this facility is subject to NSPS Subpart UUU
(Standards of Performance for Calciners and Dryers in Mineral Industries).In 2010, Robert Hayden and Cindy
Grimes called Frank Ketchum (facility's Authorized Contact)to get information concerning the rotary sand
dryer. The dryer here was installed in the 1950's,thus predating the requirements of this subpart(installation
date must be after 23 April 1986 to be subject).
Bousal American appeared to be in compliance oil 24 August 201 l.
/clg
cc: DAQ Central Files