AQ_F_0400009_20100715_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Fayetteville Regional Office
AIR QUALITY Hornwood Inc
NC Facility ID 0400009
Inspection Report County/FIPS Anson/007
Date: 07/23/2010
Facility Data Compliance Data
Hornwood Inc inspection Date 07/15/2010
766 Hailey's Ferry Road Inspector's Name Maureen Matroni-Rakes
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/RI3
Kenneth Horne It Kenneth Horne Jr Kenneth Horne Jr Issued 10/12/2009
Executive Vice President "Executive Vice President Executive Vice President Expires 9/30/2014
(704)'848-4121 > [phone] (704) 848-412L Classification Synthetic Minor
Permit Status Active
Inspector's Signature: *V1 Comments:
Oak
Date of Sig : ,71Z-7/Zoto
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- 1/4 miles Hornwood is on
the right.
Safety: Safety glasses and safety shoes;helmet and ear protection optional (not needed). Boilers, high
pressure steam leaks, and associated hot piping are the principal hazards.
Description: Hornwood,Inc is a textile company that warps, weaves, dyes yam,and heat-sets(tenter
frame finishes)and doffs (textures)nylon and polyester knit fabrics. They produce baseball uniforms,
cloth for reverse osmosis,gauze, liners for tennis shoes, and cowboy shirts to name a few. Last
compliance inspection conducted on 10 June 2009 by Robert Hayden.
Current throughputs: There facility employs 360 people and operates 24 hrs/day, 6 days/wk, 51 wks/yr
or 6000 hours/yr.

Permitted Sources are:
. . _ ._ __... - - ._. _ _
,R
Boiler Operation,including:
O1 11natural gas/No 2 fuel oil fired oil boiler(9.06 mmBtu/hr ( N/A N/A I
maximum permitted heat input) 3
Main-031 (NSPS) natural gas/No.2 fuel oil fired boiler(44.398 mmBtu/hr N/A
N/A I
maximum permitted heat input)
Main-032 NSPS) natural gas/No 2 fuel oil-fired boiler(15.7mmBtu/hr N/A N/A
( l
i maximum permitted heat input)
---��--- —
03 natural gas/No 2 fuel oil feed boiler(22 65 mmBtu/hr
I—� maximum permitted heat input).. N/A: N/A
Textile Operation,including �~
05-tenter.no.I textile tenter frame(1,500 lbs of cloth per hour maximum,
_ capacity)consisting of the following:
a) pad applied finishing station, and CD 2 I Condenser/Mist I
b) ,natural gas fired four zone thermonol (hot oil) ! Eliminator ;
heated oven B million
8 4. mon Btu per hour maximum! i
( P I
--_- -- -- - heat input)_._ ._.__. ._._i . _..__._._. ... _..._.
f07.tenter.no.2 textile tenter frame(2,3001bs of cloth per hour maximum, s .. _.-�'�1 capacity)consisting of the following:
a) pad-applied finishing station,and CD-2 Condenser/Mist ;
b) natural gas fired six zone thermonol(hot oil) Eliminator
heated oven9 0 million Btu per hour maximum j
( P � ,
heat input)
I
06.tenter.no.3 textile tenter frame(2,000 lbs of cloth per hour maximum —1
capacity)consisting of the following: i
a) pad-applied finishing station,and
b) natural gas fired four zone thermonol(hot oil) I I
heated oven(7.2 million Btu per hour maximum 4 I
input) _._..__.. _-.. CD-1 Condenser/Mist +'
10 ^textile tenter frame(2,100 lbs of cloth per hour maximumi Eliminator
capacity)'consisting of the following. I l a) pad applied finishing station,and i
b) natural gas fired six zone thermonol(hot oil)
I heated oven(6 million Btu per hour maximum i
heat input)
Insignificant/Exempt Activities
2s a
I-ES 11 Surface Fmtshi g�OS/30/2006 2Q .0102(c)(2)(E)(i) Yes Yes-�.�

Preinspection Conference: On 15 July'2010, I,Maureen Matroni-Rakes,FRO DAQ,met with Mr.
Kenneth Horne Jr. We verified all FacFinder information and found it current and up-to-date. Mr.
Horne said that there had been no changes in processes,equipment or formulations over the past year.
The facility has no fire pumps or generators.Mr. Benny Burr and Mr.Wayne Martin provided some of
the needed records that Mr. Home did not have access to:
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 yam 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 aroller and dye water and is constantly in motion through solution in the bottom of
the chamber. They are now adding fire retardant hereto 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 shutdown. 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: I checked VE from the operating condenser and boilers prior to entering the
plant. We toured the plant and confirmed the accuracy of the permit and that there were no unpermitted
sources. I was given a full tour of the facility and all permitted emission sources were pointed out. On the
day of the inspection one of the boilers was down ES-01 which runs ES-06 and ES-10(two textile tenter
frames).The boiler was fixed as I was leaving and no VE was observed from the stacks in question.

Stipulation Review:
2D.503 Particulate control from combustion.
In Compliance. The boilers were operating on natural gas for most of the year and AP-42 emission
factors indicate compliance. 23,226 gallons of No.2 at 0.5%sulfur was used during the winter and
emission calculations show they are incompliance.
2D.0515 Particulate control from miscellaneous processes(tenters,presumably).
In Compliance. Determined compliance at initial permit review. Should likely have improved within
installation of condensers.Last year the facility processed I million pounds and the highest through put
was 725 lb/hr.
2D..0516 Sulfur Dioxide control.
In compliance. The boilers were operating on natural gas on the day of the inspection. Natural gas
emission factors demonstrate compliance. 23,226gallons of No.2 at 0.5%sulfur was used during the
winter and emission calculations show they are incompliance.
2D.0521 Visible Emissions control.
In Compliance.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. Fuel oil certifications were kept for the No. 2 oil that was bought this past winter.Fuel
oil certifications show 0.5% sulfur for all oil.
2D.0511 —Condenser/Mist Eliminator Requirements. Elements of the logbook include:
a) Annual internal inspection-looking for structural integrity,coolant leakage,pressure
checks,presence of coolant in condensate. While frequent maintenance was recorded
(2 or 3 checks during each day of operation), there was no listed annual,
comprehensive 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.
In Compliance. 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.
In Compliance. No rags,buckets or containers with VOC containing materials were left open or
unsealed.
2D.1806 Control and Prohibition of Odorous Emissions.
In Compliance. No offensive odors were noticed during my inspection.
2D.0540 Dust Control
In Compliance. No dust was seen on the entrance of the facility or in the roadway.
2Q.0711 Toxic Air Pollutant Emission Limit.
In Compliance. No applicable changes in operating rate or formulations since last permit review.
Therefore they are incompliance from modeling done during their permit application process.
112R Status: Hornwood does not store any regulated chemicals in amounts that would make them
subject.
5 Year Compliance History:
16 June 1999 Hornwood received a warning letter for late annual report.
6 January 2003 Hornwood received a NOV for late quarterly reporting.
28 February 2003 Hornwood received a NOV for late annual report.
23 September 2003 Hornwood received a NRE for VE violation.
18 June 2004 Hornwood received a NOV for late annual report.
11 August 2005 Hornwood received a NRE for VE violation.
18 August 2005 Hornwood received a Continuing Violation for Visible Emissions.
Comments and Compliance Statement:
On 15 July 2010,Hornwood appeared to be in compliance with their permit number 4888 R13.
/mdr
cc: DAQ Central Files(yellow)