AQ_F_0400043_20100720_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Fayetteville Regional Office
AIR QUALITY Triangle Brick Co-Wadesboro
NC Facility ID 0400043
Inspection Report County/FIPS:Anson/007
Date: 08/05/2010
Facility Data Compliance Data
Triangle Brick Co=Wadesboro Inspection Date 07/20/2010
US Hwy 52 Inspector's Name Heather Hawkins
Wadesboro,NC 28170 Operating Status Operating
Lat: 35d 1.1463m Long: 80d 5.1235m Compliance Code Compliance-inspection
SIC: 3251/Brick And Structural Clay Tile Action Code FCE
NAICS: 327121/,Brick and Structural Clay Tile Manufacturing On-Site Inspecti}on Result Compliance
Contact Data Permit Data
Facility Contact Authorized Contact Technical Contact permit 08179/T07
Paul Maxwell Howard Brown,Jr Howard Brown,Jr Issued 12/11/20,07
2012
Plant Manager VP of Production& VP of Production& Expires, Lion Title V
[phone] Engineering - Engineering 'Classification Title .;
[phone] [phone] Permit Status Active
Inspector's Signature- Comments:
C --
Date of Signature: /v
_611
1. MACT/GACT APPLICABILITY:
Triangle Brick Co-Wadesboro facility was subject to the Brick MACT(Subpart JJJJJ),until it was
Vacated: Now they are seeking a synthetic minor status by using a Dry Lime Adsorber(DLA)to reduce
BF emissions below TV thresholds. This way they can avoid being subject to the Brick MALT,
whenever it is re-promulgated.,They have no generators on site, and therefore are not subject to the
Reciprocating Internal Combustion Engine(RICE)NIACT(Subpart ZZZZ).
2. DIRECTIONS TO SITE: .
Triangle Brick is located on US52 in Wadesboro,NC,Anson County. From FRO,take US401 south to
US74;turn right onto US74 West. Follow US74 thru Wadesboro. On the west side of Wadesboro,turn
right,following US52 north. Go approximately 35 miles and turn right into the first facility entrance;the
office is on the left. Check opacities prior to entering(DLA stack, openings in bldg with grinders).
3. SAFETY:
Safety glasses and shoes required;helmet and ear protection optional. An operating kiln is hot to touch;
exiting bricks and cars are hot. Keep hands out of brick-making mechanisms, grinders and extruders.
_40 FACILITY DESCRIPTION:
Triangle Wadesboro is the second largest brick plant in the country. 'They make'a variety of bricks from
cl
ay and shale mined onsiThe mai� hey mine is a consistent mixture of clay and shale. As the
material is mined, it is trucked up the hill to the facility where it is fed through a sizing grate. The smaller
material passes via conveyors'to the storage shelter and the oversized material goes through,a jaw crusher
to reduce the size and then continues on to the storage shelter: From the storage shelter material is
scooped into a feeder,--run through a scalper(oversized material goes to hammer mill)then material (the
consistency of cornmeal)is conveyed to storage silos. From the storage silos the material is sent through
I -

two u mills in series where it is combined with sawdust loam and water and mixed to an even
pug ,
consistency then fed through a machine that extrudes the brick in a slab. The;slabs are'treated.with a.
decorative coating,cut into individual bricks and then loaded on a`car' for transport through the dryer
and kiln. The firing takes more than two days. After firing the brick are packaged into skid loads(by a
very cool robot)and stored prior to purchase and shipment.
5. INSPECTION SUMMARY:
On 20 July 2010,I,Heather Hawkins, and DENR Intern Michael Underwood,met with Paul Maxwell,
Plant Manager,to do a compliance inspection. Mr.Maxwell verified the facility contact information and
led a tour of the facility. Mr.Nathan Wallace,Kiln Supervisor,provided and discussed the records;
Triangle is currently operating at-25%capacity(one kiln operating at 50%)as housing construction
slow-down lowers the demand for,brick. Kiln K4 was.operating during the inspection. While not
currently required to,Triangle continues to operate the DLA(dry limestone absorber),but there are no
mon
itoring,n record kee in �or reporting requirements. Mr:Maxwell indicated that the facility,is seeking a
. P g p . ,
Title III minor permit classification in order to avoid the(yet to be re-promulgated)Brick MACT. Their
application has been submitted to the DAQ, and is under review.
6. PERMITTED EMISSION SOURCES:
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Two Brick Tunnel Kilns
K-1 One natural gas/No.2 fuel oil/No.b fuel oil- CD-K1** Dry Limestone
fired Brick Tunnel Kiln(29.0 tons per hour Adsorber(DLA)
material output rate,418 million Btu per hour
heat input rate
K-2* One natural gas/No.2 fuel oil/No.6 fuel oil- CD-K2* Dry Limestone
fired Brick Tunnel Kiln(29.0 tons per hour Adsorber(DLA)
material output rate,42.8 million Btu per hour
heat input rate)
Rotary Coatings Dryer
SD-1 One natural gas-fired Rotary Coatings Dryer N/A N/A
(8.1 tons of clay per hour material input rate,
0.3 million Btu per hour heat input rate)
NSPS 40 CFR Part 60 Subpart UUU
Primary Crushing Plant and Associated Conveyances
PC-1 and PC-2 Two shale feeders N/A N/A
PC-3 and PC-4 ` Two scalp screens N/A N/A
NSPS-40 CFR Part 60 Subpart 000
PC-5 and PC-6 Two jaw crushers N/A N/A
NSP­S—4-0-CFR-Part 60 Subpart 000-- -- -----
PC-7 One conveyor under PC-3 and PC-5 N/A N/A
NSPS-40 CFR Part 60.Subpart 000
PC-8 One conveyor under PC-4 and PC-6 N/A N/A
NSPS-40 CFR Part 60 Subpart 000
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PC-9 One cross-over conveyor N/A N/A
NSPS 40 CFR Part 60 Subpart 000
PC-10 One shuttle conveyor N/A. N/A
� NSPS-
40 CFR Part 60 Subpart 000
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Two Secondary Clay Grinding Plants and Associated Conveyances
CG=1 One clay feeder N/A 'N/A
CG-2 One conveyor belt to scalping screen N/A N/A
NSPS,-40 CFR Part 60 Subpart 000
CG-3 One scalping screen. N/A N/A
NSPS-40 CFR Part 60 Subpart 000
CG-4 One return conveyor belt for oversize from N/A N/A
screens;
'I
NSPS-40 CFR Part 60 Subpart 000
CG=S One conveyor belt to hammer mill N/A N/A
NSPS-40 CFR Part 60 Subpart 000
CG-6. One.hammer mill N/A N/A
NSPS-40 CFR Part 60 Subpart 000
CG-7 One conveyor belt under hammer'mill N/A N/A
NSPS-40 CFR Part 60 Sub art 000
CG-8 One conveyor belt to finish screens N/A N/A
NSPS-40 CFR Part 60 Subpart 000
CG-10 through CG-13. Four finish screens N/A N/A
NSPS'-40 CFR Part 60 Subpart 000
CO-14 One fines conveyor belt under screens N/A N/A
NSPS 40 CFR Part 60 Subpart 000
CG-15 One conveyor belt to storage bins N/A N/A
NSPS-40 CFR Part 60 Subpart 000
CG-16 One Conveyor,belt over storage bins N/A N/A
l.
NSPS-40.CFR Part 60 Subpart 000 -
CG-17 through CG-21 Five storage bins N/A N/A
� NSPS-40 CFR Part
60 Subpart 00.0
CG-22,through CG-26 Five feeders under storage bins N/A N/A
NSPS-40 CFR Part 60 Subpart 000
CG-27 One conveyor in front of storage bins _ N/A N/A
NSPS-40 CFRPart 60 Subpart 000
CG-28 One conveyor to pug mill N/A N/A
NSPS-40 CFR Part 60 Subpart 000
CG-29* One clay feeder N/A N/A
CG-30* One conveyor belt to scalping screen N/A N/A
NSPS-40 CFR Part 60 Subpart 000
CG-31* One scalping screen N/A N/A
NSPS-40 CFR Part'60 Subpart 000
CG-32* One return-conveyor'belt for oversize from N/A NIA
screens
NSPS-40 CFR Part 60 Subpart 000
CG-33* One conveyor belt to hammer mill N/A N/A
NSPS-40 CFR Part 60 Subpart,000
CG-34* One hammer mill N/A N/A
NSPS 40 CFR Part 60 Subpart 000

CG-35* One conveyor belt under hammer mill N/A N/A
NSPS-40 CFR Part 60 Subpart 000
CG-36* One conveyor belt to.finish screens N/A N/A
NSPS-40 CFR Part 60.Subpart 000
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CG-37 through CG-40* Four fmish screens N/A N/A
NSPS 40 CFR Part 60 Subpart 000
CG-41* One fines conveyor belt under screens N/A N/A
NSPS 40 CFR Part 60 Subpart 000
CG-42* One conveyor belt to storage bins N/A N/A
- NSPS 40 CFR Part 60 Subpart,000
CG-43* One conveyor belt over storage bins N1A N/A
NSPS 40 CFR Part 60 Subpart 000
CG-44 through CG-48* Five storage bins N/A N/A
-
NSPS-40.CFR Part 60 Subpart 000
CG-49 through CG-53* Five feeders under storage"bins N/A`. N/A
NSPS-40 CFR Part 60�$ub art 000
CG-54* One conveyor in'front of storage;bins N/A N/A
NSPS-40 CFR Part 60 Subpart 000
CG-55* One conveyor to pug mill N/A N/A
NSPS-40 CFR Part 60 Sub art 000:
Loam/ Sawdust Preparation Operation and Associated Conveyances
LS-1 Loam/'sawdust feeder N/A N/A
LS-2 One conveyor from loam/sawdust feeder to N/A N/A
finish screens
NSPS-40 CFR Part 60 Subpart 000
LS-3 One loam screen N/A N/A
NSPS 40 CFR Part 60 Subpart 000
LS-4 One:loam crusher N/A N/A
NSPS 40 CFR Part 60 Subpart.000: -
LS-S One oversize return conveyor from LS-3 N/A N/A
NSPS-40 CFR Part 60 Subpart 000
LS-6 One oversize return chute N/A N/A
- NSPS=40 CFR Part 60 Subpart 000
LS-7 One fines.conveyor belt under LS-3 to bunker N/A N/A
belt conveyor
NSPS-40 CFR Part 60 Subpart 000
LS-8 One belt conveyor to bunker N/A N/A
NSPS-40 CFR Part'60 Subpart 000
—L S-9 - —One-storage-bunk —N/A N/A
NSPS 40 CFR Part 60 Subpart 000
LS-10 One sawdust screen N/A N/A
NSPS-40 CFR Part 60 Subpart 000
LS-11 One conveyor to storage bins N/A N/A
NSPS 40 CFR Part 60 Subpart 000

LS-12 One oversize conveyor from sawdust screen N/A N/A
NSPS-40 CFR Part 60 Subpart 000
' -
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Above Ground Storage Tanks
III
T-1 One 24,000 gallon above ground No.6 fuel oil N/A N/A
storage tank
NSPS-40 CFR Part 60 Sub art Kb
T-2 and T-3 Two 24,000 gallon above ground No.2 fuel oil N/A N/A
storage tanks
NSPS 40 CFR Part 60 Sub art Kb
T-4 One 24,000 gallon above ground highway N/A N/A
diesel fuel oil storage tank
NSPS--40'CFR Part 60 Sub art Kb
T-5 One 24,000 gallon above ground Additive"A" N/A N/A
storage tank
NSPS 40 CFR Part 60 Subpart Kb
7.' PERMIT-EXEMPT EMISSION SOURCES:
I�
IS-Tank
3 000 ga
llon aboveb oun d sas oline storage tank
8. APPLICABLE AIR QUALITY REGULATIONS:
A. 15A NCAC 2D .0515 PARTIUCLATES FROM MISCELLANEOUS INDUSTRIAL
PROCESSES-Particulate emissions from each kiln,K-1 and K-2, shall not exceed.35.4 lbs%hour at a
production rate of 25 tons/hour,(4.1.x P 0-67): The Permittee shall'perform a semi-annual visual
inspection of kiln emissions ductwork and a'semi-annual visual inspection of the kiln's fuel combustion
system, and send semiannual summary reports to.DAQ.
IN COMPLIANCE—Facility operates on NG with fuel oil as backup. They haven't used fuel oil
since 2007. The AP-42 factor for particulates from a natural gas fired kiln is 0.371bs%ton,or 10.25
lbs/hour. During the inspection,I reviewed the I&M records documenting internal and external
hat were con
ducted semi-annuall however,the- records appeared somewhat artificial,
ins ections t y, pP
P
see Inspector's Note below. Kiln#2 has not operated since Dec 2008. The.last semiannual report was
received on time and appeared complete and valid.
INSPECTOR'S NOTE: The facility made some changes to recordkeeping since the last inspection in
regards to the inspector's concerns. However, the records still appear somewhat "artificial." There
are still no recorded incidents of needed maintenance, deviations or equipment malfunctions. Sources
j are grouped for various inspections and observations, but there is nothing to indicate which sources
are in the groups, or where and how the insp and obs are made.. There is still no language describing
what a "normal"opacity looks like, and nothing citing the initial 30-day period when'it was
determined. Mr. Wallace said he would make t e necessary changes.
REQUIREMENT—Sulfur dioxide
D .0516 SULFUR DIOXIDE CONTROL RE U
B. 15ANCAC 2 Q
emissions from each kiln,K-1 and K-2,and from rotary coatings dryer SD-1 shall not exceed 2.3
lbs/mmBtti heat input. For kilns K-1 and K-2,the Permittee shall monitor the sulfur content and the
i ,
Btu content of the No. 6 fuel oil through fuel supplier certifications.
i
i

i
IN COMPLIANCE—Since 2007,the facility has only received one shipment of No. 6 fuel oil and has
not combusted any of it to date: Kiln#2 has not operated since Dec 2008. The AP-42 factor for sulfur
dioxide from natural gas is 0.001 lbs/mmBtu;No.2 fuel oil is 0507 lbs/mmBtu No. 6 fuel oil is 2.1
lbs/mmBtu. The rotary coatings dryer SD-1 started operation in June 2005;on natural gas.
C. 15A NCAC 2D .0521 VISIBLE EMISSIONS CONTROL REQUIREMENT-Visible emissions
from kilns K-1 and K-2 shall not be more the 20 percent opacity.--The`Permittee shall observe the kiln
emission point once each month vs normal,and submit semiannual summary reports to DAQ.
IN COMPLIANCE-During the inspection,I-observed 0%VE from the common kiln stack at the
DLA,however Kiln#2 has,not operated since Dec 2008. I reviewed the log that documents VE
observations"as:normal each month,however,these records appear somewhat artificial, see Inspector's
Note above. The last semiannual report was received on time and appeared complete and valid:
D. 15A NCAC 2D .0524 NEW SOURCE PERFORMANCE STANDARDS SUBPART UUU For the
Rotary coatings dryer(SD-1),the Permittee shall comply with the notification and recordkeeping
requirements: dates of construction,anticipated startup and actual startup; performance test data; excess
emissions reports. VE shall not be greater than 10%;Permittee shall observe source stack daily for
normal vs abnormal VE.'The Permittee shall inspect and maintain the rotary coatings dryer in
accordance with the manufacturer's recommendation and shall perform a semi-annual internal
inspection for deterioration, damage and leaks.
IN COMPLIANCE-All notifications have been completed. During the inspection,I reviewed the
logbook of daily VE observations made at the building opening; a11 were recorded"normal." There
was no drying occurring,during the inspection. The facility has opted to rely on Method 22 checks at
the building openings. However,Mr.Wallace stated that he only makes the observations at the opening
closest to the hwy and not at"the other opening. J explained that he would need'to make the
observations at both openings. This source is also grouped,in Mr. Wallace's records,with other
sources for which he observes the VE at building openings and there is nothing to indicate which
i
-sources are in the group,where the VE observations are made or how they are made. I also reviewed
records of semi--annual inspections on the dryer,.which appeared complete and valid.:
E. 15A NCAC 2D .0524 NEW SOURCE PERFORMANCE STANDARDS SUBPART 000 For
the primary,crushing plant scalp screens 'aw crushers`and conveyors ID Nos.PC-3 through PC-10 ,
p rY_ g P P �J � Y ( g )
the Pennittee shall comply,with the notification and recordkeeping requirements: dates of construction,
anticipated startup and actual startup;performance test data; and excess emissions reports. The VE
shall not be greater than 10%except for crushers not greater than 15%;Permittee shall observe the
source stack�monthly for normal or abnormal VE. Permittee shall submit semiannual;summary reports
to DAQ.
IN COMPLIANCE-Sources PC-2,4, 6,8 &9,have not been installed;therefore NSPS notifications
have not been submitted. All notifications have been submitted for sources PC-1;3,5, 7, & 10. A
records review indicated compliance but the records appeared somewhat.artificial(see Inspector's Note,,
above). The sources are grouped, in Mr. Wallace's records,and there is nothing to indicate which
sources are in the group,where the VE'observations are made or how they,are in The crushing_
operations were not operating during the inspection. The last semiannual report was received on time
i and appeared complete and-valid.
F.13A NCA—C 2D�—.0524JNEW-SOURCE-PERFORMANCE-STAh1D- SJSUBPART-000=For-the
!i clay grinding plant scalp screens, finish screens,hammer mill, storage bins,feeders and conveyors(ID
Nos-. CG-2 through CG-8 and CG-10 through CG-28),source stack VE shall be'not be greater than 7"0/05
non-stack VE shall not be greater than 10%except for crushers not greater than 15%;Permittee shall
monthly observe building openings for any VE or source stacks for normal or abnormal VE. Permttee
shall submit semiannual summary reports to DAQ.
i

IN COMPLIANCE-During the inspection,I reviewed the logbook of monthly VE observations and
found it in order, if somewhat artificial(see Inspector's Note above). There are two openings to the
building, and Mr.Wallace stated that monthly Method 22 observations are made at the building
opening closest to the highway. Mr. Wallace has grouped the sources,for his recordkeeping, and some
are closer_to the other building opening,but observations are.,not being made at that location. I told him
that he needed to be making.observations at both locations,and indicating same. Additionally,Mr.
Wallace stated that he has never observed abnorrtial opacity during his VE observations,but that there
have been times when he has seen abnormal VE at the building openings. He stated that theywould
find the source of the VE,usually a belt of part of the hammer mill,and replace it. The last semiannual
report was received on time and,appeared complete and valid.
G. 15A NCAC 2D.0524 NEW SOURCE PERFORMANCE STANDARDS SUBPART 000-`For the
loam/sawdust preparation area loam screen,loam crusher,storage bunker,sawdust screen, and
conveyors(ID Nos.LS-2 through LS-12), stack source VE shall be not be greater,than 7% non-stack
VE shall not be greater than 10%except for crushers not greater than 15%;Permittee shall observe
building openings monthly for any VE Permittee shall submit semiannual reports to DAQ.
IN COMPLIANCE-Durng I reviewed the to book of monthly VE observations and
- ;the inspection,: g
found it in order, if somewhat artificial(see Inspector's Note,above). According to Mr. Wallace,these
4
sources are grouped in with other sources in the records,but nothing indicates which sources are in the
group,where the readings are made;or how they are made. The last semiannual report was received on
time and appeared complete;and valid.
H. 15A NCAC 2D:0524 NEW SOURCE PERFORMANCE STANDARDS SUBPART Kb The
Permitted shall maintain records showing the dimension and capacity of storage vessels.
IN COMPLIANCE-Previous inspection reports indicate that these records were reviewed and kept
onsite. However,during this inspection,these records were not available for review. 'I explained to Mt.
Maxwell that he needed to located these records and keep them onsite
I. 15A NCAC 2D'.0524 NEW SOURCE PERFORMANCE STANDARDS SUBPART 000 For.the
secondary clay grinding plant scalp screens, finish screens,hammer mill, storage bins,feeders and
conveyors(ID Nos. CG-30 through CG-55"), stack source VE shall be not be greaterthan 7%o,non-stack
VE shall not be greater than.10%o except for crushers not greater than 15% Permittee shall observe
monthly the building openings for any VE or source stacksfor normal vs abnormal VE. Semiannual .
report to DAQ.
IN COMPLIANCE During the inspection,I reviewed"the logbook of monthly VE observations and
found it in order. This operation is part of the Kiln#2 process,which has not operated since Dec 2008
t semiannual report was received on time and appeared complete,
`
(see Inspector's Note above).. The last p PP lete
p
and valid.
J.15A NCAC 2D A06 CONTROL AND PROHIBITION OF ODOROUS EMISSIONS The
Permitted shall not allow obj ectionable i odors to extend beyond the facility's boundary.
IN COMPLIANCE—I did not notice an objectionable odor upon entering or exiting the facility.
K. 15A NCAC 2D.1100 TOXIC AIR POLLUTION EMISSION LIMITATIONS AND
REPORTING REQUIREMENT—TAP emissions shall be controlled by limiting the amount of clay
and additives processed into each of the kilns-,K�..1 a K-- ,to 5$;00Y0-1bs/hour(29 TPH` -Quarterly --
summary reporting to DAQ
IN COMPLIANCE-Triangle is currently operating Kiln#1 at-50%capacity,which is-25% of the
facility's total capacity. The highest;hourly rate during the last 12 months was in June 2010- 13,164
tons through Kiln#1,resulting in 19.094 TPH. Reports have been received on time and appear accurate
and complete.

L. 15A NCAC 2Q.0711 PERMIT REQUIREMENTS FOR TOXIC AIR POLLUTANTS—The -
Permittee shall operate the facility,in such a way that any listed TAP emissions.from the facility do not
exceed TPERs.
IN COMPLIANCE-Based on emissions reported in the 2009 El,plus the current and last 12 months'
operating rates,Triangle Brick TAP emissions are below the listed TPERs with the exception of
fluorides. The TPER limit for fluorides in the permit is 0.34 lbs/day. Triangle Brick modeled for HF
and has a permit limit of 144 lbs/day from the two kilns(K-1 &K-2) -Therefore, it appears that the
TPER limit for fluorides that is currently listed in the permit is an error.
M. 15A NCAC 2Q.0317:AVOIDANCE CONDITION FOR 15A NCAC 2D`.0530 PREVENTION OF
SIGNIFICANT DETERIORATION-The sulfur dioxide emissions from;each kiln shall be less than
250 tons per 12-month period. The kiln production is limited"to 58,000 lbs/hour each and the amount of
No. 6 fuel oil,.with 2.1%sulfur,burned is limited to 920,000,gallons per 12-month period. \Quarterly
summary reporting to DAQ.
IN COMPLIANCE-Fuel oil has not been combusted since 2007, and the current production rates are
far below the monthly triggers. The last report was received on time and indicated compliance,but was
not formatted exactly correctly. See Note,below.
INSPECTOR'S NOTE: The facility records each kiln's throughput and fuel usage, but has only been
submitting 12 months of data, rather than the required 14-months of data. I informed Mr. Maxwell of
this and requested that they resubmit their July,2010 quarterly report with the correct data. The
corrected report was received on 29 July 2010. ---
COMPLIANCE HISTORY:
June"200Z NOV Late reporting
Sept 2002 NOV-Failure to comp
lete plete NSPS performance testing
-
Nov 2003-NOV—Late reporting
Sept 2005—NOV Late reporting
Dec 2005-NOV-Failure to complete NSPS performance testing
10. CONCLUSIONS AND RECOMMENDATIONS:
Based on the observations made during the 20 July 2010 compliance inspection,Triangle Brick appeared
to be generally in compliance with the requirements,with the exception of the items in italics, above.
Recommend sending a Compliance Information letter summarizing the minimally acceptable
requirements for recordkeeping.
During the next inspection,verify that the changes have been made to the I&M and opacity records.
/hsh
cc: RCO Central Files(yellow)