AQ_F_0400053_20090714_CMPL_InspRpt

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NORTH CAROLINA DIVISION OF F iyetteviIle Regional Office
AIR QUALITY Boggs Paving,Inc. -Anson Plant
NC Facility ID 0400053
Inspection Report County/PIPS: Anson/007
Date: 07/14/12009
P Facility Data Compliance Data
I Boggs Paving,Inc.-Anson Plant Inspection Date 07/14/2009
481 Pee Doe Road Inspector's Name Robert Hayden
Lilesville,NC , 28091 Operating Status Operating
Latt 34d 56,0450ua Long:79d 53.2263m Compliance Code Compliance-inspection
SIC :'29511 Paving Mixtures And Blocks Action Code FCE
NAICS: 324121 /Asphalt Paving Mixture and Block Manufacturing On-Site Inspection Result Compliance
Contact Data Pei nut Data
Faeihty Cmftact Authorized Contact Technical Contact permit 09882/R00
Mark Jounen Drew Boggs Tim Melton Issued 3/
Operator President Asphalt Plant Manager ClassifExpires 2/28/20/2013
(7,04)848-4280 [phone] [phone] Permit Status
Synthetic Minor
Permit Status Active
{ Inspector's Signature: Comments:
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Date of Signature:
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DIRECTIONS TO SITE: From FRO take US401 south to US74; take US74 west into Anson County.
Less than I mile into Anson County,turn south (left) onto NC145. After 0.3 miles, turn left onto County Road
1842 at the Boggs Paving sign; it later becomes Pee Dee Road.. The plant is on left just past the railroad tracks.
(h) FACILITY DESCRIPTION: Boggs Paving is a batch hot mix asphalt(HMA) plant with a screen and
feed system for adding recycled asphalt pavement(RAP). Sand, gravel and fine gravel are received by truck and
=fed via bucket loader into hoppers that meter the material into a mixture. The mixture is shaken and loaded into
the natural gas/No. 2/No. 4/recycled No. 2/recycled No. 4 oil-fired rotary drum dryer to remove any moisture.
The dried mixture is then mixed with RAP (max. 15%) and asphalt cement. The asphalt is ready for use, and
loaded into tricks for transport to the paving site. Boggs employs 4 workers for 12 hours during a five-day week.
(III) 'INSPECTION SUMMARY: On 14 July 2009,1,Robert Hayden,Fayetteville Regional Office, arrived
at the Boggs Paving facility about9:45 AM for a compliance inspection. I first checked the bagfilter vent, non-
process dust from truck traffic and fugitives from the aggregate transfers (photos). I then met with Mark Jounen,
just as a hose broke on the bucket loader, and the decision was made to shut down the process until repairs were
matte. I then reviewed the fuel records,fuel certifications and the control device inspection and maintenance
records, all of which were good. DAQ issued the greenfield air permit in March 2008, and the facility began
producing asphalt oil 16 May 2008. DAQ SSCB approved the results of the NSPS stack test by letter dated xxx.
{ The facility was combusting recycled No. 4 during the inspection.
I inquired about the silo that was lying on its side near the entrance to the facility(photo). Mr. Jounen said that it
wasewlime silo that would hopefully be installed in the future, maybe this year. I "reminded"him to call FRO for
,permit applicability prior to installation.
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(IV) PERMITTED EMISSIbN SOURCES: The pormitincludes the following emission soarers and control
devices:"
A," NSPS Subpart 1"portableArmu hot inix asphalt plant(HMA), 385 tons per hour capacity,,con sistin
of.
I" i. " a cyclone(120 mch,wide, l08 i#ieh high, Ib No CD2) in series with a liagfiltcr(12,390" "
square fect of filter aioa,aD No. CDI) installed on a natural,gas/No.2Tuel ail/recycled Nq,2
fueloil/No. 4 fuel"oil/recycled No.44461 oil tired aggregate dryer/mixer(lD"No, GSl,120
mmBto/hour"heat input),
I ii: a surge bin(ID No. ES3), and
iii. "a"tiuck loadout operation(ID',No. FI).
B":" Portable recycled asphalt pavement(RAP)Tlanf, 193 tons per hour capacity, consisting of,, " .
j is two RAP conveyors (ID No.112), and "
j it. " a RAP screen (ID No;F3),
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(V), APP1 ICABhE AIR QUALITY REGULATIOMt ,
A; ISA NCAC'2D .0S60 jPAI2TICULATP,CONTROL"I21�QUII2EMPNT-' The particrihue cr fissions
` from the I1MA plant shall be invited to 66 pounds per hole`foi facilities processing more than 300"tonss "
hour.
I IN COMPLIANCE—"The AP-42 controlled omission,factor for a 385-ton per hour LIMA Plant is"5,.4 Mounds ,
per hour, and the 23,'Sep 09 stack testing indicated 129 lb"s/hr." .
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B, "15A'NC,AC'21) ,0515 M]SCEI.LANU4 0U,S PARTICULATE EMISSIONS—Tlie Pcrrilittpe shall limit"
particulate omissions to'E=4.9445 P^0.4376 f¢rP<300 tph and$-60lbs/hr for P>-30,01ph. .
IN"COMPLIANCE Sarne as above: "
C 15A NCAC 2D.0516 SULFUI2 DIOXIDE EMISSIONS—Sulfur'dioxide cntissi6ns from the,natural
ga"s/No. 2,fuel oil/No. 4 f1ie1 oil Fred aggregate/mixer(CD No. ES I)shall not exceed 2.3 pounds per ini Ilion
Btu heatillput.
I COMPLIANC> " =The AP-42 emissions factor for Nd. 2 it the maximum 0,5%sulfur content is 0,51 ,
' lbs/mmBtu; No. 4 fuel oil at 1 0%sulfur:uataral is 1.02,1bs/mmBtu.
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D. 1SA NCAC 2D,0521 CONTROL"OF VISIBLE VMISSIOINS—Visible emissions from the facility; ,
manufactlured after 11July�1971 shall not,exceed 2010 opacity. "
IN COMPLIANCE—During the inspection,I viewed the,baghouse exhaust, and the VE was 0%.
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I I . 1SA NCAC 20 .0524 NEW SOURCE PERF()I2IVIANCE STANDARDS;SUBPART I-The
aggregate diyer/mixer limited to 90 nng/dscm particulate matter or 20010 2pacity; ,Performance testing and
j notifications required,
IN COMPLLANCE—During the hispectiott;I observed 0%V B, except dul3lrg truck leaden when th,c V E
' surged to 10%to IS%. NSPS`testing on 23.Sep 08 tesultedili 9.7 mg/dsof.
F." 15A NCAC 2D .0524 NEW SOURCE PERFORMANCE STANDAOS SUBPART 1{6 -The
Potmittoo.shall maintain readily available documentatiorril dicating the capacity of the tank000s. : "
IN COMPLIANCE—The nameplate on one""asphalt cement Tank Iists the capacity"as 35, gallons. "The ,,
£acihty had docurnentation,of the sizo of tho other,,which. "Boggs-has added an additional AC tank,with,
NSPS nofi£Ication to FRO;the Tank should be"pmk=sheoted and added at the next permit touch.
I G. 15A NCAC 21) .
D.0540"FUGITLVE"NON PROCESS,DITS"I'EMISSIONS ThePertnittee shall not
allow fugiti ve Lion-process"dust�mi sions to contribute to substanfive complaints. "
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I IN COMPLIANCE—This site long and.nar"row with the 11MA-set back away from the roads I did observe a
number of trucks driving through the plant and the traffic did create some dust. About half of the distance
from"the road to the HMA has been paved with"'test' asphalt. N1r. Jounen said that a water truck is on site ,
and will"be used if the dust worsens. Eventually, the entire site'Will he paved.
i 11, 15A NCA,C 2D ,0611"FABRIC FIhT) R RtQLIHtEMENTS `The Permittee sliall record bagfiltcr
inspections and maintenance p,a logbook.
IN'-COMPLIANCE-The baghoase"kas inspected just prior to,startup oii 27 March 2008,including a leak
check using the flaorescenYdtlst, The last,apnual check was the"day prior- 13 July 09,.
I." " 15A NCAC 2D 0611 CYCLON V,REQUIRFMtI NTS-The Pcrmittee,shall:record cyclone inspections "
I and maintenance in a;logbook,.
IN COMPLIANCE The cyelono is checked weekly-good records. The internal iaspections,are"sehedulcd
on a"iluartorly basis;the eXte1`naLinspcetion for=uimulily,
J, 15A NCAi2 2D<;1100 TOXIC AIR"PO"LLUTAN'1, EMISSIONS LIMITATION ANTI REPORTING
REQUIREMENT—To'colnply with tile,air dispersion model"submitted with the permit application;the
Drum/Oryei, ID"No. ES 1,and the Singe lain,ID No. E93, shalt be,no closer than"I66 feet from the nearest,
i proporty loundary: Additionally,,asphalfproduction shalt be limited to 3$5 tons%hr and 890,000 tonslyr.
IN COMPLIANCE,—Robert Kennedy,FRO,, checked the load-out to properly line distill ice "
" previous inspeotton, The"hesfproduction to date has been 1 July 2009 . 1032"tons in about 7 hours. "
K =-1SAN ,AC 2D 1806 CONTROL AND PPOHI`1'ION OF ODOROUS EMISSSIONS—The odor at "
the facility's boundary shall not bo objectionable ,
11 IN"COMPLIANCE—During-the inspection th"ere was the slight'asphalt odor neat the rotary dryer;but that"
dissipated fat•short of the property,boundary. Mr. lounelrA d not know of any odor complaints;
a. "15A"NCACZQ .0315"LINIITATION,TQAV01615ANCAC2Q`.050t: Facility-widesulfurdoxide
omrssions,and car on monoxide emissions shall each be 12 less tliat.100"foils per conseoufive "month period,
To comply with Ithis limit,the asphalt production is limited to=800;000 tons por 12�ruonth period, and the "
sulfur conte[it of the No.2"is innited.to 0 S%and the No. 4 is lin}ited to;1.0%. The Perrhittee shall record
i montfily and total anuuali thn"asphi It production. The fuel certifications shall be,retained on site." "
IN" `C COMPLIANCE= umulative production Tecords are maintained at Boggs' niain office.'Mr Melton
faxed these,iccords toFRO on 30,July MO, Production"for the 12-month period"ending 30 June 2009,was
72,281,toiis,"T1 fuel oil"certifications stated the sulfur content ofthe N6,4'reeyeled fuel"oil ranged from "
�0.24%to"0,2$%,"
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M."15ANCAC 2Q .93IT LIMITAVON TO AV OID"PRtiVPNTION OF SIGNIFICANT"" "
DuritatoRATION,Facility-wide sulfur dioxide emissions shall be Icss that 250 tons;per consecutive 12-
month period.,To comply with this limit,t11e facility"mast comply with the 2Q.031 S"stipulation above':
TN COMPLI'ANCL ,During"the inspection, I reviewed the asphalt"production for2008: 69 695,tons.
" N, REC1`CLED NO.2anti RECYCLEWNO.4 FUEL Olt,REQUIREMENTS-The,Perniittec shall
feeord the amount of recycled oil"combusted,anJ,ther•esults of the analytical lestirrg."The No:21"ccycled fuel
oil is limited to 0,5%sulfur;the;No.4`recyclotl fuel oil is limited to 1:010 sulfur." ArmualxepottIng,
j IN COMPLIANCE—,During the inspection,l reviewed the records ofrecycled oil,(No, 4)receipts and the
" supii ercertifieations—IWMatEnvi9onmental (2l0Daltmi,Avc,"Charlotte-704/332-5600) 'Alldeliuerieso'
" showedsulfur less than'0.3%-15y weight„arid all parameters within the regulatory,limits." Thd annual report
was received atTRO on 23,,tan 69 and indicated cofriphancc.
(VW , PERMIT"EXEMPT EMISSION SOURCES:
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A. Hot Oil Heater,l.0 mmBtu heat input,ID No. IB81,
B. 30,00,0-g4llon Asphalt Cement Tank,ID No, I} S21 "
C. ""2a;000-gallon"Fue[Oil Tank,ID No IES3,and
D. Off=Road Tark 7,5010 gallon,ID No. IES4. "
I (VII) , CQMKtANCE"$IST0l2Y: None:
(Vill)",CONCLUSIONS AND RECOMMEND kTIONS: Based on"the obseiyations made duffing the 14,Ju1y"
20Q9 inspection, Boggs Paving=Anson appeared to be in compliance-with all of the regnirearients outlinedin their,
air permit,
ij l3nei; photos
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jcc: RCO Central Files(yellow)w/o enclosure,
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Boggs Paving, Inc Anson Plant
Photos taken by Robert Hayden, 14 July 2009
vY f �'.ilia f_�"'. s/�.� i.—...4.+15•( ..
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Fugitive dust from weigh hopper loading To-be-installed(?) lime silo

16131toU9bve1113OULa md,P_0. BOX 1609
Monme,WC 23111-16ID9
DATE, TOME:
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FAX: 5- 7 �
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JUL 3 oDENR
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F'AYETTEVILLE REGIONAL.OFFICE
diT,:a�pd L9bLS860'C6T :�1 :wo-+d 26:25 600cI -Hz--]Af

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Yearly Totals By Month m
Plant#5 Lilesville, NC
Production items w
Items Received
Month Produced I Sold Gallons Used Hot Oil Heater #4 Waste Oil 1#2 Non-Hi hwa Lime PG 64-22 G7 PG 5 - W.
Juy-OB 828 G -n
.
0 0 404.25 0 q p o
Augus4-06 7512 7246.41 11633 2149 5922 5999 0 259.35 p 0
.
September-08 2673,59 2279.93 4790 1434 6156 7530 0
94.03 D 0 0
October-0$ 7765.72 6941.73 14450 2832 12740 5600 0 191.6 23.89 0 0
November-08 8336.87 5654.14 12548 2958 0 7599 0 1 94.17 0 0 p
December OS 10060.98 9629.91 18556 2542 @ 15300 0 214 164.1 D p
January-09 4612.15 4471.17 9299 3473 6519 7600 0 65.73 138.55 0 .
February-49 4942.18 3764.04 7616 3395 6507 1 6018 0 47.9 73.04 0
March-09 © .. 0 p 823 0 7714 0 0 ® Q 0
AprH9 2764.3 2610.3 4773 2792 6420 7496 0 23.7 0 0
May-09 7409.37 7036,96 13514 3271 1300 7658 0 122.49 143.47 p 0
0
June-09 I I 10991A1 100@6.84 20274 2946 19454 763D
402.28 23.98
TOTALS:L 75281.38 1 70054.81 135594 31643 68771 86144 1 1) 2p19.5 567.03 1 p
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JUL 30 2009 -91
CEDE
Y -E REGIONAL OFFICE
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