The URL can be used to link to this page

Home My WebLink AboutAQ_F_0400037_20220525_CMPL_InspRpt NORTH CAROLINA DIVISION OF Fayetteville Regional Office AIR QUALITY The Quikrete Companies- Peachland Plant NC Facility ID 0400037 Inspection Report County/FIPS: Anson/007 Date: 06/03/2022 Facility Data Permit Data The Quikrete Companies-Peachland Plant Permit 06907/R10 13471 Highway 74 West Issued 12/14/2020 Peachland,NC 28133 Expires 10/31/2022 Lat: 34d 59.3110m Long: 80d 17.8790m Class/Status Synthetic Minor SIC: 3272/Concrete Products,Nec Permit Status Active NAICS: 32739/Other Concrete Product Manufacturing Current Permit Application(s)None Contact Data Program Applicability Facility Contact Authorized Contact Technical Contact SIP Leroy Bean Leroy Bean Braden Keiger Plant Manager Plant Manager (704)272-7677 (704)272-7677 (678)234-3344 Compliance Data Comments: Inspection Date 05/25/2022 Inspector's Name Mike Thomas Inspector's Signature: Operating Status Operating Compliance Status Compliance- inspection Action Code FCE Date of Signature: Inspection Result Compliance G Total Actual emissions in TONS/YEAR: TSP S02 NOX VOC CO PM10 * HAP 2013 1.87 --- 0.8400 0.1300 0.9700 0.7441 --- 2008 0.4870 --- 1.78 0.1400 1.03 0.2750 --- Highest HAP Emitted inpounds) Five Year Violation History:None Date Letter Type Rule Violated Violation Resolution Date Performed Stack Tests since last FCE:None Date Test Results Test Method(s) Source(s)Tested I. Directions: From FRO,head south on Green St toward Maiden Ln. At the traffic circle,take the 2nd exit onto Gillespie St. Turn right onto W Russell St. Turn left onto Robeson St. Use the left 2 lanes to turn left onto Raeford Rd and continue for 10 miles. Just past Wagram,turn right onto Old Wire Road (NC Hwy 144).Turn right onto Old Wire Road(Hwy 144)and go— 11 1/z miles to Laurel Hill. Merge onto HWY 74 W. and continue for 65 miles to Peachland. The facility is on the left right before the Union County line. II. Safety Considerations: Standard DAQ safety equipment. Be alert to trucks entering and exiting property. III. Facility and Process Description: The Quikrete Companies-Peachland is a dry concrete mixing facility that dries and packages play sand, concrete,mortar and mason mix, and grout. This facility is permitted under Air Permit No. 06907RI0 effective from 25 November 2014 until 31 October 2022. The facility receives cement and mortar in powder form and stores these materials in silos. The facility dries sand and gravel in a rotary dryer and stores these materials in silos. The facility has single silos for dry sand/gravel, all-purpose sand, and play sand. The fourth is a"split" silo that holds masonry cement,fly ash, and Portland cement. The materials are metered out of the silos and mixed prior to packaging in 50-pound bags or large bulk bags. Particulate emissions from the silos,the dryer and the mixing/packaging operation are controlled by a total of eight bagfilters. The packaging system for filling bags is located inside a building. There is a central dust collection system that captures dust that comes from bag filling and from several other points along the packaging process. The company has 45 employees(including drivers)and operates one 12-hour shift a day, 6:OOAM-6:30 PM, 7 days/week, 52 weeks/year.Half of the employees work 12-hours a day three days/week,the remaining employees work 12-hour days four days/week. The following week the employees switch so the employees who worked three days/week work four days/week. 1 IV. Permitted Emission Sources: Emission Emission Source Control Control System Source ID Description System ID Description One LPG-fired rotary dryer 140 tons per hour maximum throughput Bagfilter ES-1 20 mmBtu/hr maximum heat input CD-8 (3,240 square feet of filter area) Operating 0%V.E. ES-4 Cement packaging operation CD-2 Bagfilter Operating 0%V.E. (2,403 square feet of filter area) ES-6 One Sand silo CD-14 Bagfilter Operating 0%V.E. I (125 square feet of filter area) One compartment of split silo ES-9S1 (cement or flyash) CD-9 Bagfilter Operating 0%V.E. (125 square feet of filter area) One compartment of split silo ES-9S2 (cement or flyash) CD-9 Bagfilter Operating 0%V.E. (125 square feet of filter area) .......... ............................... ... ..........._ _ __ .... e------ Emission, Emission Source Control Control System Source ID Description System ID Description One compartment of split silo E Bagfilter ES-11S (cement or flyash) CD-11 i Operating 0% V.E. (125 square feet of filter area) One compartment of split silo Bagfilter ES-12S (cement or flyash) CD-12 (125 square feet of filter area) Operating 0% V.E. Two sand/aggregate silos e Bagfilter ES-13S Operating 0% V.E. CD-13 (250 square feet of filter area) j V. Inspection Conference: On 25 May 2022 I, Mike Thomas of FRO DAQ, conducted a compliance evaluation inspection of the Quickrete Companies—Peachland Plant. This was a prearranged inspection to assist with the facility's emissions inventory and permit renewal. I met with David Snyder, Production Manager. The facility contact, Leroy Bean was called away unexpectedly before I arrived. We discussed the following: a) I verified the FACFINDER information; no changes are required. b) I reviewed the facility's bagflter logbooks. Entries are arranged by process and appeared to be complete and up to date. c) Mr. Snyder stated that production was still high but that it had leveled off the past couple of months. d) I went over how to log into AERO and the basic steps of using it. Mr. Snyder stated that someone from their corporate office had already gotten information from his facility and would be handling the emissions inventory and permit renewal. e) Throughputs: Year Portland Masonry Sand(lbs.) Gravel Fly Ash Cement(Ibs.) Cement(lbs.) lbs. (lbs.) 2021 28,210,110 12,452,520 142,845,230 68,752,331 231,500 2020 27,473,020 12,215,880 14100,460 66,587,669 226,800 2019 28,085,862 13,555,280 —107,234,000 47,785,700 —4,300,000 2018 —25,315,000 —6,752,000 —107,234,000 —59,915,00 —4,300,000 2017 —25,275,000 —6,525,000 —107,000,000 —59,800,000 —4,300,000 2016 —25,300,000 —6,600,000 —107,0001000 —59,800,000 —4,300,000 2015 —25,300,000 —6,600,000 —107,000,000 —59,800,000 —4,300,000 2014 —25,300,000 —6,600,000 —107,000,000 —59,800,000 —4,300,000 2013 28,406,000 8,954,000 112,694,000 65,974,000 4,324,000 2012 25,298,000 6,602,000 107,164,000 59,752,000 4,294,000 2011 24,000,000 6,000,000 99,866,000 58,556,000 3,834,000 VI. Inspection Summary: Mr. Snyder led me on a tour of the facility,which was operating, starting at the dryer and proceeding to the silos. I did not observe any indications of excess emissions. The duct work all appeared to be in good working order with no leaks or compromises. The facility was very clean.Due to the large increase in production currently,the facility has finished product stacked on pallets around the yard. Travel ways at the facility appeared to be in good shape and there was no indication of trucks tracking material onto the highway as they are leaving the facility. VII. Permit Stipulations: A.2 15A NCAC 2D .0202 &2Q .0304-PERMIT RENEWAL AND EMISSION INVENTORY REQUIREMENT-The facility shall submit a permit renewal request and a completed air emissions inventory at least 90 days prior to permit expiration. APPEARED IN COMPLIANCE—The next renewal and inventory are due Aug 8,2022,for calendar year 2021. 1 assisted Mr. Snyder with logging into the AERO system and basic operation. He stated that Quikrete's Corporate office would be handling their emissions inventory and permit renewal. A.3 15A NCAC 2D .0515 PARTICULATE CONTROL REQUIREMENT—"Particulates from Miscellaneous Industrial Processes",particulate matter emissions from the emission sources shall not exceed allowable emission rates. APPEARED IN COMPLIANCE—Compliance was determined during the most recent permit review based on operating the source as described in the permit conditions. No changes have been made to operations since that determination. A.4 15A NCAC 2D .0516 SULFUR DIOXIDECONTROL REQUIREMENT—Sulfur dioxide emissions from Dryer(ID No. ES-1) shall not exceed 2.3 pounds per mmBtu heat input. APPEARED IN COMPLIANCE—The facility combusts LP gas in their 20 mmBtu rotary dryer. The AP-42 SOz EF is 0.001 lb/mmBtu resulting in emissions well below their limit. A.5 15A NCAC 2D .0521 VISIBLE EMISSIONS REQUIREMENT-"Control of Visible Emissions",visible emissions from the emission sources manufactured after July 1, 1971, shall not be more than 20%opacity. APPEARED IN COMPLIANCE—I observed 0% V.E. from all operating emission sources. A.6 15A NCAC 2D .0535 NOTIFICATION REQUIREMENTS—The Permittee of a source of excess emissions lasting more than four hours and that results from a malfunction,breakdown of process or control equipment or any other abnormal conditions shall notify the Director or his designee. APPEARED IN COMPLIANCE—Mr. Snyder stated that there were no instances of excess emissions requiring notification. A.7 15A NCAC 2D .0540 FUGITIVE DUST CONTROL REQUIREMENT—Facility shall not cause or allow fugitive dust emissions to cause or contribute to substantive complaints or excess emissions beyond property boundary. APPEARED IN COMPLIANCE—No dust was observed leaving the boundaries of the facility and Mr. Bean stated that there have been no dust complaints.No dust complaints have been received by FRO. I did not see any indications of dust on the highway in front of the facility. A8 15A NCAC 2D .0611 FABRIC FILTER REQUIREMENTS—Particulate matter emissions shall be controlled as described in the permitted equipment list. The permittee shall perform,at a minimum, an annual internal inspection of each particulate collection system. The permittee shall also perform periodic inspections and maintenance as recommended by the equipment manufacturer. The results of all inspections and maintenance activities shall be recorded in the logbook and kept onsite. APPEARED IN COMPLIANCE—Logbooks are kept and are grouped according to process. Last internal inspections: Interior BH(CD-2)—packaging 4/29/22,Dryer BH(CD-8)4/7/22, Rock/Sand silo BH(CD-13)4/28/22,Rock/Sand silo BH(CD-14)4/28/22,and Flyash/Lime silo BH(CD-9)3/4/22, (CD-11)4/7/22,(CD-12)4/21/22. A.9 2Q.0315 LIMITATION TO AVOID 15A NCAC 2Q.0501—Pursuant to 15A NCAC 2Q .0315 "Synthetic Minor Facilities," facility-wide PMro emissions shall be less than 100 tons per consecutive 12-month period. Facility complies with this limitation by properly operating and maintaining their bagfilters and record keeping in accordance with 15A NCAC 2D .0611 BAGFILTER REQUIREMENTS. APPEARED IN COMPLIANCE—Facility met the requirements by performing the required inspections,maintenance, and record keeping as prescribed in 15A NCAC 2D .0611 BAGFILTER REQUIREMENTS. VIII. Non-compliance History Since 2010: 10/21 —NOD for replacement of equipment without a permit. IX. 112R Status: This facility does not store any of the listed chemicals above threshold quantities and is not required to maintain a written Risk Management Plan(RMP). X. Comments and Compliance Statement: On 25 May 2022,The Quikrete Companies-Peachland Plant appeared to be IN COMPLIANCE with the conditions outlined in their current Air Permit. Pink Sheet: No comments. /rest e4 4 '..ggg AX; I'T Azft ss ,tA vn� Ani -J, At, ing-m7v X El, 1—W qk �3 NZA, "M g-'L.% Zia IN I- TO iv VWT,.., S ik _vo P qi� y. f WM yv "Af ,7, I fvl�' AK 1;,P 0011" rp4"M OR D ------------- rk -�Mp 'ell 44 .4,4 ftwp ".7 31-1 Al qli� ll�_`_NO; , �i, . M, �1.0 f " 1 ffal�� ,J: I hKi '71 "A'A p; gq v*Va RN., WM 4 W W '7.T�" :7,on Sow E2 I'M$Y1111"M 1, �5 1 114- a �14 PW Rlll_� "�`M 110 M R W .va- on F �l AR 30415 Z -S"If A, gg NQUE-15-RANUM A. xlt_lVwllNA�= NOE "P� TO '.No,