AQ_F_0400016_20220913_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Fayetteville Regional Office
AIR QUALITY Wade Manufacturing Co- Wadesboro
NC Facility ID 0400016
Inspection Report County/FIPS: Anson/007
Date: 09/13/2022
Facility Data Permit Data
Wade Manufacturing Co-Wadesboro Permit 03577/R19
Highway 74 East Issued 10/2/2018
Wadesboro,NC 28170 Expires 9/30/2026
Lat: 34d 57.8720m Long: 80d 2.6476m Class/Status Synthetic Minor
SIC: 2261 /Finishing Plants,Cotton Permit Status Active
NAICS: 313311 /Broadwoven Fabric Finishing Mills Current Permit Application(s)None
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact SIP
Sherry Wallace Bernard Hodges Sherry Wallace
Cost Manager President Cost Manager
[phone] [phone] [phone]
Compliance Data
Comments:
Inspection Date 09/13/2022
Inspector's Name Mike Thomas
Inspector's Signature: Operating Status Operating
J - Compliance Status Compliance- inspection
Action Code FCE
Date of Signature: Inspection Result Compliance
Total Actual emissions in TONS/YEAR:
TSP S02 NOX VOC CO PM10 * HAP
2017 5.72 0.0200 4.99 8.32 4.14 5.72 1321.63
2014 12.39 1.02 5.51 9.77 4.49 12.38 1525.84
* 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 1/2 miles to Laurel Hill.Turn right onto US 74 West and continue for
25 miles until you enter Anson County.Continue on to Wadesboro. Wade Mfg. is on the north(right)side of
the Hwy 74,just after the `Welcome to Wadesboro' sign.
II. SAFETY:
Standard DAQ FRO Safety Gear.Main safety concerns are slips trips and falls from uneven and
slippery floors, stairs, and forklift traffic.
III. FACILITY DESCRIPTION/PROCESS DESCRIPTION:
Wade Manufacturing is a Synthetic Minor facility for S02,mainly from the burning of No. 6 fuel oil.
Wade Manufacturing makes, dyes and prints cotton and polyester/cotton blend fabric. The process
includes bleaching,dying,printing,and finishing of cloth. This facility has fabric-finishing equipment
consisting of natural gas-fired tenter frame ovens and several napping areas. A tenter frame stretches
fabric under tension and consists of chains fitted with pins or clips to hold the selvages of the fabric,and
travelling on tracks.As the fabric passes through the heated chamber, creases and wrinkles are
removed,the weave is straightened,and the fabric is dried to its final size. The napping process is used
to raise a velvety, soft surface to fabric. The process involves passing the fabric over revolving
cylinders covered with fine wires that lift the short, loose fibers,usually from the weft yarns,to the
surface, forming a nap. The process,which increases warmth, is frequently applied to woolens and
worsteds and also to blankets.
Two natural gas/No. 6 fuel oil-fired boilers are used to provide steam for some of these processes. The
company started business in 1926.Wade Manufacturing currently operates under air permit no.
03577R19,which has an expiration date of 30 September 2026.
Employees: 45
Hours: 3 or 4 days a week, 7 AM to 3 PM
Average weightge of fabric(yd/lb): 0.89-3.4
Throughput:
Year Throughput in million yards Average weight of fabric d/lb
2021 3.1 - 1.62
�2018 F_ —5.47 1.70
2017 ��..�..,.�..._._...—.__5.17 1.58 ,
�2016 — 5.99 1.65
2015 �---- -6.28 ~ 1.49
2014 — 6.77
2013 6.25 1.55

IV. PERMITTED EMISSION SOURCES (PLUS CONTROLS):
Emission Emission Source �, Controls Control System
Source ID Description __�5 �. System ID Description
Natural gas/No. 6 fuel oil-fired boiler
B 1 (72 mmBtu/hr maximum heat input) N/A N/A
Operating on natural gas with 0% VE
Natural gas/No.6 fuel oil-fired boiler
B2 (24.76 mmBtu/hr maximum heat input) N/A N/A
Not operating
Textile roller printer
(3,600 pounds of cloth per hour process
capacity)consisting of:
PR3 a)8 print stations N/A N/A
b) 1 natural gas direct-fired dryer
(2 mmBtu/hr maximum heat input)
Not operated since April 2022.
Textile screen printer
(3,600 pounds of cloth per hour process
capacity)consisting of:
PR4 a)8 rotary screen printing stations N/A N/A
b) 1 natural gas direct-fired dryer
(4.8 mmBtu/hr maximum heat input)with
four zones
Not operated since May 2021
Textile screen printer
(3,600 pounds of cloth per hour process
capacity)consisting of:
PR5 a) 12 rotary screen printing stations N/A N/A
b) 1 natural gas direct-fired dryer
(4.8 mmBtu/hr maximum heat input)with
four zones
Not operated since May 2021
� Finishing range
(5,760 pounds of cloth per hour process
capacity)consisting of:
a) 1 pad applied finishing station
TEN2 b) 1 natural gas direct-fired(12.0 mmBtu/hr N/A N/A
maximum heat input)eight zone tenter frame
oven
Not operating due to fire.
Finishing range
(4,320 pounds of cloth per hour process
capacity)consisting of:
a) 1 pad applied finishing station
TEN3 b) 1 natural gas direct-fired(6.0 mmBtu/hr N/A N/A
maximum heat input)two zone tenter frame
oven
Not operating due to fire.

..___..... .._._. . ........... ._._.,_.... ..._....._ ,
Emission Emission Source Control Control System {ems
Source ID Description System ID Description
;One(1)bleach range and one(1)natural gas
direct-fired(8.5 mmBtu/hr maximum heat
BL 1 and TEN4 input)three zone tenter frame oven N/A N/A
Not operating and only operate
occasionally.
CR1 Steam heated cotton dye range N/A N/A
Not operating due to fire.
Pigment range
(4,800 pounds of cloth per hour process
capacity)consisting of:
a) 1 natural gas direct-fired dryer(4.0
PIG 1 mmBtu/hr maximum heat input)predryer N/A N/A
b) 1 pad applied ink dyeing station
c) 1 steam heated dryer
jNot operating and only operate
occasionally.
Thermasol range
(4,800 pounds of cloth per hour process
I
capacity)consisting of:
TR1 a) 1 pad applied finishing station N/A N/A
b) 1 natural gas direct-fired dryer
_
(7.0 mmBtu/hr maximum heat input)dryer
Not operating and only operate
occasionally.
Shop lathe
SLl (500 pounds per hour of rubber covered pad SL-IC Cyclone
rolls) (15 inch diameter)
No longer at the facility.
BF-1 Bagfilter
(12 square feet of filter
area)
Starch storage silo
SS 1 (22.5 tons per hour filling rate) In parallel with In parallel with
Not operating
BF-2 Bagfilter
j (12 square feet of filter
area)
OP-1 CA Paper Panel Filter
(6.55 square feet of
� filter area)
1 Blendomat
OP1 (2,600 pounds per hour of cotton fiber) In series with In series with
Not operated since April 2022.
� OP-1 CB Rotary Drum Filter
(46.5 square feet of
filter area)
Carding and drawing operation Rotary Drum Filter
(54
AC 1/CARD 1 (2100 pounds per hour of cotton fiber) CARD 1-1 C surface
square feet of
Not operated since April 2022. surface area)

i
Emission Emission Source Control Control System
Source ID Description System ID Description
Paper Filter
Spinning operation
AC2 (2100 pounds per hour of cotton fiber) AC24C (266.8 square feet of
Not operated since April 2022. surface area)
AC3 Three(3)weaving areas AC-1 C Paper Filter
(1,870 pounds per hour of cotton yarn, (371.2 square feet of
total capacity of AC3,AC4, and AC5) surface area)collecting
Not operated since April 2022. from AC-3
AC4 AC4-1 C Rotary Drum Filter
(834.9 square feet of
surface area)collecting
AC-4.
i
AC5 AC5-1 C Rotary Drum Filter
(545.3 square feet of
surface area)collecting
AC-5.
NAP 1 Two(2)napping areas NAP 1-1 C Rotary Drum Filter
(2,370 pounds per hour of cotton cloth,total (483.3 square feet of
capacity of NAP 1 and NAP2) surface area)collecting
Not operating and only operate from NAP 1.
occasionally.
NAP2 NAP2-1 C Rotary Drum Filter
(142.1 square feet of
surface area)collecting
from NAP 2.
RP Retention Pond N/A N/A
Operating,no odor present
V. INSPECTION CONFERENCE:
On 13 September 2022,I Mike Thomas,of FRO DAQ conducted a compliance evaluation inspection of the
Wade Manufacturing Co.—Wadesboro Plant. I met with Facility Contact, Sherry Wallace. We discussed
the following:
a) Ms. Wallace verified the FACFINDER information;no changes were needed.
b) Ms. Wallace informed me that the facility had stopped the production portion of their operation
back in April of 2022,due to a lack of business. She went on to say that all of the equipment is still
in place but there are no plans of starting back up in the foreseeable future.
c) Ms.Wallace went on to say that there had been a fire in the finishing area of the plant the day before
(9-12-22)and that none of that equipment was operating. She had no idea when the facility would
be back up and running.
d) I went through the permitted equipment list with Ms.Wallace to determine what sources and
controls are still operating at the facility.

e) I reviewed the facilities maintenance records. Entries were complete and up to date for all control
devices.The facility did internal inspections on the control devices on the portion of the plant that is
no longer operating after operations had ceased.
VI. INSPECTION TOUR:
Ms. Wallace led me on a tour of the facility which was not operating due to the fire mentioned above. I
observed both of the boilers,the cyclone,all of the baghouses,the rotary drum filters,and the paper panel
filters. All the control devices appeared well maintained and in good working order. Due to the facility
having a fire the previous day,I did not go into the production area for safety reasons.
VII. PERMIT STIPULATION REVIEW:
1. 15A NCAC 02D .0202,"EMISSION INVENTORY REQUIREMENT"—Entire facility subject.
Submit permit renewal application and EI at least 90 days prior to permit expiration.
Appeared to be in compliance—The facility's permit expires on 30 September 2026 The application
and emission inventory will be due no later than 2 July 2026 with CY2025 data.
2. 15A NCAC 02D .0503,"PARTICULATES FROM FUEL BURNING INDIRECT HEAT
EXCHANGERS"—The particulate emissions from boiler ID No.B 1 shall not exceed an emission rate
of 0.33 lbs/mmBtu and boiler ID No.B2 shall not exceed 0.471bs/mmBtu.
Appeared to be in compliance—The facility burns NG exclusively with oil as a backup during
curtailment. The worst case fuel is No. 6 at 2.1%sulfur(from current fuel certification), which emits
0.15 lbs/mmBtu. The AP-42 emissions factor for natural gas is 0.007 lbs/mmBtu. The facility currently
only operates boiler B1.
3. 15A NCAC 02D .0515,"PARTICULATE CONTROL REQUIREMENT"—Particulate emissions
from miscellaneous sources shall not exceed those limits listed in the permit.
Appeared to be 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
their facility since the last permit review.
4. 15A NCAC 02D .0516,"SULFUR DIOXIDE EMISSIONS"—Sulfur dioxide emissions shall not
exceed 2.3 lbs/mmBtu heat input.
Appeared to be in compliance—The worst-case fuel is No. 6 at 2.1%sulfur(current fuel certification),
would emit SOz at rate of].7 lbs/mmBtu. The fuel oil certifications indicated sulfur content 1.62%the
last several times it was purchased. The last purchase of No.6 fuel oil was 313114.
5. 15A NCAC 02D .0521,"VISIBLE EMISSIONS CONTROL REQUIREMENT"—Visible
emissions from source ID Nos.PR4,PR5, TEN2,TEN3, TR1,B1,B25 BLl,TEN4,OP 1, SL1,and
SS manufactured after July 1, 1971, shall not be more than 20 percent opacity when averaged over a
six-minute period.
Appeared to be in compliance—The facility was not operating during this inspection due to afire the
previous day. I observed no indication of excessive visual emissions.
6. 15A NCAC 02D .0521,"VISIBLE EMISSIONS CONTROL REQUIREMENT"—Visible
emissions from source ID Nos.PIG 15 PR33 AC 1/CARD 1,AC2,AC3,AC4,AC5,NAP 1 and NAP2,
manufactured before July 1, 1971, shall not be more than 40 percent opacity when averaged over a
six-minute period.
Appeared to be in compliance—The facility was not operating during this inspection due to afire the
previous day.

7. 15A NCAC 02D .0535, "NOTIFICATION REQUIREMENT"—The facility is required to notify
DAQ if excess emissions occur for more than a 4-hour period caused by a breakdown or other abnormal
condition.
Appeared to be in compliance—Ms. Wallace stated that the facility has had no exceedances,
breakdowns, or abnormal conditions requiring notification.
8. 15A NCAC 02D .0540, "FUGITIVE DUST CONTROL REQUIREMENT"—Fugitive dust
emissions shall not cause or contribute to substantive complaints or excess visible emissions beyond
the property boundary.
Appeared to be in compliance— There was no dust on the roadways about the facility. Ms. Wallace
stated that they have not received any dust complaints since the last inspection. FRO has not received
any complaints of dust for this facility.
9. 15A NCAC 02D .0611, "CYCLONE REQUIREMENTS"—Annual& periodic I&M and
recordkeeping requirements.
Appeared to be in compliance—The shop lathe controlled by this device is no longer at the facility and
the cyclone is no longer being used. Logs indicate I&M is done by the facility mechanic, Mr. Steven
Burroughs. The last annual inspection was done on 7 July 2021.
10. 15A NCAC 02D .0611, "FABRIC FILTER REQUIREMENTS"—Annual internal inspection&
periodic I&M and recordkeeping requirements.
Appeared to be in compliance—The facility inspects rotary drum filters and bagfilters on a monthly
basis. Logs indicate I&M is done by the facility mechanic, Mr. Steven Burroughs. The last annual
internal inspection was done on 4 April 2022 for each of the filters.
11. 15A NCAC 02D .1100,TOXIC AIR POLLUTANT EMISSIONS LIMITATION AND
REPORTING REQUIREMENTS- Pursuant to 15A NCAC 2D .1100 and in accordance with the
approved application for an air toxic compliance demonstration,the permit limit shall not be exceeded.
Record daily; report annually.
Appeared to be in compliance-Records showed TAP limits had not been exceeded. Records are
maintained for the maximum hourly rate of ammonia input to each printer (ID Nos. PR3, PR4, and
PR5)for each day of production, and the maximum hourly rate of formaldehyde input to each tenter
frame (ID Nos. TEN2, and TENS)for each day of production. Usage and emissions reports are
provided to FRO annually. The last annual report containing this data was submitted on
10 January 2022 and appeared to be complete and in compliance. There have been no changes in
chemicals used or chemical formulations since the toxic demonstration was conducted.
12. 15A NCAC 02D .1806, "CONTROL AND PROHIBITION OF ODOROUS EMISSIONS." No
objectionable odors beyond property line.
Appeared to be in compliance-No objectionable odors were noted during the inspection. The facility
contact, Ms. Wallace, stated that no odor complaints have been received since the last inspection. FRO
also has not received any odor complaints regarding this facility.

13. 15A NCAC 02Q.0315,LIMITATION TO AVOID 15A NCAC 2Q.0501—Facility-wide emissions
Of PMIo,S02,and NOx shall each be less than 100 tons per consecutive 12-month period;sulfur content
of the No. 6 fuel oil<2.1%by weight; combust<601,000 gallons of No. 6 fuel oil during any
consecutive 12-month period. The amount of fuel oil combusted shall be totaled monthly and reported
annually. Fuel certifications shall also be kept onsite.
Appeared to be in compliance—Since the last inspection the facility has not combusted any fuel oil.
The last annual report containing this data was submitted on 10 January 2021 and appeared to be
complete.
14. 15A NCAC 02Q .0317,AVOIDANCE OF BOILER NESHAP(GACT 6T)—Subject sources are
boilers B 1 &132. Facility avoids applicability of this rule by burning Natural Gas,with fuel oil only as
back-up during emergencies,testing and curtailment. Keep records of fuel oil usage and reason for
usage. Notify DAQ within 30 days of switch to fuel oil outside of emergencies,testing and curtailment.
Appeared to be in compliance—Since the last inspection, the facility has not combusted any fuel oil.
15. 15A NCAC 02Q. 03179 AVOIDANCE OF PREVENTION OF SIGINIFICANT
DETERIORATION-Discharge into the atmosphere less than 250 tons of PMIo and S02,
respectively,per consecutive twelve-month period.
Appeared to be in compliance- The facility has met the requirements of stipulation 15A NCAC 02Q
.0315, Limitation to Avoid 15A NCAC 02Q.0501, and therefore has complied with this rule.
VIII. NON-COMPLIANCE HISTORY SINCE 2010
20 June 2014 NOD for Visible Emissions for failure to re-establish"normal"VE for emission
sources by 7 March 2014.
10 May 2013 CAI VE Monitoring and Record Keeping
9 Nov 2012 NOV for VE>20%
IX. 112r STATUS
The facility does not store any of the listed chemicals above the threshold quantities, and is not required to
maintain a written Risk Management Plan(RMP).
X. CONCLUSIONS AND RECOMMENDATIONS:
Wade Manufacturing Co.-Wadesboro appeared to be IN COMPLIANCE with their current air permit on
13 September 2022.
Pink Sheet Comments: None
/mst