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HomeMy WebLinkAboutAQ_F_0800018_20210902_CMPL_InspRpt NORTH CAROLINA DIVISION OF Washington Regional Office AIR QUALITY FSC II,LLC-Windsor Asphalt Plant NC Facility ID 0800018 Inspection Report County/FIPS:Bertie/015 Date: 09/07/2021 Facility Data Permit Data FSC II,LLC-Windsor Asphalt Plant Permit 03707/R20 129 County Farm Road(SR 1527) Issued 5/11/2021 Lewiston Woodville,NC 27849 Expires 2/28/2025 Lat: 35d 58.8630m Long: 76d 57.0360m Class/Status Synthetic Minor SIC: 2951 /Paving Mixtures And Blocks Permit Status Active NAILS: 324121 /Asphalt Paving Mixture and Block Manufacturing Current Permit Application(s)None Contact Data Program Applicability Facility Contact Authorized Contact Technical Contact SIP Tim Perry Brent Wood Tim Perry Plant Superintendent Vice President of Legal Plant Superintendent (252)287-7829 Affairs (252)287-7829 (919)740-7325 Compliance Data Comments: The facility appeared to operate in compliance with all applicable air quality regulations and permit conditions at the time of inspection. Inspection Date 09/02/2021 Inspector's Name Doug Byrd Inspector's Signature: Operating Status Operating �- Compliance Status Compliance-inspection Action Code FCE Date of Signature: September 7,2021 Inspection Result Compliance Total Actual emissions in TONS/YEAR: TSP S02 NOX VOC CO PM10 * HAP 2015 0.4800 1.12 1.28 0.4000 4.07 0.3000 54.58 2011 0.7100 1.68 2.04 0.6600 6.62 0.4600 89.40 * Highest HAP Emitted inpounds) Five Year Violation History:None Performed Stack Tests since last FCE:None Location: This facility is in Windsor, Bertie County, NC. From WaRO take Hwy 17 North to the junction of Hwy 17/Hwy 64. Turn on Hwy 64 East/17 North, south of Williamston, and follow Hwy 17/13 North. Prior to the separation of Hwy 13/17 North,turn right onto Country Farm Road(SR1527) at the North Carolina National Guard Armory. The facility is located about half a mile on the left. Safety: PPE should be used at the facility. The inspector will need a hard hat, safety glasses, hearing protection, and safety shoes. Additionally, a safety vest should be worn when you inspect the yard. Facility Summary: The facility is a 250-ton/hr batch asphalt mixing plant. The aggregate is conveyed to a drum where it is dried. A screening process then separates the aggregate. The aggregate is then mixed in the desired proportions, injected with asphalt, weighed and unloaded into trucks and transported to job sites. This facility has a multi-site permit that allows for them to locate in Lewiston or Windsor; both sites are in Bertie County. List of Permitted Sources: Emission Emission Source Control Control System Source ID Description System ID Description ES-1 Nos. 2 and 4/Nos. 2 and 4 equivalent waste fuel oil-fired 24768,Ra-15-60 Simple cyclone(120 in), batch asphalt plant,250 tons per hour maximum production Bagfilter(11,466 sq ft) capacity, 84 million Btu per hour maximum heat input, allowed to utilize recycled, post-consumer waste, asphalt (asbestos-free)shingles as an option in the mix GS3630AR/HC 50 TPH asphalt and concrete crusher N/A N/A Inspection Results: I conducted a Full Compliance Evaluation (FCE) of the FSC II, LLC- Windsor Asphalt Plant on 08/02/2021. The facility was in operation at the time of the inspection. I met with Tim Perry and toured the facility. Several trucks were being loaded during the inspection.VE of%5-%10 was observed coming from the hopper and%10-%15 coming from the stack. Mr.Perry and I then reviewed the Windsor Facility Records which included; • Monthly asphalt production • Monthly pollutants (PM, S02,NOx, CO, VOC and HAPs) • Shingle analysis for asbestos • Fuels sulfur content (All deliveries below limit, only use ULSD besides the recycled#4) • Recycled#4 fuel analysis • Fabric filter and cyclone inspection and maintenance No fugitive emissions were noted during the inspection. A water truck is available for use if needed. A slight odor was observed while trucks were loaded but the odor did not leave the facility boundaries. Reiulatory Review: 2D .0506 "Particulates from Hot Mix Asphalt Plants" Using the equation, E =4.9445(P)0.4316, where P is the process throughput rate in tons/hr and E is the allowable rate in lbs/hr,the facility has an allowable particulate emission rate of 55.4 lbs/hr(based on maximum production rate). The facility tested for PM on 5/3/2018 with results from the test being 1.22 lbs/hr. This is well below the permitted limit. Compliance is indicated. 2D .0515 "Particulates from Miscellaneous Industrial Processes" This standard applies to the crusher. Using the equation, E= 55.0 (P)0-" —40, where P is the process throughput rate in tons/hour and E is the allowable rate in lbs/hr, the 50 tph crusher has an allowable particulate emission rate of 44.6 lbs/hr. The crusher was not in operation during inspection. Recycled shingles are delivered pre-crushed and already tested. Compliance is indicated. 2D .0516 "Sulfur Dioxide Emissions from Combustion Sources" All fuel oil combustion is limited to 2.3 pounds per million Btu. The facility started using recycled No. 4 fuel oil in June 2008 (allowed by the permit). The fuel oil has a sulfur content of<2.0% by weight, which was documented by fuel receipts. All other fuel is used ULSD which is less than the permitted limit. Compliance is indicated. 2D .0521 "Visible Emissions" This standard requires visible emissions (VE) from all permitted equipment shall not be more than 20 percent opacity when averaged over a six-minute period, except that six-minute periods averaging not more than 87 percent opacity may not occur more than once in any hour nor more than four times in any 24-hour period. The facility was in operation at the time of the inspection. VE of%5-%10 was observed coming from the hopper and %10-%15 coming from the stack. Compliance is indicated. 2D .0535 "Notification Requirement" No notifications of malfunctions taking more than four hours to repair resulting in excess emissions have been received. Compliance is indicated. 2D .0540 "Particulates from Fugitive Non-Process Dust Emission Sources" I did no observed any fugitive emission from the facility during the inspection. Compliance is indicated. 2D .0611 "Bagfilter Requirements & Cyclone Requirements" The facility must perform an annual internal inspection of the bagfilter system and cyclone system and record the results in a logbook along with other maintenance activities. A logbook is maintained in the control room containing all air quality permit records. The last annual inspections for the bagfilter and cyclone systems was performed on 01/07/2021. Compliance is indicated. 2D .1806 "Control and Prohibition of Odorous Emissions" No nuisance odors were detected past the facility fence line and there were no records of any complaints. Compliance is indicated. 2Q.0311 "Permitting of Facilities at Multiple Temporary Sites" This rule gives the Director the right to issue a single permit authorizing emissions from a facility or source at multiple temporary sites. Permits for facilities at multiple temporary sites shall include: the identification of each site; the conditions that will assure compliance with all applicable requirements at all approved sites; a requirement that the facility notify the Division at least 10 days in advance of each change of site; and the conditions that assure compliance with all other provisions. The plant has not moved since the last inspection. Compliance is indicated. 2Q.0315 "Synthetic Minor Facilities" Under the current permit there is no restriction on the tonnage of asphalt that can be produced. The facility is required to calculate and document monthly S02, CO, and NOx emissions from their production/combustion of various fuels. Reports are being maintained. Compliance is indicated. 2Q.0317"Vendor Supplied Recycled No. 2 and No 4 Fuel Oil Requirements" The plant has been using Recycled No. 4 fuel oil since the last inspection. I examined the fuel certifications for all fuel oil deliveries for CY2020. The facility combusted 90,964 gallons of recycled No. 4 in CY2020. Compliance is indicated. REQUIREMENTS FOR USE OF RECYCLED ASPHALT SHINGLES The facility started receiving Post-Consumer Recycled Asphalt Singles (PRAS) for the first time in February 2012 and started using them in various asphalt mixes in March 2012. All receipts and test reports for CY2020 were reviewed and appear to be complete. Recycled Shingles are delivered pre- crushed with lab analysis of the shingles. Compliance is indicated. Compliance History: No non-compliance issues have been documented in the last five years. Conclusions, Comments, and Recommendations: The facility appeared to operate in compliance with all applicable air quality regulations and permit conditions at the time of inspection. NORTH CAROLINA DIVISION OF Washington Regional Office AIR QUALITY FSC II,LLC-Windsor Asphalt Plant NC Facility ID 0800018 Inspection Report County/FIPS:Bertie/015 Date: 09/07/2021 Facility Data Permit Data FSC II,LLC-Windsor Asphalt Plant Permit 03707/R20 129 County Farm Road(SR 1527) Issued 5/11/2021 Lewiston Woodville,NC 27849 Expires 2/28/2025 Lat: 35d 58.8630m Long: 76d 57.0360m Class/Status Synthetic Minor SIC: 2951 /Paving Mixtures And Blocks Permit Status Active NAILS: 324121 /Asphalt Paving Mixture and Block Manufacturing Current Permit Application(s)None Contact Data Program Applicability Facility Contact Authorized Contact Technical Contact SIP Tim Perry Brent Wood Tim Perry Plant Superintendent Vice President of Legal Plant Superintendent (252)287-7829 Affairs (252)287-7829 (919)740-7325 Compliance Data Comments: The facility appeared to operate in compliance with all applicable air quality regulations and permit conditions at the time of inspection. Inspection Date 09/02/2021 Inspector's Name Doug Byrd Inspector's Signature: Operating Status Operating �- Compliance Status Compliance-inspection Action Code FCE Date of Signature: September 7,2021 Inspection Result Compliance Total Actual emissions in TONS/YEAR: TSP S02 NOX VOC CO PM10 * HAP 2015 0.4800 1.12 1.28 0.4000 4.07 0.3000 54.58 2011 0.7100 1.68 2.04 0.6600 6.62 0.4600 89.40 * Highest HAP Emitted inpounds) Five Year Violation History:None Performed Stack Tests since last FCE:None Location: This facility is in Windsor, Bertie County, NC. From WaRO take Hwy 17 North to the junction of Hwy 17/Hwy 64. Turn on Hwy 64 East/17 North, south of Williamston, and follow Hwy 17/13 North. Prior to the separation of Hwy 13/17 North,turn right onto Country Farm Road(SR1527) at the North Carolina National Guard Armory. The facility is located about half a mile on the left. Safety: PPE should be used at the facility. The inspector will need a hard hat, safety glasses, hearing protection, and safety shoes. Additionally, a safety vest should be worn when you inspect the yard. Facility Summary: The facility is a 250-ton/hr batch asphalt mixing plant. The aggregate is conveyed to a drum where it is dried. A screening process then separates the aggregate. The aggregate is then mixed in the desired proportions, injected with asphalt, weighed and unloaded into trucks and transported to job sites. This facility has a multi-site permit that allows for them to locate in Lewiston or Windsor; both sites are in Bertie County. List of Permitted Sources: Emission Emission Source Control Control System Source ID Description System ID Description ES-1 Nos. 2 and 4/Nos. 2 and 4 equivalent waste fuel oil-fired 24768,Ra-15-60 Simple cyclone(120 in), batch asphalt plant,250 tons per hour maximum production Bagfilter(11,466 sq ft) capacity, 84 million Btu per hour maximum heat input, allowed to utilize recycled, post-consumer waste, asphalt (asbestos-free)shingles as an option in the mix GS3630AR/HC 50 TPH asphalt and concrete crusher N/A N/A Inspection Results: I conducted a Full Compliance Evaluation (FCE) of the FSC II, LLC- Windsor Asphalt Plant on 08/02/2021. The facility was in operation at the time of the inspection. I met with Tim Perry and toured the facility. Several trucks were being loaded during the inspection.VE of%5-%10 was observed coming from the hopper and%10-%15 coming from the stack. Mr.Perry and I then reviewed the Windsor Facility Records which included; • Monthly asphalt production • Monthly pollutants (PM, S02,NOx, CO, VOC and HAPs) • Shingle analysis for asbestos • Fuels sulfur content (All deliveries below limit, only use ULSD besides the recycled#4) • Recycled#4 fuel analysis • Fabric filter and cyclone inspection and maintenance No fugitive emissions were noted during the inspection. A water truck is available for use if needed. A slight odor was observed while trucks were loaded but the odor did not leave the facility boundaries. Reiulatory Review: 2D .0506 "Particulates from Hot Mix Asphalt Plants" Using the equation, E =4.9445(P)0.4316, where P is the process throughput rate in tons/hr and E is the allowable rate in lbs/hr,the facility has an allowable particulate emission rate of 55.4 lbs/hr(based on maximum production rate). The facility tested for PM on 5/3/2018 with results from the test being 1.22 lbs/hr. This is well below the permitted limit. Compliance is indicated. 2D .0515 "Particulates from Miscellaneous Industrial Processes" This standard applies to the crusher. Using the equation, E= 55.0 (P)0-" —40, where P is the process throughput rate in tons/hour and E is the allowable rate in lbs/hr, the 50 tph crusher has an allowable particulate emission rate of 44.6 lbs/hr. The crusher was not in operation during inspection. Recycled shingles are delivered pre-crushed and already tested. Compliance is indicated. 2D .0516 "Sulfur Dioxide Emissions from Combustion Sources" All fuel oil combustion is limited to 2.3 pounds per million Btu. The facility started using recycled No. 4 fuel oil in June 2008 (allowed by the permit). The fuel oil has a sulfur content of<2.0% by weight, which was documented by fuel receipts. All other fuel is used ULSD which is less than the permitted limit. Compliance is indicated. 2D .0521 "Visible Emissions" This standard requires visible emissions (VE) from all permitted equipment shall not be more than 20 percent opacity when averaged over a six-minute period, except that six-minute periods averaging not more than 87 percent opacity may not occur more than once in any hour nor more than four times in any 24-hour period. The facility was in operation at the time of the inspection. VE of%5-%10 was observed coming from the hopper and %10-%15 coming from the stack. Compliance is indicated. 2D .0535 "Notification Requirement" No notifications of malfunctions taking more than four hours to repair resulting in excess emissions have been received. Compliance is indicated. 2D .0540 "Particulates from Fugitive Non-Process Dust Emission Sources" I did no observed any fugitive emission from the facility during the inspection. Compliance is indicated. 2D .0611 "Bagfilter Requirements & Cyclone Requirements" The facility must perform an annual internal inspection of the bagfilter system and cyclone system and record the results in a logbook along with other maintenance activities. A logbook is maintained in the control room containing all air quality permit records. The last annual inspections for the bagfilter and cyclone systems was performed on 01/07/2021. Compliance is indicated. 2D .1806 "Control and Prohibition of Odorous Emissions" No nuisance odors were detected past the facility fence line and there were no records of any complaints. Compliance is indicated. 2Q.0311 "Permitting of Facilities at Multiple Temporary Sites" This rule gives the Director the right to issue a single permit authorizing emissions from a facility or source at multiple temporary sites. Permits for facilities at multiple temporary sites shall include: the identification of each site; the conditions that will assure compliance with all applicable requirements at all approved sites; a requirement that the facility notify the Division at least 10 days in advance of each change of site; and the conditions that assure compliance with all other provisions. The plant has not moved since the last inspection. Compliance is indicated. 2Q.0315 "Synthetic Minor Facilities" Under the current permit there is no restriction on the tonnage of asphalt that can be produced. The facility is required to calculate and document monthly S02, CO, and NOx emissions from their production/combustion of various fuels. Reports are being maintained. Compliance is indicated. 2Q.0317"Vendor Supplied Recycled No. 2 and No 4 Fuel Oil Requirements" The plant has been using Recycled No. 4 fuel oil since the last inspection. I examined the fuel certifications for all fuel oil deliveries for CY2020. The facility combusted 90,964 gallons of recycled No. 4 in CY2020. Compliance is indicated. REQUIREMENTS FOR USE OF RECYCLED ASPHALT SHINGLES The facility started receiving Post-Consumer Recycled Asphalt Singles (PRAS) for the first time in February 2012 and started using them in various asphalt mixes in March 2012. All receipts and test reports for CY2020 were reviewed and appear to be complete. Recycled Shingles are delivered pre- crushed with lab analysis of the shingles. Compliance is indicated. Compliance History: No non-compliance issues have been documented in the last five years. Conclusions, Comments, and Recommendations: The facility appeared to operate in compliance with all applicable air quality regulations and permit conditions at the time of inspection.