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Home My WebLink AboutAQ_F_1800517_20220105_CMPL_CAV-Rpt NORTH CAROLINA DIVISION OF Mooresville Regional Office AIR QUALITY Carolina Pelleting and Extrusion,Inc. NC Facility ID 1800517 Inspection Report County/FIPS: Catawba/035 Date: 01/04/2022 Facility Data Permit Data Carolina Pelleting and Extrusion,Inc. Permit n/a 1694 Fisher Court Issued n/a Newton,NC 28658 Expires n/a Lat: 35d 38.6020m Long: 8ld 12.1660m Class/Status Permit Exempt SIC: 3087/Custom Compound Purchased Resins Permit Status Inactive NAICS: 325991 /Custom Compounding of Purchased Resins Current Permit Application(s)None Contact Data Program Applicability Facility Contact Authorized Contact Technical Contact SIP Douglas Hicks Douglas Hicks Douglas Hicks President President President (828)695-8505 (828)695-8505 (828)695-8505 Compliance Data Comments: Inspection Date 01/04/2022 Inspector's Name Sandra Sherer Inspector's Signature: Sand to Shvte4 Agm Operating Status Operating Compliance Status Compliance-inspection Action Code FCE Date of Signature: 1/5/2022 Inspection Result Compliance Total Actual emissions in TONS/YEAR: TSP SO2 NOX VOC CO PM10 *HAP 2015 0.0156 --- 0.0200 --- 0.0200 0.0156 0.8480 2010 0.0900 --- --- --- --- 0.0800 --- Highest HAP Emitted(in pounds) 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 Carolina Pelleting and Extrusion,Inc. January 4,2022 Page 2 Type Action: _Full Compliance _Partial Compliance _Complaint Other: Compliance Assurance Visit Evaluation Evaluation/Reinspection Investigation Data Date submitted for initial review 1/5/2022 IBEAM WARN/OB or NOD or NOV or NOV/NRE Tracking: X IBEAM Document X IBEAM Inspection,list date inspected X IBEAM LAT/LONG,Facility Locked X IBEAM Inspection,list date draft is submitted X IBEAM LAT/LONG,Coordinates checked X IBEAM Inspection,pollutants/programs checked IBEAM Complaint X IBEAM Planning,Next Inspection Date l/l/2024 Directions: From MRO,travel Hwy. 150 west to Hwy. 16 north toward Newton. Travel approximately 10 miles and turn left onto East P ext. (across from Dale Earnhardt Chevrolet),then left onto Fisher Court. The facility is located on the left at 1694 Fisher Court. Safety Equipment: Safety glasses are required and safety shoes are recommended. Safety Issues: None. COVID-19 Information: This facility does not have any COVID-19 protocols in place at this time. I wore a mask at all times and practiced social distancing during the compliance visit. Lat/Long Coordinates: A review of"Maps of DAQ Regulated Facilities"website indicates the facility's location is correct. The latitude and longitude coordinates in IBEAM are accurate. Email Contacts: The facility contacts were verified with no changes needed. 1. The purpose of this site visit was to conduct a compliance assurance visit. This facility processes powders into "non-dusting, free flowing pellets"which are used as extrusion additives by various industries. The facility is currently operating eight hours per day, five days per week. Approximately six people work at the facility. Mr. Douglas Hicks, President, accompanied me during the compliance visit. 2. Facility Contact Information: During the inspection, I verified the facility contact information in IBEAM. No changes were needed. 3. Compliance history file review: No compliance issues have occurred at this facility in the last five years. 4. Source Observations: Various fine powders (packaged in 450-pound bags up to 1500-pound bags) are unloaded into the mixer and mixed(dry or wet, according to the"recipe"). The fine powders are mixed with various additives such as antioxidants(to stabilize the final plastics from UV radiation).The product is then fed into the extruder, where rollers force the powder into holes in a large metal plate to form the Carolina Pelleting and Extrusion,Inc. January 4,2022 Page 3 pellets. The product is then fed into the dryer/cooler, which either dries or cools the product depending on the moisture content (most of the emissions come from the dryer/cooler process). The pellets are then conveyed to a classifier (screener), which uses two screens to remove any pellets that are too small or too big.The product is then packaged either into bags or fifty-five gallon drums for shipment. Waste is recycled back into the process. Emissions from all processes are controlled by the bagfilter located inside the facility, which vents to the outside atmosphere. Depending on the product, the facility can process 300 to 1000 pounds of product per hour. The facility was not operating the pelleting process at the time of the compliance visit. The facility continues to keep records of their baghouse inspections. I observed no fugitive dust beyond the property boundary. 5. Exemption Qualification: This facility submitted a request to rescind Air Permit No. 09188R03 since the actual facility-wide emissions of particulate matter(PM10), sulfur dioxide,nitrogen oxides,volatile organic compounds, carbon monoxide,hazardous air pollutants(HAP) and toxic air pollutants(TAP), each are less than five tons per year and the total actual aggregate emissions of these pollutants are less than ten tons per year. During the rescission review conducted on May 25,2021,the facility-wide actual emissions of particulate matter(PM 10), sulfur dioxide, nitrogen oxides, volatile organic compounds, carbon monoxide, hazardous air pollutants (HAP), and toxic air pollutants (TAP), from previous years, each has been less than five (5) tons per year and the total actual aggregate emissions of these pollutants have been less than 10 tons per year. The letter also indicated that there are no plans to make any changes that would increase emissions above these exemption thresholds. During my inspection, I did not see any new equipment added and Mr. Hicks said that no new products have been added that would have increas-ed emissions. 6. Compliance determination: Based on my observations,this facility appeared to be in compliance with the air quality rules(21) .0515-particulate control requirement;2D.0521-visible emissions;2D.0535-excess emissions;and 2D .0540-fugitive dust emissions; and 2D .0611-fabric filter requirements) at the time of the compliance visit. The compliance assurance visit checklist is attached on page 4. SLS:Ims https://ncconnect.sharepoint.com/sites/DAQ-MRO/Counties/CATAWBA/00517/INSPECT_20220104_CAV.docx Carolina Pelleting and Extrusion,Inc. January 4,2022 Page 4 Compliance Assurance Visit Checklist rev.11/03/16 Facility Name: Carolina Pelleting and Extrusion,Inc. Physical Site Address: 1694 Fisher Court City: Newton Zip Code: 28658 County: Catawba Facility Contact: Douglas Hicks Title: President Phone No.: 828-695-8505 Mailing Address: P.O. Box 146 Newton,NC 28658 Facility Contact Email Address: dhicks(@carolinapelletin_ com Is the facility contact the person that you met? If not,fill out the following: (same) Contact Name: Title: Phone No.: Mailing Address: Email Address: Safety requirements:safety shoes(yes)-safety glasses(yes)-hearing protection(no)-hardhat(no) other(please describe): Normal operating schedule(hr/d,d/wk,wk/yr): 8 hrs.per day,5 days per week Opacity(%)-indicate any non-zero opacities observed: None Odors-indicate if any objectionable odors were detected beyond the property boundary: None Fugitive dust-indicate whether fugitive dust was observed leaving property boundary: No Since last inspection,have there been any changes in equipment or operation? No Throughput and/or fuel usage with units:N/A Control device(s)(list): bagfilter(1,716 square feet of filter area) Properly operated and maintained? Yes For a permit exempt facility found to be improperly operating or maintaining plant equipment:1)provide compliance assistance as a first option;2)initiate enforcement action in egregious/repeat cases;3)re-evaluate facility's emissions using a more representative control efficiency/emission factor;4)If re-evaluated actual emissions result in a classification/registration change,follow enforcement guidelines for operation without a permit/registration;and 5)increase compliance visit frequency. Permit Exemption: •Actual emissions from the previous year(s)(and projected actual)of PM10,S02,NOx,VOCs,CO,HAPs,and TAPS are each<5 tpy and whose actual total aggregate of these emissions are<10 tpy •Can be subject to 40 CFR Part 63(MACT or GACT)and 40 CFR Part 60(NSPS) •Cannot be subject to Rule 2Q.0315(Synthetic Minor Facilities)or 2Q.0500(Title V Procedures)