AQ_F_0400009_20211117_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Fayetteville Regional Office
AIR QUALITY Hornwood Inc
NC Facility ID 0400009
Inspection Report County/FIPS:Anson/007
Date: 11/19/2021
Facility Data Permit Data
Hornwood Inc Permit 04888/R16
766 Hailey's Ferry Road Issued 9/7/2021
Lilesville,NC 28091 Expires 4/30/2022
Lat: 34d 57.2115m Long: 79d 57:6182m Class/Status Small
SIC: 2258/warp Knit Fabric Mills Permit Status Active
NAILS: 313312/Textile and Fabric Finishing(except Broadwoven Fabric)Mills Current Permit Application(s)None
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact
S
Benny Burr Charles Horne Dale Kelly NSPS: Subpart Dc
Environmental Manager President Plant Engineer
[phone] [phone] [phone]
Compliance Data
Comments:
Inspection Date 11/17/2021
Inspector's Name Mike Thomas
Inspe tor's Si attire° Operating Status Operating
Compliance Status Compliance-inspection
at o Xignature: Action Code FCE
el I Z_1f-Z/
Inspection Result C0111 liance
Total Actual emissions in TONS/YEAR:
TSP Sot Nox voc coPM10 P
2013 8.97 0.0500 6.35 10.30 5.32 8.97 194.60
2008 23.58 0.0400 5.00 16.01 4.14 23.46 1878.00
*Highest HAP Emitted inpounds)
Five Year Violation History:
Date Letter Type Rule Violated Violation Resolution Date
10/01/2020 NOV Part 60-NSPS Subpart Dc Small Industrial- 10/05/2020
Commercial-Institutional Steam Generating Units
10/01/2020 NOV 2D .0524 New Source Performance Standards 10/05/2020
04/26/2019 NOV/NRE 2D.0521 Control of Visible Emissions 05/13/2019
04/26/2019 NOV/NRE 2D.0611 Monitoring Emissions from Other Sources 05/13/2019
Performed Stack.Tests since last FCE: None
1. CT SITE,:
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,just after crossing the Pee Dee River.
Go— 5 more miles to Hailey's Ferry Road(crossroads SR 1801),continue approximately 0.5 mile and
Hornwood is on the right. Check in at the guardhouse.

SAFETY:
Standard FIFO safety gear. Inspectors should be wary of hot surfaces.
DESCRIPTION:
Hornwood,Inc. is a textile company that warps,weaves, dyes yarn,heat-sets(tenter frame finishes)and
doffs(textures)nylon and polyester knit fabrics. They produce baseball uniforms,automobile seat
fabric,cloth for reverse osmosis water purification,gauze liners for tennis shoes,and cowboy shirts to
name a few.
This process may be divided into several distinct operations as follows;
Warping: Yarn is spun onto a single spool for processing in the knitting room. Yarn may also be draw
warped which draws the diameter of the yarn down by heat and tension,and effectively reduces the size
of the yarn.
Knitting Room: Spools go onto a mandrel that feeds the knitting machines.
Middle Warehouse: This is where both finished and unfinished fabric is stored until either future
processing is done or shipped to the customer.
DyeHouse: Dye is added to the fabric in one of two processes,beam or jet dying. In beam dying, fabric
is wound onto a beam with holes that allow the dye to pass through. The dye solution is pumped from the
rear of the chamber and passes through holes in the beam and out through the fabric. In jet dying,the
cloth is pulled through a tube in the top of the dye chamber by means of a roller and is constantly in
motion through a dye water solution in the bottom of the chamber.
Finishing: Cloth is passed through one of four tenter frames which heat sets the fabric to reduce
shrinking and stretching;chemicals which stiffen or coat the material may be added.
Napping: One of three things may be performed on the material during this process. The fabric will be
napped which gives it the appearance of fleece, or shearing which cuts off the top of the fleece, or sueded
which sands the fabric.
Mist li inators: The facility was histrically permitted to operate two condenser/mist eliminators(CD-
1 and CD-2). CD-1 is no longer in use and was last.operated on 3 March 2021. The exhaust air from the
tenter frames flows through a pre-filter that takes out some of the dry particles with a one-inch fiberglass
mesh using two trays to pass the air through. In Condenser/Mist Eliminator(ID No. CD-2),which
currently controls TF-1 and TF-2, the air passes over four(4)cold water coils and six(6)spray rings that
both condense the vapor prior to the mist eliminator. Both mist eliminators house sixteen(16)two-inch
wire mesh cylinders that are each surrounded by a fiberglass mesh. The condensed vapor passes through
the center of these filter tubes and then proceeds out the stack. The rinse water is collected at the bottom
of each collector unit and sent through oil/water separators to a single holding tank for collection and
disposal. Prior to the units being shut down for cleaning,jet nozzles located at the bottom center of each
filter tube are used to spray wash water into each.
Electrostatic Precipitators: The facility is permitted to operate two electrostatic precipitators(CD-3 and
CD-4)both of which are 2,367 square feet of collection surface area. CD-3 controls emissions from
Tenter Frames#3 and#4. CD-4(which is currently still under construction)will control emissions from
Tenter Frame#1.In electrostatic precipitator(ID No. CD-3),which controls TF-3 and TF-4, emission

gases are passed through transmission plates,particles in the gas stream are ionized and obtain an
electrical charge. The charged particles are.then collected on the collection plates and removed from the
gas stream.
PERMITTED EMISSION SOURCES:
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f,,: yam• .-: ,.,,,-,. ,. ,.,.:. :: t-.. >.
Main-031 Natural as/Ultra-low Sulfur No.2 fuel oil-fired boiler
g N/A
SS (44.398 mmBtu/hr maximum heat input)
Natural gas/Ultra-law Sulfur No.2 fuel oil-fired boiler
B-03 2.65 mmtu/h i heat input)
r maxmum eaN/A
(.2 B ..
Natural gas/Ultra-low Sulfur No.2 fuel oil-fired
TK-01 therminol heater N/A
(9.06 mmBtu/hr maximum heat input)
7777-77
77777
:1
Textile tenter frame
(1,500 lbs of cloth per hour maximum capacity) Electrostatic Precipitator
Tenter 1 consisting of the following: CD-4 (2,367 sq.ft.collection surface
a)pad-applied finishing station,and area)
b)therminol(hot oil)heated oven.
Textile tenter frame it
(2,000 lbs of cloth per hour maximum capacity)
Tenter 2 consisting of the following: CD-2 Condenser/Mist Eliminator
a)pad-applied finishing station,and
b)natural gas-fired four zone heated oven s
(7.2 million Btu per hour maximum heat input)
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Textile tenter frame
2 000 lbs of cloth per hour maximum capacity)
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Tenter 3 consisting of the following:
a)pad-applied finishing station,and x
b)therminol(hot oil)heated oven
Electrostatic Precipitator
Textile tenter frame
CD 3 (2,367 sq.ft.collection surface area)
(2,100 lbs of cloth per hour maximum capacity)
Tenter 4
consisting of the following:
_
a)pad-applied finishing station,and
b)natural gas-fired six zone heated oven
(6 million Btu per hour maximum heat input)
INSIGNIFICANVEXEMPT SOURCES
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I-E S 11
Yes
Surface Finishing Operation
2Q .0102(h)(5) Yes
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a z
z I-Main-058
0102.2 h 1 B Yes Yes
Natural as-fired therminol heater Q O( )O
r s

(15 mmBtu/hr maximum heat input)
(NSPS Subpart Dc
h
The facility employs about 360 people and operates 24 hours per day, 6 days per week, 52 weeks per
year.
Throughputs:
mgg
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.M-- -._0
2020 6,457,521
2019 7,345,321
2018 4,365,985
2017 7,d3600
2016 8,11%816
2015 759085000
2014 75937,000
2013 10,312,041
VI, INSPECTION SUMMARY:
On 17 November 2021,I,Mike Thomas with FRO DAQ,conducted a compliance inspection of the
Hornwood,Inc.facility. I met with Dale Kelly,Plant Engineer. This was a prearranged inspection to
assist with the facility's upcoming permit renewal and emissions inventory. we discussed the following:
a) Mr. Kelly verified the FACFINDER information: no changes were needed.
b) I went over the user ID and password information for the AERO system with Mr.Kelly and made
certain that he was able to lag in successfully. Mr. Kelly showed me the data he had collected for
his emissions inventory and stated that he felt like he knew what needed to do to complete their
inventory.
INSPECTION
Mr.Kelly led me on a tour of the facility starting at the control panel for the Condenser/Mist Eliminators,
which graphically displays parameters for both units. These parameters were as follows:
-Condenser/1V4ist Eliminator(ES ID No. CD-1)Last operated on 3 March 2021.
-Condenser/Mist Eliminator(ES ID No. CD-2)
FME Inlet Temperature(°F) 215
FME outlet Temperature(°F) 105
Pre-Filter Differential Pressure(Inches of H2O) 0.35
Overall(i.e.,Post-Filter)Differential Pressure(Inches of Hzo) 7
Mr.Kelly provided all the production records and the natural gas usage records both monthly and
annually for 2020. I asked Mr.Kelly if fuel oil was combusted since the last inspection and specifically
during the most recent annual tune-up on the boiler. Mr. Kelly explained that the facility had been
curtailed 7 August 2019 and used fuel oil for only a few hours. On 8 August 2019,the facility resumed
burning natural gas. The facility burned approximately 43 8 gallons of fuel.ail.Mr.Kelly also stated that
the annual tune up occurred on 13 September 2021 and that fuel oil was fired then as well.

U. e then proceeded to the boiler room where I observed the Natural gas/No. 2 fuel oil-fired boiler(ID No.
Main-031),the Natural gas-fired therminol heater(ID No.I-Main-05 8)and the Natural gas/No. 2 fuel oil-
fired boiler(ID No. I-03)both operating on NG at 0%opacity. The Natural gas/No. 2 fuel oil-fired
therminol heater(ID No. I-01)was not operating.
VIII. APPLICABLE AIR QUALITY REGULATIONS:
. 15A NCAC 2D .0202—PERMIT RENEWAL AND EMISSION
The Permittee shall submit an application for permit renewal, including an emission inventory for
CY 2020,no later than 90-days prior to permit expiration..
APPEARED IN L NCE: The facility's current permit was renewed on time. The facility's
permit expires on 30 April 2022, and the renewal application and El are due to be submitted no later
than 31 January 2 022 for calendar year 2 02 0.
2. '15A NCAC 2 . 5 —PARTICULATES
EXCHANGERS—Particulate emissions from the facility's boiler(ID No. Main-031) shall not
exceed 0.39 lb/mmBtu.
APPEA .N CO1 L NCE: The facility is permitted to combust both natural gas and No. 2
Fuel oil in Main-031, but combusts mainly natural gas. AP-42 emission factors for particulates from
combustion of natural gas and No. 2 fuel oil are 0.0007 lb/mmBtu, and 0.02 lb/mBtu respectively.
3. 1A NCAC 2D.0515—PARTICULATES FROM MISC.INDUSTRIAL PROCESSES-PM
emissions shall not exceed emission rates as calculated by the following:
E=4.10 * (P)'-" for P<—3 0 tons/hr, or
E— 55 * (P)'-11-40 for P>3 0 tons/hr
APPEAR-APPEAR-ED IN C P NCE: 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.
. 15A NCAC 2 . 1 SULFUR DIOXIDE EMISSIONSCOMBUSTION SOURCES—
Sot emissions from the facility's combustion sources shall not exceed 2.3 lb/mmBtu.
APPEARED IN CO L CE: The facility combusts primarily natural gas, but may combust No.
2 uel oil if necessary. The facility only accepts ultra-low sulfur diesel(ULSD), as verified by fuel
f
certifications. AP-42 S02 emission4 factors for natural gas and ULSD are 0.0006 lb/mmBtu, and
0.002 lb/mmBtu respectively,
5. 15A NCAC 2 . 52 —CONTROL OF VISIBLE EMISSIONS—Visible emissions from each
emission source manufactured after 1 July 1971,shall not exceed 20%opacity when averaged over a
six-minute period.
APPEARED IN COMPLL4NCE I observed 0%emissions from all sources during this inspection.

. 15A NCAC 2D .0524NEW SOURCE PERFORMANCE S (Subpart Dc) The
facility's boiler(Main-03 1)is subject. Fuel sulfur content<0.5 wt.% and monthly records of fuel
usage. VE<20%opacity. Initial start-up testing,and periodic testing for visible emissions when
switching from natural gas to fuel oil. Semiannual reporting.
APPEARED C NCE: The facility maintains records of fuel uel use. The fuel certifications
show that the facility only combusts ULSD. The facility received an NOV on I November 2020 for
failing to conduct.Method 9 testing after switching fuels. The current interval for.Method 9 testing is
one year based on the results of the last test. The most recent Method 9 was conducted on 14 January
2021. The highest 6-minute average for that test was 0%. The most recent semiannual report was
received on 16 July 2021 and was compliant. Mr. Kelly stated that he had already made
arrangements to conduct a Method 9 the first week of January 2022.
7. 15A NCAC 2 .0535—NOTIFICATION —Notify DAQ in the event of excess
emissions lasting longer than 4 hours.
APPEARED IN CO PL NCE: Mr. Kelly stated that the facility has had no excess emissions,
breakdowns, or abnormal conditions requiring notification before the inspection.
. 15A NCAC 2D.0540—PARTICULATES FROM FUGITIVE DUST EMISSIONSOURCES—
Fugitive dust emissions shall not cause/contribute to substantive complaints or excessive VE across
property boundaries.
APPEARED IN C P NC`E: No fugitive dust concerns were noted during the inspection.All
roads are paved, and there have not been any complaints received by DAB}. Mr. Kelly stated that
there had been no dust complaints in the past year.
. 15A NCAC 2D .0605-RECORDS MAINTENANCEREQUIREMENT-the Permittee shall
maintain fuel certification records and confnn that the ultra-low sulfur No.2 fuel oil combusted
meets the specification.for ASTM D975 Orade No.2-D S 15 fuel oil (maximum 15 ppm [0.00 15%]
sulfur content,by weight).
APPEARED N C PL NCE. The facility maintains records of fuel uel use. The fuel certifications
provided with the facility's annual report, show that the facility only combusts ULSD that meets the
specifications of ASTMD975.
. 15A NCAC 2 . 611—CONDENSER/MIST ELIMINATORCONDENSER/MIS N S—Annual
internal and structural integrity inspections of CD-2. Change pre-filter weekly. Monitor pressure
drop daily and implement wash procedures when mist eliminator AP reaches 7.5-8.0"H2O, or when
water coil AP reaches 3.0"II2O.Weigh oil and particulate collected in the mist eliminator weekly.
APPEARED IN CO PL NC.E: T P.Ehe facility monitors pressure drop across the mist eliminator
during each shift, and records the values in a logbook. All values in the logbook were below the
level, which would require awash procedure.
The mist eliminator is also inspected semiannually with the most recent internal inspection occurring
on I March 2021 for CD-2. The facility performs weekly maintenance on CD-2. The last weekly
inspection on CD-02 was on 12 November 2021.

1. 15A NCAC2D .0611—ELECTROSTATIC PRECIPITATOR REQUIREMENTS—Shall
perform I&M as recommended by the manufacturer,maintain records of I& ,with dates and actions
in a logbook, inspections should include checking the power pack, visual inspection for contaminate
buildup,visual inspection of the ionizer section contact spring,wires, ground plates and cell plates for
contamination, an annual inspection must be completed for each 12 month period.
APPEARED N C L NCE: The electrostatic precipitator(CD-3) is visually inspected weekly
and a more in depth inspections semiannually. The last weekly inspection was on 9 November 2021.
The last semiannual inspection was conducted on 8 duly 2021. The facility maintains detailed records
for inspections and maintenance. A second electrostatic precipitator(CD-4) has yet to be installed:
CD-4 will control emissions from Tenter Frame I once it is installed.
12. 1A NCAC 2 .1 6—CONTROL S EMISSIONS-
Permittee shall not cause or contribute to objectionable odors beyond the property boundary.
APPEARED IN CO NCEe No objectionable odors were noted as I approached the,facility,
nor were there any noticeable odors while inside. Mr. Kelly stated that there had been no odor
complaints in the past year, and.FRO has not received any odor complaints for this facility.
13. 15A NCAC . 12--FEDERAL AND STATE S APPLICABLE
SOURCES—Insignificant boiler,I-Main-058, is subject to the requirements of NSPS Subpart Dc,
record keeping for inspection and maintenance and records of fuel usage.
APPEARED IN C L NCE: I discussed the fact that boiler (ID No. I-Main-058) is subject to
NSPS Subpart Dc with Mr. Kelly. The boiler is only capable of firing natural gas and Mr. Kelly
keeps all I&M records of the boilboiler I-Main-058 in his office and they appeared to be up to date. The
fuel usage records are also kept in Mr. Kelly's office and appeared to be up to date.
1 . 15A NCAC 2 . 3 7—AVOIDANCE CONDITION FOR AREA SOURCES SUBJECT
CFR 63 Subpart J (6 -In accordance with 15A NCAC 2Q .0317,the Permittee is avoiding
applicability of 40 CFR 63 Subpart JJJJJJ(6J) "Industrial,Commercial,and Institutional Boilers Area
Sources."the Permittee is allowed to fire liquid fuel only during periods of gas curtailment,gas
supply interruptions, startups, or for periodic testing on liquid fuel (periodic testing not to exceed a
combined total of 48 hours during any calendar year)., shall maintain records for when liquid fuel is
burned, fuel certifications,must provide notice within 30 days of switching fuels if not for the reasons
stated above,and must demonstrate compliance within 180 days of the effective date of the fuel
switch.
APPEARED N C I, NCE: The facility normally fires boiler(ID No. Main-031) with natural
gas. Mr. Kelly stated that the facility had burned 27 gallons of No. 2 fuel oil during the first quarter
of 2021 for testing. The facility combusted 19 gallons offuel oil dining testing conducted on 13
September 2021.

15. 15A NCAC 2Q .0711—EMISSION RATES REQUIR.ING A PERMIT—The Permittee has made
a demonstration that facility-wide actual emissions,where one or more emission release points are
obstructed or non-vertically oriented, do not exceed the Toxic Permit Emission Rates(TPERs) listed
in 15A NCAC 2Q .0711(a). The facility shall be operated and maintained in such a manner that
emissions of any listed TAPs from the facility, including fugitive emissions,will not exceed TPERs
listed in 15A NCAC 2Q .0711(a). In accordance with the approved application,the Permittee shall
maintain records of operational information demonstrating that the TAP emissions do not exceed the
TPERs as listed below:
MIBK(methylisobutylketone)(108-10-1) 52 7.6
Toluene(108-88-3) 98 14.4
xylene(mixed isomers)(1330-20-7) 57 16.4
APPEARED IN CO L C.E: Compliance was determined during the most recent permit review
based on operating the source as described in the permit conditions. There have been no changes in
chemicals or chemical formulation since that determination. }
. NON-COMPLIANCE STORY SINCE 2 1 :
Date of Non-Compliance Non-Compliance Description
Issue
l l/l/2020 NOV for failing to conduct Method 9 testing within 45 days of
switching fuels.
7/29/2020 NOD Issued for installing an Unpermitted Air Pollution Control
Device,
4/28/2017 CAI issued for expressing concern with V.E. from Mist Eliminators
5/16/2016 NOD issued for failure to perform M9 when burning No.2 fuel oil,
per NSPS Dc requirements.
6/2/2015 CAI Issued requesting records which were unavailable during the
5/26/15 inspection.
X. S MANAGEMENT(1 1 ):
This facility does not store any 112(r) subject materials above threshold limits. Therefore, it is not
required to maintain a written Risk Management Plan(R1\4P).
CONCLUSION AND REC A :
On 16 November 2021,Ilornwood, Inc. appeared to be operating IN COMPLL4NCE with the conditions
of their current air permit.
PINK S S:
No comments.
/mst