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HomeMy WebLinkAboutAQ_F_1800462_20220408_CMPL_InspRpt NORTH CAROLINA DIVISION OF Mooresville Regional Office AIR QUALITY Midstate Contractors,Inc. NC Facility ID 1800462 Inspection Report County/FIPS: Catawba/035 Date: 04/08/2022 Facility Data Permit Data Midstate Contractors,Inc. Permit 08115/R08 2260 Indian Trail Issued 8/21/2014 Newton,NC 28658 Expires 7/31/2022 Lat: 35d 37.8594m Long: 8ld 12.7206m 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)Renewal Contact Data Program Applicability Facility Contact Authorized Contact Technical Contact SIP Raymond Lovins James Abernethy Raymond Lovins NSPS: Subpart I Plant Manager President Plant Manager (828)464-0601 (828)322-9497 (828)464-0601 Compliance Data Comments: Inspection Date 04/08/2022 Inspector's Name Jim Vanwormer Inspector's Signature: Operating Status Operating �tirrr ,asr .e2sae� 193.E Compliance Status Compliance-inspection Action Code FCE Date of Signature:4/18/2022 Inspection Result Compliance Total Actual emissions in TONS/YEAR: TSP S02 NOX VOC CO PM10 *HAP 2021 3.23 0.0100 1.48 2.74 7.56 1.84 364.00 2013 0.8200 --- 0.4800 0.9000 2.47 0.5200 119.00 *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 Midstate Contractor's,Inc. April 8,2022 Page 2 Type Action: X Full Compliance _Partial Compliance _Complaint Other: Evaluation Evaluation/Reinspection Investigation Data Date submitted for initial review 4/12/2022 _IBEAM INFO,WARNING/OB,NOD,NOV,NRE Tracking: X IBEAM Document X IBEAM Inspection,list date inspected _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_4/l/2023 Directions: From MRO,travel Hwy. 150 west toward Lincolnton. Turn right onto Hwy. 16 north. Travel approximately 9 miles and turn left onto Smythe Farm Road. Travel approximately 3 miles and the facility is located on the left. Safety Equipment: Safety glasses,hardhat and safety shoes are recommended. Safety Issues: None noted Lat/Long Coordinates: A review of the facility's coordinates on "Maps of DAQ Regulated Facilities" indicates the facility's latitude and longitude coordinates are accurate and are not locked in IBeam. Email Contacts: IBEAM email contacts were verified. 1. The purpose of this site visit was to conduct a routine air quality inspection. This facility is a drum-mix asphalt plant. The facility is currently operating forty hours per week,with production of asphalt during approximately 20 hours a week. The facility typically shuts down for 4-6 weeks between mid-January and mid-March depending on weather conditions. I arrived at the facility with Emily Supple at 9:00 am and met with Mr. Raymond Lovins, Plant Manager, who accompanied us during this inspection. 2. Facility Contact Information: During the inspection,I verified the facility contact information in IBEAM. 3. Compliance history file review: No problems have been noted in the last five years by DAQ. The current compliance status is discussed in the following sections. Midstate Contractor's,Inc. April 8,2022 Page 3 4. Observations of permitted air emission sources and control devices: Emission Emission Source Control Control System Source ID Description I System ID Description ES1 (NSPS) natural gas-fired hot CD I, CD2 cyclone(112 inches in drum-mix asphalt/RAP diameter) and bagfilter plant(110 million Btu (11,581 square feet of per hour maximum heat filter area) installed in input rate, 350 tons per series hour maximum capacity) Observed. At the time of the inspection the plant was operating. There were no visible emissions observed other than steam from the drum. Emission Emission Source Control Control System Source ID Description System ID Description F14 RAP screen(200 tons per N/A N/A hour maximum capacity) Observed.The RAP screen was operating with no visible emissions observed. Emission Emission Source Control Control System Source ID Description System ID Description F18 RAP crusher(50 tons per N/A N/A hour maximum capacity) Observed.The RAP crusher was operating with no visible emissions observed. Emission Emission Source Control Control System Source ID Description System ID Description F15 Three(3)RAP conveyors(200 tons per N/A N/A hour maximum capacity each) Observed. All 3 RAP conveyors were operating with no visible emissions observed. Midstate Contractor's,Inc. April 8,2022 Page 4 5. Observations of insignificant air emission sources and control devices listed on the current >l ermit: Source Exemption Source of Source of Title V Regulation TAPs? Pollutants? I-FI I -liquid asphalt tank(30,000 gallons MQ .0102 yes Yes capacity) (c)(1)(L)(xii) I-F12 -liquid asphalt tank(30,000 gallons M ) .0102 yes Yes capacity) (c)(1)(L)(xii) _F I-ES3 -natural gas-fired burner(0.5 million M)(2)(B)(i)(l) —F .0102 yes Yes Btu per hour maximum heat input rate) I-ES2 -natural gas-fired burner(0.8 million M .0102Btu per hour maximum heat input rate) 2)(B)(i)(n Yes Yes Observed. Each burner is attached to an asphalt tank to keep the material warm prior to injection into the mixing drum. At the time of inspection, the burners were operating. There were no emissions observed from the process. Source 7Rxelg emption Source of Source of Title V ulation TAPS? Pollutants? 1-17 13 -one (1)No. 2 fuel oil storage tank 2Q .0102 (20,000 gallons capacity) (c)(1)(D)(i) Yes Yes Observed. The storage tank had been disconnected from the asphalt drum. The fuel is used for vehicles only, it is filled twice a year and records are kept by the facility. There were no emissions observed. Source Exemption Source of Source of Title V Regulation TAPS? Pollutants? I-F17 -RAP feeder bin(200 tons per 2Q .0102 hour maximum capacity) �(c)(2)(E)(i) No Yes Observed. The feeder bin was in operation with no visible emissions. Source F-Exemption Source of Source of Title V Regulation TAPS? Pollutants? I-F9 -hot-mix asphalt storage silos(200 12Q .0102 tons) (c)(1)(L)(xii) No No I-F7 -drum main conveyor(525 tons per 2Q .0102 hour maximum capacity) (c)(2)(E)(i) No Yes Observed. At the time of the inspection, the plant was operating with no emissions observed other than steam from the asphalt. Midstate Contractor's,Inc. April 8,2022 Page 5 6. Observations of air emission sources and control devices not listed on the current permit: a. None noted. 7. Compliance with specific permit conditions and limitations: a. Condition A. 2. "Permit Renewal and Emission Inventory Requirement" states that at least 90 days prior to the expiration date of this permit,the Permittee shall request permit renewal by letter with AA application form and submit air pollution emission inventory report with certification sheet for 2021 calendar year to MRO DAQ. Observed. The facility has a permit that expires on July 31, 2022,they have submitted their renewal application on time and was received on February 14, 2022. Compliance with this stipulation is indicated. b. Condition A. 3. 15A NCAC 2D .0506, "Particulates from Hot Mix Asphalt Plants" states: i. Particulate matter emissions resulting from the operation of a hot mix asphalt plant shall not exceed allowable emission rates. ii. Visible emissions from stacks or vents at a hot mix asphalt plant shall be less than 20 percent opacity when averaged over a six-minute period. iii. Fugitive dust emissions shall be controlled as required by 15A NCAC 2D .0540 "Particulates from Fugitive Dust Emission Sources." iv. Fugitive emissions for sources at a hot mix asphalt plant not covered elsewhere under this Rule shall not exceed 20 percent opacity averaged over six minutes. Observed. At the time of this inspection,the plant was in operation. No visible emissions were observed other than steam. Compliance with this stipulation is indicated. C. Condition A.4. 15A NCAC .0516, "Sulfur Dioxide Emissions from Combustion Sources" states that the facility cannot burn fuel with sulfur dioxide emissions from the combustion sources shall not exceed 2.3 pounds per million Btu heat input. Observed. The facility operates solely on natural gas,compliance with this stipulation is indicated. d. Condition A.5. 15A NCAC .0521, "Control of Visible Emissions." The facility is limited twenty percent opacity. Observed. At the time of this inspection,the plant was in operation with no visible emissions other than steam. Compliance with this condition is indicated. e. Condition A. 6. 15A NCAC 2D .0524, "New Source Performance Standards." NSPS Subpart I. The facility must comply with all applicable provisions,including the notification,testing,reporting,record-keeping and monitoring. Midstate Contractor's,Inc. April 8,2022 Page 6 Observed. The facility has complied with applicable NSPS requirements. Testing was conducted on June 11-12, 2019 for total particulate matter(PM) and on June 17,2019 for opacity. Test results were received by the Mooresville Regional Office on July 11, 2019 indicating 0.4% visible emissions and PM emissions of 6.7 g/dscm (limit 90 gr/dscm). The test results were reviewed and approved by the SSCB on October 29, 2019. Compliance with this condition is indicated. f. Condition A.7. 15A NCAC 2D .0535, "Notification Requirement." The permittee of a source of excess emissions that last for more than four hours and that results from a malfunction, a breakdown of process or control equipment or any other abnormal conditions, shall notify the Director or his designee of any such occurrence by 9:00 a.m. Eastern time of the Division's next business day of becoming aware of the occurrence. Observed. Based on a records review and a conversation with Mr. Lovins, no excess emissions have occurred at the facility. Compliance with this stipulation is indicated. g. Condition A.8. 15A NCAC 2D .0540, "Particulates from Fugitive Dust Emission Sources." The Permittee shall not cause or allow fugitive dust emissions to cause or contribute to substantive complaints or excess visible emissions beyond the property boundary. Observed. The MRO has not received any complaints regarding the facility and no fugitive dust emissions were observed at the time of this inspection. Compliance with this condition is indicated. h. Condition A.9. 15A NCAC 2D .0605, "Testing Requirement." The facility is required to conduct PM emission testing on the drum-mix asphalt/RAP plant (ID No. ES1) and submit two (2) copies of the results to DAQ by September 30, 2020. The facility is also required to submit a testing protocol to DAQ at least 45 days prior to testing for approval. Observed. Testing was conducted on June 11-12, 2019 for total particulate matter(PM) and on June 17, 2019 for opacity. Test results were received by the Mooresville Regional Office on July 11, 2019 indicating 0.4%visible emissions and PM emissions of 6.7 g/dscm(limit 90 gr/dscm). The test results were reviewed and approved by the SSCB on October 29, 2019. The next test will be due by June 2029. Compliance with this condition is indicated. i. Condition A.10. 15A NCAC 2D .0611, "Fabric Filter Requirements." The facility is required to conduct an annual internal inspection of the fabric filter system and record the results of this inspection and any maintenance performed in a fabric filter log book. Observed. The facility conducts periodic inspections of the fabric filter system and records the results in a fabric filter log book. The last two internal inspections were conducted on October 30,2021 and December 4,2020. Compliance with this condition is indicated. j. Condition A.11. 15A NCAC 2D .0611, "Cyclone Requirements." The facility is required to conduct an annual inspection of the cyclone system and record the results and any maintenance performed in a cyclone log book. Midstate Contractor's,Inc. April 8,2022 Page 7 Observed. The facility conducts periodic inspections of the cyclone system and records the results in a log book. The last two internal inspections were conducted on October 30,2021 and December 4,2020. Compliance with this condition is indicated. k. Condition A.12. 15A NCAC 2D .1806, "Control and Prohibition of Odorous Emissions." Control odors properly. Observed—The MRO has not received any odor complaints concerning the facility, and no odors were noted outside the facility at the time of this inspection. Compliance with this condition is indicated. 1. Condition A.13. 15A NCAC 2Q .0501, "Synthetic Minor Facilities." Facility-wide emissions of CO shall be less than 100 tons per consecutive 12-month period. To comply with the permit limit, the production of hot-mix asphalt shall be less than 1,490,941 tons per consecutive 12-month period. The facility shall record monthly and total annually the total asphalt produced. Within 30 days after each calendar year,the facility is required to submit an annual report to DAQ containing the total amount of hot-mix asphalt produced during the previous 12 months and the facility-wide CO emissions for the previous 12 months. Observed - The facility is maintaining daily and monthly records of asphalt production. The required annual report for calendar year 2021 was received by the Mooresville Regional Office on January 30, 2022, indicating compliance with the permit limits. The report showed total asphalt production of 114,050.17 tons with resulting CO emissions of 7.41 tons. Compliance with this condition is indicated. 8. NSPS/NESHAP Review The drum mixer at the facility is subject to 40 CFR Part 60 Subpart 1. There are no boilers, emergency generators,or gasoline tanks at the facility. 9. Summary of changes needed to the current permit: The RAP crusher and associated screen and conveyors will be removed. The facility pays a contractor to crush the bulk piles of RAP. The material that goes into the RAP crusher has already been crushed, the device simply breaks up the clumps that have formed in the RAP pile due to heat and rain. The yellowsheet has been updated. 10. Compliance assistance offered duringtpection: None. 11. Section 112(r) gpplicabilitX: This facility does not appear to be subject to the requirements of the Chemical Accident Release Prevention Program, Section 112(r)of the Clean Air Act. Midstate Contractor's,Inc. April 8,2022 Page 8 12. Compliance determination: Based on my observations, this facility appeared to be in compliance with the applicable air quality regulations at the time of the inspection. JRV:lms c: MRO File https://neconnect.sharepoint.com/sites/DAQ-MRO/Counties/CATAWBA/00462/INSPECT 20220408.doex