AQ_F_0400009_20210114_ST_STO-Rpt

NORTH CAROLINA DIVISION OF Fayetteville Regional Office
AIR QUALITY Homwood Inc
NC Facility ID 0400009
Stack Test Observation Report County/FIPS:Anson/007
Date: 01/22/2021
Facility Data Compliance Data
Homwood,Inc Observation Date 01/14/2021
766 Hailey's Ferry Road Observer's Name Mike Turner
Lilesville,NC 28091 Operating Status Operating
Lat: 34d 57.2115m Long: 79d 57.6182m Action Code 23/STACK TEST
SIC: 2258/Warp Knit Fabric Mills OBSERVED
NAICS: 313312/Textile and Fabric Finishing(except Broadwoven Fabric)Mills
Contact Data Permit Data
Facility Contact Autho7PIant
Technical Contact permit 04888/R15
Benny Burr Charles le Kelly Issued 4/3 0/2 0 22 0
Env ronmental Manager Owner Engineer Expires 4/30/2022
[phone] (704)8404)848-4121 Classification Synthetic M nor
Permit Status Active
Inspector's Signature: I _ Comments:
Date of Signature:
I. DIRECTIONS TO SITE: From FRO,take Hwy 401 S to Wagram,then right on Wire Road past Laurel
Hill.Turn right(west) onto Hwy 74 and travel 27 miles. Turn left onto Hailey's Ferry Rd/SR 1801 /Pit
Road;the facility is located—1/4 mile away, on the right. Check in at the guard house prior to entry.
H. SAFETY: Standard FRO safety gear. Inspectors should be wary of hot surfaces.
HI. FACILITY 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.
Dye House: 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 Eliminators: 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),the air then passes over four(4) cold water coils and six(6)
spray rings that both condense the vapor prior to the mist eliminator. In Condenser/Mist Eliminator(lD
No. CD-1),the air passes over six(6)spray rings that help condense the vapor prior to the mist
eliminator. There are no cooling coils in CD-1. 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.
The facility employs about 360 people and operates 24 hours per day, 6 days per week, 52 weeks per
year.
PURPOSE OF THE TEST:
Homwood is required by 15A NCAC 2D .0524 to conduct Particulate Matter monitoring within 45 days
of switching fuel combustion from natural gas to a fuel with an opacity standard(such as coal, oil, or
wood).
STACK TEST OBSERVATIONS:
On 14 January 2021,I, Mike Turner,of the Fayetteville Regional Office of DAQ, and Stephen Allen, also
of FRO DAQ, arrived at this facility to observe a Method 9 VE test for fugitive emissions. Scott Bowers
of TexPro from Kemersville,NC conducted the test.
We met with Dale Kelly, Plant Engineer and Technical Contact for this facility. Mr.Kelly had us setup
138 feet away from the emission point. Mr. Bowers was to perform one 1-hour EPA Method 9 VE
observation for one emission point. I performed one 1-hour EPA Method 9 VE observation of the same
emission point. Mr. Bowers and I began our observation at 10:00 AM and completed our observation at
11:00 AM. Background for the roof stack emission point was overcast. Temperature was approximately
41IF. Winds were approximately 0-5 mph and out of the SW.
Mr. Bowers,myself,and Stephen Allen left the facility at approximately 11:15 AM.
COMPLIANCE STATEMENT:
The VE observations appeared to be conducted according to the requirements of EPA Method 9.
The highest 6-minute average VE opacity observed by Mike Turner from the observation point was 0%
opacity. The next Method 9 observation will be due in 12 months.
See the attached VE observation forms and calculation sheets.
WMT
cc: FRO Facility Files