AQ_F_0400009_20200415_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Fayetteville Regional Office
AIR QUALITY Homwood Inc
NC Facility ID 0400009
Inspection Report County/FIPS:Anson/007
Date: 04/15/2020
Facility Data Permit Data
Homwood Inc Permit 04888/R14
766 Hailey's Ferry Road Issued 5/23/2014
Lilesville,NC 28091 Expires 4/30/2022
Lat: 34d 57.2115m Long: 79d 57.6182m Class/Status Synthetic Minor
SIC: 2258/Warp Knit Fabric Mills Permit Status Active
NAICS: 313312/Textile and Fabric Finishing(except Broadwoven Fabric)Mills Current Permit Application(s)None
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact SEP
Benny Burr Charles Horne Dale Kelly NSPS: Subpart Dc
Environmental Manager Owner Plant Engineer
[phone] [phone] [phone]
Compliance Data
Comments: PARTIAL INSPECTION—COVID-19
Inspection Date 04/15/2020
Inspector's Name Jeffrey Nelson
Inspector's Signature: p , Operating Status Operating
�Cwaa "V _ Compliance Code Compliance-inspection
Action Code PCE
Date of Signature: ac o On-Site Inspection Result Compliance
Total Actual emissions in TONS/YEAR:
TSP S02 NOX VOC CO PM10 *HAP
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
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
Date Test Results Test Method(s) Source(s)Tested

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.
M. 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 yam 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(ID
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. During COVID-19 outbreak,the facility has reduced production to 4 days a week but normal
operating hours.
IV. INSPECTION SUMMARY:
a. Is the facility operating?
Yes,the facility is operating but only on 4 days of the week as opposed to the normal 5 days.
b. Is the facility continuing to operate all relevant control devices?
Yes, all control devices are being operated when the sources are operated.
C. Are all the required monitoring, inspection, and recordkeeping activities being conducted
as required in the air permit?
Yes, all these activities are being conducted as required.
d. Are all periodic reports being submitted per the permit requirements?
Yes, all reports have been submitted as required. It is expected that all reports will be
submitted as per the permit requirements.
e. Is the permit nearing expiration?
No. The permit expires on April 30, 2022. The company plans to submit a permit renewal
application on time.
f. Is the Air Quality Emission Inventory due soon?
No the Emission Inventory is not due until the next permit application, which will be during
2022.
g. Is there any upcoming testing required?
There is no upcoming testing.
h. Are there any operating issues at this time, or do they foresee any operating issues that
will affect their ability to meet the air quality requirements?
Production has slowed due to back orders from suppliers,but not a lack of manpower. All
operations are occurring as normal.
i. Do they require any assistance from DAQ at this time?
No assistance is required at this time.
V. NON-COMPLIANCE HISTORY SINCE 2010:

04/26/2019 NOV issued for violations of Control of Visible Emissions and Condenser/Mist Eliminator
Requirements.
04/28/2017 CAI issued expressing concern with VE from mist eliminators
05/16/2016 NOD issued for failure to perform M9 when burning No. 2 fuel oil,per NSPS Dc
requirements.
06/02/2015 CAI issued requesting records which were unavailable during the 05/26/2015 inspection.
VI. RISK MANAGEMENT (112r): This facility does not store any I I2(r) subject materials above threshold
limits. Therefore, it is not required to maintain a written Risk Management Plan(RMP).
VH. CONCLUSION AND RECOMMENDATIONS:
This inspection was completed over the phone during the COVID-19 outbreak. The facility appears to be
in compliance with applicable air quality rules at the time of the call. I recommend that we visit the
facility later this fiscal year after the COVID-19 restrictions are lifted to conduct a full compliance
inspection
PINK SHEET ADDITIONS:
• None
/jln