AQ_F_0800018_20200708_CMPL_InspRpt (4)

NORTH CAROLINA DIVISION OF Washington Regional Office
AIR QUALITY Rose Brothers Paving Co Inc. -Windsor
NC Facility ID 0800018
Inspection Report County/FIPS:Bertie/015
Date: 07/10/2020
Facility Data Permit Data
Rose Brothers Paving Co Inc. -Windsor Permit 03707/R18
129 County Farm Road(SR 1527) Issued 3/21/2017
Lewiston Woodville,NC 27849 Expires 2/28/2025
Lat: 35d 58.8630m Long: 76d 57.0360m 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)None
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact SIP
Tim Perry Tim Perry Tim Perry
Plant Superintendent Plant Superintendent Plant Superintendent
[phone] [phone] [phone]
Compliance Data
Comments: The facility appeared to be operating in compliance with all applicable
Federal and State rules,regulations and permit conditions at the time of the Inspection Date 07/08/2020
inspection. Inspector's Name Kurt Tidd
Operating Status Operating
Compliance Code Compliance-inspection
Inspector's Signature: Action Code FCE
On-Site Inspection Result Compliance
Date of Signature: 07/13/2020
Total Actual emissions in TONS/YEAR:
TSP S02 NOX VOC CO PM10 *HAP
2015 0.4800 1.12 1.28 0.4000 4.07 0.3000 54.58
2011 0.7100 1.68 2.04 0.6600 6.62 0.4600 89.40
Highest HAP Emitted inpounds)
Five Year Violation History:None
Performed Stack Tests since last FCE:None
Location:
This facility is in Windsor, Bertie County,NC. From WaRO take Hwy 17 North to the junction of Hwy
17/Hwy 64. Turn on Hwy 64 East/17 North, south of Williamston, and follow Hwy 17/13 North. Prior
to the separation of Hwy 13/17 North, turn right onto Country Farm Road (SR1527) at the North
Carolina National Guard Armory. The facility is located about half a mile on the left.
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Safety:
PPE should be used at the facility. The inspector will need a hard hat, safety glasses, hearing protection,
and safety shoes. Additionally, a safety vest should be worn when you inspect the yard.
Facility Summary:
The facility is a 250-ton/hr batch asphalt mixing plant. The aggregate is conveyed to a drum where it is
dried. A screening process then separates the aggregate. The aggregate is then mixed in the desired
proportions, injected with asphalt, weighed and unloaded into trucks and transported to job sites. This
facility has a multi-site permit that allows for them to locate in Lewiston or Windsor; both sites are in
Bertie County.
List of Permitted Sources:
Emission Emission Source Control Control System
Source ID Description System ID Description
ES-1 Nos. 2 and 4/Nos. 2 and 4 equivalent waste fuel oil-fired 24768,Ra-15-60 Simple cyclone (120
batch asphalt plant, 250 tons per hour maximum in), Bagfilter(11,466 sq
production capacity, 84 million Btu per hour maximum ft)
heat input, allowed to utilize recycled, post consumer
waste, asphalt (asbestos-free) shingles as an option in the
mix
GS3630AR/HC 50 TPH asphalt and concrete crusher N/A N/A
Inspection Results:
I conducted a Full Compliance Evaluation (FCE) of the Rose Brothers Paving Company's asphalt plant
located in Windsor,NC on 07/08/2020. I arrived at the facility at 8:30. The facility was not in operation
at the time of the inspection. I had spoken with Tim Perry earlier that week and he said that the Windsor
Facility was operating mainly for local work and had not operated much in 2020. Mr. Perry had left the
records for me to review at the Murfreesboro facility. These records included;
• Monthly asphalt production
• Monthly pollutants (PM, S02,NOx, CO, VOC and HAPs)
• Shingle analysis for asbestos
• Fuels sulfur content(All deliveries below limit, only use ULSD besides the recycled#4)
• Recycled#4 fuel analysis
• Fabric filter and cyclone inspection and maintenance
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The ground was wet from a rain the night before and no fugitive emissions were noted during the
inspection. I did note a slight asphalt odor as I entered the facility, but it did not extend outside of the
perimeter. I concluded my inspection at 8:45 AM.
Re2ulatory Review:
2D .0506 "Particulates from Hot Mix Asphalt Plants"
Using the equation, E = 4.9445(P)0.4376, where P is the process throughput rate in tons/hr and E is the
allowable rate in lbs/hr, the facility has an allowable particulate emission rate of 55.4 lbs/hr (based
on maximum production rate). The facility tested for PM on 5/3/2018 with results from the test
being 1.22 lbs/hr. This is well below the permitted limit. Compliance is indicated.
2D .0515 "Particulates from Miscellaneous Industrial Processes"
This standard applies to the crusher. Using the equation, E= 55.0 (P)O-" —40, where P is the process
throughput rate in tons/hour and E is the allowable rate in lbs/hr, the 50 tph crusher has an allowable
particulate emission rate of 44.6 lbs/hr. The crusher was not in operation during inspection.
Compliance is indicated.
2D .0516 "Sulfur Dioxide Emissions from Combustion Sources"
All fuel oil combustion is limited to 2.3 pounds per million Btu. The facility started using recycled
No. 4 fuel oil in June 2008 (allowed by the permit). The fuel oil has a sulfur content of<2.0% by
weight, which was documented by fuel receipts. All other fuel is used ULSD which is less than the
permitted limit. Compliance is indicated.
2D .0521 "Visible Emissions"
This standard requires visible emissions (VE) from all permitted equipment shall not be more than
20 percent opacity when averaged over a six-minute period, except that six-minute periods averaging
not more than 87 percent opacity may not occur more than once in any hour nor more than four
times in any 24-hour period. The facility was not in operation at the time of the inspection, no VE's
were observed during my inspection. Compliance is indicated.
2D .0535 "Notification Requirement"
No notifications of malfunctions taking more than four hours to repair resulting in excess emissions
have been received. Compliance is indicated.
2D .0540 "Particulates from Fugitive Non-Process Dust Emission Sources"
I did no observed any fugitive emission from the facility during the inspection. Compliance is
indicated.
2D .0611 "Bagfilter Requirements & Cyclone Requirements"
The facility must perform an annual internal inspection of the bagfilter system and cyclone system
and record the results in a logbook along with other maintenance activities. A logbook is maintained
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in the control room containing all air quality permit records. The last annual inspections for the
bagfilter and cyclone systems was performed on 03/06/2020. Compliance is indicated.
2D .1806 "Control and Prohibition of Odorous Emissions"
No nuisance odors were detected past the facility fence line and there were no records of any
complaints. Compliance is indicated.
2Q.0311 "Permitting of Facilities at Multiple Temporary Sites"
This rule gives the Director the right to issue a single permit authorizing emissions from a facility or
source at multiple temporary sites. Permits for facilities at multiple temporary sites shall include: the
identification of each site; the conditions that will assure compliance with all applicable
requirements at all approved sites; a requirement that the facility notify the Division at least 10 days
in advance of each change of site; and the conditions that assure compliance with all other
provisions. The plant has not moved since the last inspection. Compliance is indicated.
2Q.0315 "Synthetic Minor Facilities"
Under the current permit there is no restriction on the tonnage of asphalt that can be produced. The
facility is required to calculate and document monthly S02, CO, and NOx emissions from their
production/combustion of various fuels. Reports are being maintained. Compliance is indicated.
2Q.0317"Vendor Supplied Recycled No. 2 and No 4 Fuel Oil Requirements"
The plant has been using Recycled No. 4 fuel oil since the last inspection. I examined the fuel
certifications for all fuel oil deliveries for CY2019. The facility combusted 81,589 gallons of
recycled No. 4 in CY2019. Compliance is indicated.
REQUIREMENTS FOR USE OF RECYCLED ASPHALT SHINGLES
The facility started receiving Post-Consumer Recycled Asphalt Singles (PRAS) for the first time in
February 2012 and started using them in various asphalt mixes in March 2012. All receipts and test
reports for CY2019 were reviewed and appear to be complete. The facility is receiving shingles from
two sources Dominion and Premier. Both companies provided lab analysis of the shingles.
Compliance is indicated.
Compliance History:
No non-compliance issues have been documented in the last five years.
Conclusions, Comments, and Recommendations:
The facility appeared to operating in compliance with all applicable Federal and State air quality rules,
regulations and permit conditions at the time of inspection.
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