AQ_F_0900063_20190528_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Fayetteville Regional Office
AIR QUALITY Peanut Processors Inc. -Plant 1
NC Facility ID 0900063
Inspection Report County/FIPS: Bladen/017
Date: 06/07/2019
Facility Data Permit Data
Peanut Processors Inc. - Plant 1 Permit 08005/R09
7329 Albert Street Issued 7/22/2014
Dublin,NC 28332 Expires 6/30/2022
Lat: 34d 39.4840m Long: 78d 43.5440m Class/Status Small
SIC: 2099/Food Preparations Nec Permit Status Active
NAICS: 311911 /Roasted Nuts and Peanut Butter Manufacturing Current Permit Application(s)None
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact SIP
Les Hill Houston Brisson Brian Tart
Regulatory Manager President/CEO Regulatory Manager
[phone] [phone] [phone]
Comments:
G Compliance Data
Inspection Date 05/28/2019
Inspector's Name Mike Thomas
Inspector's Signature: a Operating Status Operating
Compliance Code Compliance- inspection
Action Code FCE
Date of Signature: On-Site Inspection Result Compliance
-?'-19
Total Actual emissions in TONS/YEAR:
TSP S02 NOX VOC CO PM10 *HAP
2013 2.17 --- 0.5000 0.1900 0.4000 2.17 18.00
2008 0,9300 --- 0.2400 0.0200 0.2000 0.7000 85.80
* 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

I. DIRECTIONS
From FRO take Highway 87 South and travel about 20 miles to Dublin. The facility is on the right
after passing the Highway 410 intersection. It is a good idea to call the facility on the way to allow
Mr. Hill time to travel from his other office.
IL SAFETY CONSIDERATIONS
All standard DAQ FRO safety gear is required. Be aware of hot surfaces due to high temperatures
used during facility processes as well as fork lifts.
III. III.FACILITY/PROCESS DESCRIPTION
Shelled peanuts are loaded from a hopper onto a conveyor and passed through the natural gas fired
pre-heater at—180 degrees F in hot chambers and later finished with cooling chambers that drop the
temperature down to—155 F. The purpose of this pre-heater is simply to warm the peanuts up. The
peanuts are then blanched with dry heat at—190 degrees F in 5 electric dry blanching units. The
blanching process swells the nut,cracks the skin, and allows for easy removal of the skin.After
blanching,the peanuts are roasted submerged in peanut oil at—355 degrees F. The product is then
stored for packaging.
Peanut Oil Roasting Process
Peanut oil in the oil roaster is circulated out to a heat exchanger tank at—330 degrees F. The oil
leaving the heat exchanger feeds into a filtering machine that removes any particles and debris
before the oil is recycled back to the roaster. The recycling process helps maintain a consistent
roasting temperature in the oil roaster. The peanuts reabsorb some of this recycled oil. There is no
fan used in the process. About 60 gallons of oil are added from the roasting peanuts to this recycling
system each day. About 4 to 5 gallons of oil each day are lost during filtering.
Air Emissions Description and Controls
Particulate emissions from the pre-heater are controlled by a cyclone. The two smog hogs that used
to operate in series with the cyclone are no longer in use. The exhaust from the cyclone simply
passes through the smog hog ductwork to the atmosphere. Peanut skin particles from the 5 blanchers
are vacuumed into another outside cyclone and the air is circulated back inside the building with no
release to the outside. Emissions from the oil roaster are uncontrolled and are released through two
cool zone stacks outside of the building. One of these stacks sits on top of the building near the
cyclones and the other is toward the ground at the middle of the building. The peanut oil heat
exchanger tank vapors vent uncontrolled through a stack outside of the building.

IV. PERMITTED EQUIPMENT LIST
EmissionControl
I§ySt6*` :, kip
EinissJOAA
Sour. itire , - ti rip on
Descifip"doh'T'
PlantBlanching anQ'R,oating as Were shu",
ipg down during this inspection.
- in-
Natural gas fired peanut roaster per hou
r
Cyclone(96 inches in dia.)
ESI heat input rate and 4,500 lb.per hour peanut process CDl
rate
-Not operating during inspection.
Natural Gas Fired Heat Exchanger and Oil Roaster
ES7 (2 nurn Btu per hour heat input and 5,500 lb.per hour
peanut processing rate)
-Not operating during inspection. N/A N/A
Five Blanchers(6,000 lbs per hour)
FS
-Operating at 0%opacity.
V. INSPECTION CONFERENCE
On 28 May 2019, 1 Mike Thomas and Abdul Kadir, both of FRO DAQ conducted a compliance
inspection at the Peanut Processors Plant#1 facility. We met with Less Hill, Plant Manager. We
discussed the following:
a) Verified FACFINDER information: Added Mr. Hill as the Facility Contact.
b) We reviewed the facility's maintenance and inspection logbooks. Both were well
maintained and up to date.
c) Throughputs:
',�Proeesiiid
V 5, NG
War" . Nanuits
s[Yr
2018 —3200' 4525
2017 3300.58 4917.8
2016 2821.85 3447.7
2015 4161 4272
2014 2,608 Unknown
2013 1,790 Unknown
VI. INSPECTION SUMMARY
Mr. Hill led us on a tour of the facility. The blanching operation was the only process operating
during this inspection. The blarchers operate at a lower temperature and function like a dryer to
make the skins brittle for removal. As a result,the characteristic blue smoke observed at other
roasting facilities is not present here. We observed the cyclone(CD13)that controls emissions from
the blanchers. Mr. Hill stated that they collect approximately 3 super sacks of peanut skins a week
from this cyclone. No indications of problems were observed. We also observed a second smaller
cyclone adjacent to CD13. This cyclone is no longer in operation and was part of the smog hog
system the facility used to use.

VII. PERMIT STIPULATIONS
A.2 2D .0202—PERMIT RENEWAL AND EMISSION INVENTORY REQUIREMENT—At least
90 days prior to the expiration date of this permit,the Permittee shall submit the permit renewal
application and air pollution emission inventory.
APPEARED IN COMPLIANCE—The recent permit renewal was due by 2 June 2014 and was received
on 28 May 2014. The next renewal is due in March 2022.
A.3 2D .0503 PARTICULATES FROM FUEL BURNING INDIRECT HEAT EXCHANGERS-
PM emissions from the fuel burning Natural Gas fired indirect heat exchanger, ES7 shall not exceed 0.91
Ibs/mmBtu/hr.
APPEARED IN COMPLIANCE—The AP-42 particulate emissions factor for natural gas is 0.007
Ibs/mmBtu.
AA 2D .0515 PARTICULATES FROM MISCELLANEOUS INDUSTRIAL PROCESSES-
particulate matter emissions from the emission sources shall not exceed allowable emission rates.
APPEARED IN COMPLIANCE—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.
A.5 2D .0516 SULFUR DIOXIDE CONTROL REQUIREMENTS- Shall not exceed 2.3 pounds per
million Btu heat input.
APPEARED IN COMPLIANCE The facility combusts only natural gas and AP-42 EF for sulfur
dioxide is 0.0006 lb/mmBtu
A.6 2D .0521 VISIBLE EMISSIONS CONTROL Requirement—Visible emissions from the emission
sources, manufactured after July 1, 1971, shall not be more than 20 percent opacity when averaged over a
six-minute period.
APPEARED IN COMPLIANCE We observed 0%V.E. from the blanching operation.
A.7 2D .0535 NOTIFICATION REQUIREMENT- Facility is required to notify the DAQ of excess
emissions that last for more than four hours.
APPERARED IN COMPLIANCE—Mr. Hill stated there have been no occurrences of excessive
emissions since the last inspection and he is aware of the reporting requirement.
A.8 2D .0540 PARTICULATES FROM FUGITIVE DUST EMISSION SOURCES: - Shall not
cause or allow fugitive dust emissions to cause or contribute to substantive complaints or excess visible
emissions beyond the property boundary.
APPEARED IN COMPLIANCE-No fugitive dust was observed beyond the property boundaries and
Mr. Hill stated they have not received any complaints.
A.9 2D .0611 CYCLONE REQUIREMENTS—(CD-13) - Particulate matter emissions from sources
shall be controlled as described in the permitted equipment list, including annual inspections recorded in
logbook and all maintenance activities recorded in logbook.
APPEARED IN COMPLIANCE—The facility provided records indicating the last annual I/M occurred
on 30 March 2019. Inspection and Maintenance logbook documents weekly inspections and notes any
repairs made. The facility collects approximately three super sacks of peanut skins a week from this
cyclone.

VIII. 112R STATUS
The facility does not store any of the listed chemicals above the threshold quantities, and is not required
to maintain a written Risk Management Plan(RMP).
IX. NON-COMPLIANCE HISTORY SINCE CY2010
• On 10 November 2010,higher opacity readings than usual were observed by Pam Vivian while
driving by the facility doing other work at another location. She stopped in and notified Mr. Bud
Lotz, Facility Contact, about this problem. She later returned that same day and the problem had
been corrected by cleaning the ESP control devices and lowering the facility processing
temperature. Follow Up: During this inspection,visible emissions from the oil roaster stack
outside were at—15% opacity. No other visible emissions were observed.
• Issued NOV on 11 April 2014 for B.5 violation of changing control devices without a permit
modification. Follow Up: During this inspection,the previously permitted smog hogs were still
connected in series with the permitted cyclone CD13 but were no longer operating.
X. COMMENTS/COMPLIANCE STATEMENT
Peanut Processors Inc. - Plant 1 appeared to be operating in compliance with the current air permit
on
28 May 2019.
PINK SHEET
None as of this inspection.
/mst