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Home My WebLink AboutAQ_F_0400043_20190822_CMPL_InspRpt NORTH CAROLINA DIVISION OF Fayetteville Regional Office AIR QUALITY Triangle Brick Company-Wadesboro Brick Manufacturing Plant Inspection Report NC Facility ID 0400043 Date: 08/27/2019 County/FIPS: Anson/007 Facility Data Permit Data Triangle Brick Company-Wadesboro Brick Manufacturing Plant Permit 08179/Tl 1 US Hwy 52 Issued 7/13/2018 Wadesboro,NC 28170 Expires 6/30/2023 Lat: 35d 1.1463m Long: 80d 5.1235m Class/Status Title V SIC: 3251 /Brick and Structural Clay Tile Permit Status Active NAICS: 327121 /Brick and Structural Clay Tile Manufacturing Current Permit Application(s)None Contact Data Program Applicability Facility Contact Authorized Contact Technical Contact SIP/Title V MACT Part Ricky Merritt Howard Brown,Jr. Ricky Merritt Subpart JJJJJ Director of Engineering President and CEO Director of Engineering NSPS: Subpart 000, Subpart UUU (919)544-1796 (919)544-1796 (919) 544-1796 Compliance Data Comments: Inspection Date 08/22/2019 Inspector's Name Mitch Revels Inspector's Signature: Operating Status Operating Compliance Code Compliance- inspection ''' Action Code FCE Date of Signature: / �' -& Yj ) I On-Site Inspection Result Compliance Total Actual emissions in T_ONSIYEAR: TSP S02 NOX VOC CO PM10 *HAP 2018 41.43 30.26 12.71 6.19 58.20 38.42 1218.31 2017 38.36 28.42 11.89 5.76 53.90 35.57 1127.59 2016 13.19 22.02 9.26 4.58 42.38 10.99 9503.74 * Hi est 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 1. DIRECTIONS TO SITE: Triangle Brick is located on US 52 about 4 miles north of Wadesboro, NC, Anson County. From FRO, take US 401(Raeford Rd.) south to US 74; turn right onto US 74 West. Follow US 74 thru Wadesboro. On the west side of Wadesboro, turn right, following US 52 north. Go approximately 4 miles and turn right into the first facility entrance;the office is on the left. Check opacities prior to entering (kiln stacks, openings in bldg.with grinders). 2. SAFETY: Safety glasses and shoes required; hard hat and ear protection optional. An operating kiln is hot to touch; exiting bricks and cars are hot. Keep hands out of brick-making mechanisms, grinders and extruders. 3. FACILITY DESCRIPTION: Triangle Brick Co. - Wadesboro is the second largest brick plant in the country. They make a variety of bricks from clay and shale mined onsite. The material they mine is a consistent mixture of clay and shale. As the material is mined, it is trucked up the hill to the facility where it is fed through a sizing grate. The smaller material passes via conveyors to the storage shelter and the oversized material goes through a jaw crusher to reduce the size and then continues to the storage shelter. There are two plants on site and the material from the storage shed feeds both. From the storage shelter material is scooped into a feeder, run through a scalper(oversized material goes to hammer mill)then material (the consistency of cornmeal) is conveyed to storage silos. From the storage silos, the material is sent through two pug mills in series where it is combined with water and mixed to an even consistency then fed through a machine that extrudes the brick in a slab. The slabs are treated with a decorative coating (carrying agent is a sawdust/loam mixture), cut into individual bricks and then loaded on a `car' for transport through the dryer and kilns. Hydrogen Fluoride from the kilns is controlled by a dry lime adsorber (DLA) installed on each kiln. The firing takes more than two days. After firing the bricks are packaged into skid loads (by a very cool robot) and stored prior to purchase and shipment. 4. INSPECTION SUMMARY: On 22 August 2019, I, Mitchell Revels, FRO DAQ, met with Mr. Paul Gibson, the Plant Manager, and Mr. Tommy Meggs, Kiln Supervisor to conduct the annual compliance inspection. Triangle is currently operating Kiln #1 (K-1) and Kiln #2 (K-2) at approx. 12 tons/hr. each. The facility started operating the dry lime adsorber(DLA) on K-2 in August 2016 in advance of their compliance date (September 4, 2016) for the case-by-case MACT for brick manufacturing. They started Kiln #1 on 6 February 2017 with the associated DLA. The facility operates the DLAs on the kilns in order to obtain a Title III (Hazardous Air Pollutants) synthetic minor (area source) classification, thus avoiding the case-by-case MACT for brick manufacturing and the recently promulgated NESHAP 5J (Brick MACT). The most recent AQ permit, TV Permit No. 8179T10, issued on December 29, 2017, removed the case-by-case MACT status and language now that DLAs are operating on each plant. Facility records appeared complete and in accordance with their current permit requirements. We discussed the DLA operation and factors like feeder rate settings and the interface they use to see the status and setting for the device. There is a limestone low level indicator near the base of the limestone hopper and an alarm is set to activate (visual and audible) when/if the hopper level gets below the low- level indicator. Mr. Gibson stated that they routinely refill the hopper every 4-6 weeks, well before the level reaches the low-level indicator. A screw is installed on the DLAs to feed the limestone from the cascades (area where the limestone is reacted with the exhaust stream) to the peeling drum where the outer layer of limestone is "peeled off." The peeling (dust) is dropped to a collection container and the unreacted limestone is blown back up to the hopper to pass through the cascades again. The feeder settings are peeling drum on 30 min, off 30 min; screw is on 2 min, off 2 min while peeling drum is on. Both plants were operating during the inspections and during our tour around the facility I did not observe any VE leaving any building nor any coming from the covered conveyor belt over to the pug mills. 5. EMISSION SOURCES: The following table contains a summary of all permitted emission sources and associated air pollution control devices and appurtenances: Jill K-IS One natural gas/No. 2 fuel oil/No. 6 fuel oil-fired Brick CD-KI Dry Limestone Adsorber Tunnel Kiln(29.0 tons per hour material output rate, (DLA) Operating, no 42.8 million Btu per hour heat input rate) Operating at VE observed —12 TPH K-2 One natural gas/No. 2 fuel oil/No. 6 fuel oil-fired Brick CD-K2 Dry Limestone Adsorber Tunnel Kiln(29.0 tons per hour material output rate, (DLA) Operating, no 42.8 million Btu per hour heat input rate) Operating at VE observed —12 TPH SD-1 One natural gas-fired Rotary Coatings Dryer(8.1 tons NSPS UUU of clay per hour material input rate, 0.3 million Btu per N/A N/A hour heat input rate)Not operating PC-I and Two shale feeders; Not operating N/A N/A PC-2 PC-3 and Two scalp screens;Not operating PC-4 N/A N/A NSPS 000 PC-5 and Two jaw crushers; Not operating, doing repair PC-6 N/A N/A NSPS 000 PC-7 One conveyor under PC-3 and PC-5; Not operating N/A N/A NSPS 000 PC-8 One conveyor under PC-4 and PC-6; Not Operating N/A N/A NSPS 000 PC-9 One cross-over conveyor; Not operating N/A N/A NSPS 000 PC-10 One shuttle conveyor; Not operating N/A N/A NSPS 000 G-1 One clay feeder; None of the Clay Grinding sources were operating during inspection because the initial N/A N/A crushing operation was down for repair and plant was operating on stored material already processed. CG-2 One conveyor belt to scalping screen N/A N/A NSPS 000 CG-3 One scalping screen N/A N/A NSPS 000 CG-4 One return conveyor belt for oversize from screens N/A N/A NSPS 000 CG-5 One conveyor belt to hammer mill N/A N/A NSPS 000 CG-6 One hammer mill N/A N/A NSPS 000 CG-7 One conveyor belt under hammer mill N/A N/A NSPS 000 CG-8 One conveyor belt to finish screens N/A N/A NSPS 000 CG-10 Four finish screens through CG-13 N/A N/A NSPS 000 CG-14 One fines conveyor belt under screens N/A N/A NSPS 000 CG-15 One conveyor belt to storage bins N/A N/A NSPS 000 CG-16 One conveyor belt over storage bins N/A N/A NSPS 000 CG-17 Five storage bins through CG-21 N/A N/A NSPS 000 CG-22 Five feeders under storage bins through CG-26 N/A N/A NSPS 000 IM CS One conveyor in front of storage bins N/A N/A NSPS 000 CG-28 One conveyor to pug mill N/A N/A NSPS 000 CG-29 One clay feeder N/A N/A CG-30 One conveyor belt to scalping screen N/A N/A NSPS 000 CG-31 One scalping screen N/A N/A NSPS 000 CG-32 One return conveyor belt for oversize from screens N/A N/A NSPS 000 CG-33 One conveyor belt to hammer mill N/A N/A NSPS 000 CG-34 One hammer mill N/A N/A NSPS 000 CG-35 One conveyor belt under hammer mill N/A N/A NSPS 000 CG-36 One conveyor belt to finish screens N/A N/A NSPS 000 CG-37 Four finish screens through CG-40 N/A N/A NSPS 000 CG-41 One fines conveyor belt under screens N/A N/A NSPS 000 CG-42 One conveyor belt to storage bins N/A N/A NSPS 000 CG-43 One conveyor belt over storage bins N/A N/A NSPS 000 CG-44 Five storage bins through CG-48 N/A N/A NSPS 000 CG-49 Five feeders under storage bins N/A N/A through _ s MEMO' fib` 2 d y r. '� - CG-53 NSPS 000 CG-54 One conveyor in front of storage bins N/A N/A NSPS 000 CG-55 One conveyor to pug mill N/A N/A NSPS 000 LS-1 Loam/sawdust feeder; All LS Sources were N/A N/A Operating inside building, no VE outside building LS-2 One conveyor from loam/sawdust feeder to finish NSPS 000 screens N/A N/A LS-3 One loam screen N/A N/A NSPS 000 LS-4 One loam crusher N/A N/A NSPS 000 LS-5 One oversize return conveyor from LS-3 N/A N/A NSPS 000 LS-6 One oversize return chute N/A N/A NSPS 000 LS-7 One fines conveyor belt under LS-3 to bunker belt NSPS 000 conveyor N/A N/A LS-8 One belt conveyor to bunker N/A N/A NSPS 000 LS-9 One storage bunker N/A N/A NSPS 000 LS-10 One sawdust screen N/A N/A NSPS 000 L 1One conveyor to storage binsN/A N/A S0002 One oversize conveyor from sawdust screenN/A N/A S 000