AQ_F_0400016_20190827_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Fayetteville Regional Office
AIR QUALITY Wade Manufacturing Co-Wadesboro
NC Facility ID 0400016
Inspection Report County/FIPS: Anson/007
Date: 09/05/2019
Facility Data Permit Data
Wade Manufacturing Co-Wadesboro Permit 03577/R19
Highway 74 East Issued 10/2/2018
Wadesboro,NC 28170 Expires 9/30/2026
Lat: 34d 57.8720m Long: 80d 2.6476m Class/Status Synthetic Minor
SIC: 2261 /Finishing Plants, Cotton Permit Status Active
NAICS: 313311 /Broadwoven Fabric Finishing Mills Current Permit Applications)None
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact SIP
Sherry Wallace Bernard Hodges Sherry Wallace
Cost Manager President Cost Manager
[phone] [phone] [phone]
U Compliance Data
Comments: �9
Inspection Date 08/27/2019
Inspector's Name Abdul Kadir
Inspector's Signature: Operating Status Operating
Compliance Code Compliance-inspection
/b,T[et'pj% Action Code FCE
Date of Signature: ( On-Site Inspection Result Compliance
Total Actual emissions in TONS/YEAR:
TSP S02 NOX VOC CO PM10 *HAP
2017 5.72 0.0200 4.99 8.32 4.14 5.72 1321.63
2014 12.39 1.02 5.51 9.77 4.49 12.38 1525.84
*Highest HAP Emitted(in pounds)
Five Year Violation History:None
Date Letter Tyne Rule Violated Violation Resolution Date
Performed Stack Tests since last FCE:None
Date Test Results Test Method(s) Source(s)Tested

I. DIRECTIONS:
From downtown Fayetteville,take Raeford Road,Hwy 401, south to Wagram, —32 miles. Just west of
Wagram,turn right onto Old Wire Road(SR 144)to Laurel Hill. Turn right on Highway 74,bypass
Rockingham,to Wadesboro,—35 miles. Wade Mfg. is on the north(right)side of the Hwy 74,just after
the `Welcome to Wadesboro' sign.
II. SAFETY:
Standard DAQ FRO Safety Gear. Main safety concerns are slips trips and falls from uneven and slippery
floors, stairs, and forklift traffic.
III. FACILITY DESCRIPTION/PROCESS DESCRIPTION:
Wade Manufacturing is a Synthetic Minor facility for SO2, mainly from the burning of No. 6 fuel oil.
Wade Manufacturing makes, dyes and prints cotton and polyester/cotton blend fabric. The process
includes bleaching, dying, printing, and finishing of cloth. This facility has fabric-finishing equipment
consisting of natural gas-fired tenter frame ovens and several napping areas. A tenter frame stretches
fabric under tension and consists of chains fitted with pins or clips to hold the selvages of the fabric, and
travelling on tracks.As the fabric passes through the heated chamber, creases and wrinkles are removed,
the weave is straightened, and the fabric is dried to its final size. The napping process is used to raise a
velvety, soft surface to fabric. The process involves passing the fabric over revolving cylinders covered
with fine wires that lift the short, loose fibers,usually from the weft yarns,to the surface,forming a nap.
The process,which increases warmth, is frequently applied to woolens and worsteds and also to blankets.
Two natural gas/No. 6 fuel oil-fired boilers are used to provide steam for some of these processes. The
company started business in 1926. Wade Manufacturing currently operates under air permit no.
03577R19,which has an expiration date of 30 September 2026.
Employees: 117
Hours: 4 or 5 days a week, 7 AM to 3 PM
Average weight ranee of fabric(yd/lb): 0.89-3.4
Throughput:
�.,.kar _2018 x:, , ` gh t 5.47 Fin;"m . . A g, fight
___ 1.70
2017 F 5.17 1.58
2016 5.99 F 1.65
2015 6.28 1.49
----
2014 6.77 _ 1.51
2013 1 6.25 1.55

IV. PERMITTED ENIISSION SOURCES (PLUS CONTROLS):
3 1 a rtt l $' of S �u
l 1 11. .�l4P
Natural gas/No. 6 fuel oil-fired boiler
N/A
B I (72 mmBtu/lu maximum heat input) N/A
F Operating with 0% VE
F Natural gas No. 6 fuel oilfired boiler
B2 (24.76 mmBtu/hr maximum heat input) N/A N/A
Not operating
Textile roller printer
(3,600 pounds of cloth per hour process
(capacity)consisting of:
PR3 'a) 8 print stations N/A N/A
�b) 1 natural gas direct-fired dryer
(2 mmBtu/hr maximum heat input)
!Not operating
Textile screen printer
(3,600 pounds of cloth per hour process
capacity)consisting of:
PR4 a)8 rotary screen printing stations N/A N/A
1b) 1 natural gas direct-fired dryer
1(4.8 mmBtu/hr maximum heat input)with
four zones
lNot operating
Textile screen printer m�
(3,600 pounds of cloth per hour process
capacity)consisting of:
PR5 a) 12 rotary screen printing stations N/A N/A
b) 1 natural gas direct-fired dryer
(4.8 mmBtu/hr maximum heat input)with
four zones
Not operating
Finishing range
(5,760 pounds of cloth per hour process
capacity)consisting of:
TEN2 a) 1 pad applied finishing station N/A N/A
b) 1 natural gas direct-fired(12.0 mmBtu/hr
(maximum heat input)eight zone tenter frame
oven
Not operating j
Finishing range
(4,320 pounds of cloth per hour process
capacity)consisting of:
TEN3 a) 1 pad applied finishing station N/A N/A
b) I natural gas direct-fired(6.0 mmBtu/hr j
maximum heat input)two zone tenter frame
(oven
(Operating with 0% VE
One(1)bleach range and one(1)natural gas
BLI and TEN4 'direct-feed(8.5 mmBtu/hr maximum heat N/A N/A
input)three zone tenter frame oven
Neither was operating

rfi- -- s-- j
�Off�sston, I p� stun Sbu>ce. t, ConCr ontrot$jstem
Suuree Ili i scr�pt�pu �` 3,SY�tem T Descripton
CRI fSt a heated cotton dye range N/A N/A
_ _
F jNot operating
Pigment range
(4,800 pounds of cloth per hour process �
capacity)consisting of.
a) 1 natural gas direct-fired dryer(4.0
PIGl pre dryer
N/A N/A
mmBtu/hr maximum heat input) ,
b) 1 pad applied ink dyeing station l
c) 1 steam heated dryer
j Not operating
iThermasol range
j ((4,800 pounds of cloth per hour process
capacity)consisting of.
TRI a) 1 pad applied finishing station N/A N/A
b) 1 natural gas direct-fired dryer
1(7.0 mmBtu/hr maximum heat input)dryer
jNot operating
r Shop lathe —�
SLl (500 pounds per hour of rubber covered padF SL-1C Cyclone
rolls) I (15 inch diameter)
Not operating
---- __
j BF-1 Bagfilter
(12 square feet of filter
j area)
Starch storage silo
SS I (22.5 tons per hour filling rate) In parallel with In parallel with
Not operating
BF-2 Bagfilter
(12 square feet of filter
area)
F— OPA CA Paper Panel Filter
(6.55 square feet of
filter area)
�Blendomat
OPl I(2,600 pounds per hour of cotton fiber) In series with In series with
,
jNot operating
OPA CB Rotary Drum Filter
(46.5 square feet of
filter area)
I Carding and drawing operation Rotary Drum Filter
ACl/CARDI (2 100 pounds per hour of cotton fiber) CARDIAC (545.3 square feet ofsurface area)
Not operating ;
i
Spinning operation Paper Filter
AC2 (2100 pounds per hour of cotton fiber) AC24C
(266.8 square feet of
Not operating
surface area)

lion Ept ut a €qqn oIs CO 'tSY3.
es 19 . ..
W.....w.Ntr
AC3 Three(3)weaving areas AC3-1C Paper Filter
(1,870 pounds per hour of cotton yarn, (371.2 square feet of
total capacity of AC3,AC4, and AC5) surface area)collecting
0,AC4,and AC5 were not operating.
from AC-3
AC4 AC4-1 C Rotary Drum Filter
(834.9 square feet of
surface area)collecting
AC-4.
i
i
AC5 AC5-1C Rotary Drum Filter
(545.3 square feet of
surface area)collecting
AC-5.
API ITwo(2)napping areas NAP1
-1C Rotary Drum Filter
j(2,370 pounds per hour of cotton cloth,total (483.3 square feet of
capacity of NAP 1 and NAP2) {surface area)collecting
Both were operating at—0% VE. from NAP 1.
NAP2 I NAP2-1C Rotary Drum Filter
(142.1 square feet of
j surface area)collecting
from NAP 2.
�
RP Retention Pond N/A i N/A
(Operating,no odor present
V. INSPECTION SUMMARY:
On 27 August 2019, I,Abdul Kadir and Jeffrey Cole of NCDEQ, began the compliance inspection with
an observation of the facility exhausts stacks from my vehicle prior to entering the facility. We observed
the plant in the morning around 10:00 from the east side of the facility to maintain the correct Method 9
sun angle. We did not notice any visible emissions that exceeded the permitted limits. We then entered
the facility to conduct the compliance inspection. We first met with Ms. Sherry Wallace, Plant
Environmental Manager and began by asking her to check the FacFinder,followed by a review of the
required recordkeeping. There were no changes to the Facfinder. Steven Burroughs,the Facility
Mechanic produced the maintenance records on the facility's control devices and they all seemed in order.
Ms. Wallace stated that the plant was operating normally and no changes had been made to sources or
operations since the last inspection. She showed us the data from the required recordkeeping being
accomplished for rules 02D .1100 and 02Q .0315 under their permit. All monitored emissions from
January 2019-July 2019 were below permitted levels. The annual report(received on 04 January 2019)
for CY2018 also showed that all monitored emissions were below permitted levels. Finally,Ms. Wallace
stated that the facility had not been curtailed since last inspection, so they did not use No. 6 fuel oil.
We then proceeded on an inspection of all the facility's sources with Ms. Wallace and after a while Mr.
Burroughs also joined us. After observing all the emission sources we went to the roof to see the stacks.
We used a Google Earth photo of the top view of the facility to correctly identify the stacks associated

with each emission source. This picture will be kept in the facility file for future reference and
convenience of the inspectors during visible emission observation.
At the inspection's exit summary, we summarized our observations and told Ms. Wallace that we had not
seen any deficiencies during the inspection. To be thorough,we returned after having lunch, and
observed the plant in the afternoon around 2:00 from the west side of the facility to maintain the correct
Method 9 sun angle. We did not notice any visible emissions that exceeded the permitted limits.
VI. PERMIT STIPULATION REVIEW:
1. 15A NCAC 02D .0202, "EMISSION INVENTORY REQUIREMENT"—Entire facility subject.
Submit permit renewal application and EI at least 90 days prior to permit expiration.
Appeared to be in compliance—The facility's permit expires on 30 September 2026 The application
and emission inventory will be due no later than 2 July 2026 with CY 2025 data.
2. 15A NCAC 02D.0503,"PARTICULATES FROM FUEL BURNING INDIRECT HEAT
EXCHANGERS"—The particulate emissions from boiler ID No. B1 shall not exceed an emission
rate of 0.33 Ibs/mmBtu and boiler ID No.132 shall not exceed 0.47 lbs/mmBtu.
Appeared to be in compliance—The facility burns NG exclusively with oil as a backup during
curtailment. The worst case fuel is No. 6 at 2.1%suer (from current fuel certification), which emits
0.15 lbs/mmBtu. The AP-42 emissions factor for natural gas is 0.0071bs/mmBtu.
3. 15A NCAC 02D .0515,"PARTICULATE CONTROL REQUIREMENT"—Particulate emissions
from miscellaneous sources shall not exceed those limits listed in the permit.
Appeared to be 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
their facility since the last permit review.
4. 15A NCAC 02D .0516, "SULFUR DIOXIDE EMISSIONS"—Sulfur dioxide emissions shall not
exceed 2.3 lbs/mmBtu heat input.
Appeared to be in compliance—The worst-case fuel is No. 6 at 2.1%sulfur (current fuel
certification), would emit S02 at rate of 1.7 lbs/mmBtu. The fuel oil certifications indicated suer
content 1.62%the last several times it was purchased. The last purchase of No.6 fuel oil was 313114.
5. 15A NCAC 02D .0521,"VISIBLE EMISSIONS CONTROL REQUIREMENT"—Visible
emissions from source ID Nos. PR4,PR5, TEN2, TEN3, TRI, B1, 132, 131,1, TEN4,OP 1, SL1, and
SS 1,manufactured after July 1, 1971, shall not be more than 20 percent opacity when averaged over a
six-minute period.
Appeared to be in compliance—Only two of the emission sources was operating at the time of the
walk through inspection. Before and after the internal inspection of the plant, we surveyed the roof
stack from two separate locations and noted that emissions from these sources appeared to not
exceed 20 percent opacity.
6. 15A NCAC 02D .0521,"VISIBLE EMISSIONS CONTROL REQUIREMENT"—Visible
emissions from source ID Nos. PIGI, PR3,AC1/CARD1,AC2,AC3,AC4,AC5,NAPI and NAP2,
manufactured before July 1, 1971, shall not be more than 40 percent opacity when averaged over a
six-minute period.
Appeared to be in compliance—Two of the emission sources were operating at the time of the walk
through inspection. Before and after the internal inspection of the plant, we surveyed the roof stack
from two separate locations and noted that emissions f om these sources appeared to not exceed
40 percent opacity.

7. 15A NCAC 02D .0535,"NOTIFICATION REQUIREMENT"-The facility is required to notify
DAQ if excess emissions occur for more than a 4-hour period caused by a breakdown or other
abnormal condition.
Appeared to be in compliance-Ms. Wallace, stated that the facility has had no exceedances,
breakdowns, or abnormal conditions requiring notification.
8. 15A NCAC 02D .0540,"FUGITIVE DUST CONTROL REQUIREMENT'-Fugitive dust
emissions shall not cause or contribute to substantive complaints or excess visible emissions beyond
the property boundary.
Appeared to be in compliance- There was no dust on the roadways about the facility. The facility
contact, Ms. Wallace, stated that they have not received any dust complaints since the last inspection.
The FRO has not received any complaints either.
9. 15A NCAC 02D .0611,"CYCLONE REQUIREMENTS"-Annual&periodic I&M and
recordkeeping requirements.
Appeared to be in compliance-The facility inspects its single cyclone on a monthly basis. Logs
indicate I&M is done by the facility mechanic, Mr. Steven Burroughs. The cyclone was last checked
on 12 August 2019. The last annual inspection was done on 2 July 2019.
10. 15A NCAC 02D .0611,"FABRIC FILTER REQUIREMENTS"-Annual&periodic I&M and
recordkeeping requirements.
Appeared to be in compliance-The facility inspects rotary drum filters and bagfilters on a monthly
basis. Logs indicate I&M is done by the facility mechanic, Mr. Steven Burroughs. The bagftlters
were last checked on 12 August 2019. The last annual internal inspection was done on 2 July 2019.
11. 15A NCAC 02D .1100,TOXIC AIR POLLUTANT EMISSIONS LIMITATION AND
REPORTING REQUIREMENTS-Pursuant to 15A NCAC 2D .1100 and in accordance with the
approved application for an air toxic compliance demonstration,the permit limit shall not be
exceeded. Record daily; report annually.
Appeared to be in compliance-Records showed TAP limits had not been exceeded Records are
maintained far the maximum hourly rate of ammonia input to each printer (ID Nos. PR3, PR4, and
PR5)for each day of production, and the maximum hourly rate of formaldehyde input to each tenter
frame (ID Nos. TEN2, and TENS)for each day of production. Usage and emissions reports are
provided to FRO annually. The last annual report containing this data was submitted on
4 January 2019 and appeared to be complete and in compliance.
12. 15A NCAC 02D .1806,"CONTROL AND PROHIBITION OF ODOROUS EMISSIONS." No
objectionable odors beyond property line.
Appeared to be in compliance-No objectionable odors were noted during the inspection. The
facility contact, Ms. Wallace, stated that no complaints have been received since the last inspection.
The FRO also has not received any dust complaints.
13. 15A NCAC 02Q .0315,LIMITATION TO AVOID 15A NCAC 2Q.0501 -Facility-wide
emissions of PM10, SOz, and NOx shall each be less than 100 tons per consecutive 12-month period;
sulfur content of the No. 6 fuel oil<2.1% by weight; combust<-601,000 gallons of No. 6 fuel oil
during any consecutive 12-month period. The amount of fuel oil combusted shall be totaled monthly
and reported annually. Fuel certifications shall also be kept onsite.
Appeared to be in compliance-Since the last inspection the facility has not combusted any fuel oil.
The last annual report containing this data was submitted on 4 January 2019 and appeared to be
complete.

14. 15A NCAC 02Q .0317,AVOIDANCE OF BOILER NESIIAP (GACT 6J)—Subject sources are
boilers 131 &132. Facility avoids applicability of this rule by burning Natural Gas,with fuel oil only
as back-up during emergencies,testing and curtailment. Keep records of fuel oil usage and reason for
usage. Notify DAQ within 30 days of switch to fuel oil outside of emergencies,testing and
curtailment.
Appeared to be in compliance—Since the last inspection, the facility has not comhusted any fuel oil.
There was no reported natural gas curtailment during 2018..
15. 15A NCAC 02Q. 0317,AVOIDANCE OF PREVENTION OF SIGINIFICANT
DETERIORATION-Discharge into the atmosphere less than 250 tons of PM10 and SOZ,
respectively, per consecutive twelve-month period.
Appeared to be in compliance- The facility has met the requirements of stipulation 15A NCAC 02Q
.0315, Limitation to Avoid 15A NCAC 02Q.0501, and therefore has complied with this rule.
VIL NON-COMPLIANCE HISTORY SINCE 2010
20 June 2014 NOD for Visible Emissions for failure to re-establish"normal"VE for emission
sources by 7 March 2014.
10 May 2013 CAI VE Monitoring and Record Keeping
9 Nov 2012 NOV for VE>20%
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).
CONCLUSIONS AND RECOMMENDATIONS:
Wade Manufacturing Co.-Wadesboro(0400016)appeared to be IN COMPLIANCE with their current
air permit at the time of inspection.
Pink Sheet Comments:None
/ak