AQ_F_0800018_20190305_CMPL_InspRpt (4)

NORTH CAROLINA DIVISION OF Washington Regional Office
AIR QUALITY Rose Brothers Paving Co Inc.-Windsor
NC Facility ID 0800018
Inspection Report
Date: 03/05/2019 County/FIPS:Bertie/015
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
NAICS: 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]
Comments:The facility appears to be operating in compliance with all applicable Compliance Data
Federal and State rules,regulations and permit conditions at the time of the Inspection Date 03/05/2019
inspection. Inspector's Name Kurt Tidd
Operating Status Operating
Compliance Code Compliance-inspection
Inspector's Signature: Action Cade FCE
On-Site Inspection Result Compliance
Date of Si nature:
Total Actual emissions in TONS/YEAR:
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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(in pounds)
Five Year Violation History:None
Performed Stack Tests since last FCE:None
Date Test Results Test Method(s) Source(s)Tested
5/3/20I8 Passing RM5 ES-1
Tracking Number2018-127ST
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
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to the separation of Hwy 13/17 North,turn right onto Country Farm Road(SRI527) at the North Carolina
National.Guard Armory. The facility is located about half a mile on the left.
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
Berrie County.
List of Permitted Sources:
Emission Emission Source ControlControl System
Source ID Description System ID Description
ES-1 'Nos. 2 and 4/Nos. 2 and 4 equivalent waste fue l oil fuWd.4768,Ra-15-60 [Sunple cyclone
batch asphalt plant,250 tons per hour maximum production Bagfilter(11,466 sq ft)
capacity, 84 million Btu per hour maximum heat input,
allowed to utilize recycled,post consumer waste, asphalt
,(asbestos-free)shingles as an option in the mix
-- _ ._ — _ .... !
GS3630AR/HC I50 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 3/5/2019. I arrived at the facility at 9:50 AM.I had talked to Tim Perry, Rose
Brothers Plant Superintendent the week prior and he had left the records at the facility for me,these records
include;
• Monthly asphalt production
• Monthly pollutants (PM, S02,NOx, CO, VOC and HAPs)
• Shingle analysis for asbestos (2246.50 tons used, 3217.03 tons delivered in 2018, 0 tons used and
0 tons delivered in 2019)
• 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
The facility was not in operation on the day I performed my inspection. There was some equipment
moving in the yard and trucks were delivering aggregate to the facilities' stockpiles. The ground was wet
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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 10:25 AM.
Regulatory 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)° —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 "Suter 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 o£C2.0% by
weight, which was documented by fuel. receipts. All other fuel is used fil 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. There was some
equipment moving in the yard,the ground and stockpiles were still wet from a rain storm the previous
night. 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 in
the control room containing all air quality permit records. The last annual inspections for the bagfilter
and cyclone systems was performed on 2/26/2019. Compliance is indicated.
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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 includes 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'' I
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. Records submitted for
CY2018 document the following emissions:
Limits Actual
S02: 100 TPY 2.12 TPY CY2018
NOx: 100 TPY 2.71 TPY CY2018
CO: 100 TPY - 8.8 TPY CY2018
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 CY2018. The facility combusted 66,776 gallons of recycled
No. 4 in CY2018. Compliance is indicated.
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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 CY2018 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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