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Home My WebLink About20033190.tiff i Modern Asphalt r--r . _ Plants Are Designed to Operate in a People Environment. (In a vegetation & animal environment, too!) r wb 9 !. ' a a .. *: n ___ . Jigll � / �� "t . S" I.}4. A +ni • , . ur�rru-a�..w C ♦ %1 �, „ k a (fi '44,N. a '�> `>O`E �i 4. P 'ON .;.v.. n "k 'a.`b• z• 104,4111 �g g d= .._. __ '* ..% a ' .«a' AY$. Y" + ' ₹1r: 'jai' °'. ic w w' ✓u.0''','''`.::,,‘'` ' `''t ' C'''''' '. as ' 2�. wad m^�wg^{[' - -F •.r y c ri .eaat'.I. i s . a ?,'�a.3• L.w�x� L '3,.; IA : .. ,..] .., ret,,, ._ ,,, . , .. . , ....__:. ,. . ., J . , vp,, p,,,, i, 't., it: ' ,'Atkii;x.., "y. „ No- ry �C j .�,47 .�"'4, Ffraart kii',S 'R �' �`��` � p i r -fytr 'ssa.a.,,� Our facility is where materials ASPHALT CEMENT (AC) —This is the black sticky stuff produced by petroleum refineries. It is the "glue" that holds are brought together and the pavement together. Generally, it makes up about 5 percent blended into Hot Mix Asphalt by weight,of the total pavement mixture. which is transported to the AGGREGATES —These make up the remaining 95 percent, b: paving site for construction weight,of the pavement mixture. They are usually various sizei stones,gravel, and sand. They are "any hard, inert mineral into a pavement. materials used for mixing in graduated fragments" (That's engineering talk for crushed stone,gravel, sand, etc.) We'll explain the"Hot Mix" term in a moment, but first let's correct another misnomer — the HOT MIX ASPHALT (HMA) —This is the final product use of the word asphalt. produced by our facilities,which is a mixture of AC and aggregates, up to the maximum proportions listed above. Asphalt is often loosely used to refer to a variety of asphaltic or asphalt-containing HMA PAVEMENT—This is the final form and use Hot Mix products,which often causes confusion in Asphalt generally takes. discussions concerning various asphalt products. Hence,the National Asphalt Pavement Briefly,what happens in our HMA facility is that paving Association (NAPA) has been encouraging the aggregates are dried and heated,then mixed and coatet kh Industry and government to adopt specific AC. As HMA, it is transferred to holding bins (called silos) for terminology to clear up this confusion. short-term storage,then to trucks for transportation to the paving site. It is a mixing process rather than a manufacturing process. 42 An asphalt plant in my community? So, that's all that happens at a What's going on here? Basically,yes. The paving aggregates are heated am id you asked. More than 92 percent of the nation's two Cement. The Hot Mix Asphalt is put in holding bir million miles of streets and highways are paved with asphalt. That's because state and federal highway departments have long known that asphalt pavements are smooth,cost-effective to construct and maintain, exceptionally durable, environmentally friendly,and 100 percent recyclable. Actually,the asphalt pavement industry usually speaks of asphalt facilities, not asphalt plants — because these are mixing facilities. Around the country,asphalt facilities are '' placed next to homes, businesses,golf courses,and farms. Chances are good that there has been an asphalt facility not far from you for years,and you didn't even know it was there. By the way,you may think we're nitpicking, but asphalt"plant" "~ (the most commonly used term) is misleading in that it implies the production of petroleum asphalt itself,which implies an oil refinery. 411. IRY 9 I -'co what exactly is asphalt? ' j What most people mean when they say"asphalt" — also ,1 rt known as blacktop, macadam,or tarmac — is actually a - T" '� particular product, known in our industry as asphalt pavement,or sometimes, Hot Mix Asphalt (HMA) pavement. " 411, 4. w asp z• .. OPOr ' It sounds complicated. It's really pretty simple. There are two basic ingredients in Hot Mix Asphalt. The first is aggregates, a fancy name for a mixture of crushed stone,gravel, and sand. The aggregates used are almost always locally available stone. About 95 • percent of the total weight of an asphalt pavement consists of fV aggregates. - r•t�' The remaining five percent is Asphalt Cement,the black sticky ., stuff that acts as the glue to hold the pavement together. "„. f . Asphalt Cement (AC) is a naturally occurring petroleum product. It's generally obtained commercially at the same fineries that produce gasoline for your car and heating oil • .r your house. Asphalt Cement is one of the heaviest, most f" viscous parts of petroleum. • Mix the two ingredients together,and you get Hot Mix + s Asphalt. t' _ i asphalt facility? Why do we need an asphalt facility in my community? dried,then mixed and coated with Asphalt > (silos),then trucked to the paving site. Hot Mix Asphalt is usually mixed at temperatures between 300 arm 325 degrees — cooler than what you'd use to bake a pie. And it has to be laid hot, no less than about 250 degrees. Getting HMA from the facility to the paving site is like delivering a pizza. The farther you have to carry it,the cooler it gets. If it gets too cool, it is no longer useful for paving. 4110 I'm concerned about the health risks. If you visit an HMA facility,you'll see that the people working there wear hard hats,gloves,and long-sleeved shirts. The greatest risk is from getting burned. What you won't see is anybody wearing a respirator. There is no evidence that the very low levels of emissions from an HMA facility pose health risks to humans. 40 But don't you have to keep hazardous chemicals on site? n ' w . Liquids that must be handled with care at a Hot Mix Asphalt facility ' are: I) fuel oil for the burner,which is the same kind of fuel oil you may be using to heat your home,2) fuel for vehicles,which is the same product you buy at the gas station,and 3) at some facilities,sol- vents for the quality control lab. Most of these solvents are similar or j identical to products found in the garages of most homes; new lab procedures are quickly making the solvents obsolete. By federal law,a Hot Mix Asphalt facility must keep these products, including the fuel oil, either in underground tanks that meet strict r EPA standards, or in above-ground tanks surrounded by berms that -tr.- 1, r h..T.:;!•!.. '*j`' `1 would hold ALL the contents in the event of a spill. } -i1/4-' t' a. AWhat happens if there's a spill or leak? ;.,,,,:-.7.-t.,-.-!‘4,-,.,--.:,- .., ,,,,::::,...-- - teC ..f ..,:--, ,-7),--. .:-..; . ,t.„;-;.:1/42.,_:. -O,:-.4: ...,-.4-,, Asphalt Cement starts to harden the moment it cools. Unless it's {` r.` " '` " �'t'r' 250 degrees Fahrenheit outside, it simply cannot travel over the � t>9, ` ., e• g PY ya , ..�tit x, t; -,,., J,r.5 : -. s ground more than a few feet. It will not penetrate the soil more 1i.t. :' than an inch or two before solidifying. Asphalt Cement does not mix `4.-t--5.', •d �` � � {•K� :4'�y�o'.- with,or become soluble, in water. n _ S a..> -i i `t y1„.._k 14:‘,-, C ""4-4-'-',,`, 1 �.y 5 '7.. join us for a tour which make sure they are thoroughly dried,heated,and mixed with asphalt cement before being dropped into the discharge chute and Here's what really goes on in and around a modern HMA mixing carried by conveyer (8) to the top of the storage silos (7). facility. There are two basic kinds of HMA facilities. We'll take you through a"Drum Mix" facility since most new facilities are of this An exhaust fan (8) at the end of the baghouse (8) creates an airflow velocity in the drum which pulls uncoated dust through a tyrien describe the differing components of a"Batch Mix" op, .on. knockout box (10). This is a large volume structure that allows the exhaust gas to spread out,reducing its linear velocity so a large portion of the heavy dust particles drop to the bottom to be Aggregates in cold feed hoppers (1) are measured into specified portions according to the kind of pavement required and carried by a returned to the mix in the drum. conveyor belt (2) into the drum (3) where they are dried and A small amount of lighter particles are carried into the main body of heated by a burner (4). If pavement removed from existing paved surfaces is to be recycled into new pavement,it is usually conveyed to the baghouse which functions like a series of vacuum cleaners,except the middle of the drum (5). the dust collects on the outside rather than the inside of the bags. The reason for this is that we want only clean air to be exhausted out the stack (11). Air jets at the top of the bags blow off the Asphalt cement is pumped from its holding tank in liquid form (heated to between 300°F and 325°F) and injected into the drum adhering dust which settles at the bottom of the baghouse and is also where it mixes with and coats the aggregates. returned to the mix inside drum. The drum operates very much like a clothes dryer. As it rotates, A wet scrubber system may be ace of a baghouse. Water is "flight?' along its sides keep the aggregates tumbling and dropping sprayed into the exhaust gas wh- ct narrows and particles are captured by droplets whi . -'-il. -d in a tank and ,m.. a• ' • O 1 .r, . l it eN.3✓r Mgr, ywv" r • O R / ' ./ ,YINssiisit.,. Fr _ r • tV4a . • ,„ 8 ter 4 '-,- * r 5 i -- II . transferred to a settling pond. Only clean exhaust gas and steam are What about the environment? released from the stack. The entire operation is controlled and monitored by computers,or a Thirty or more years ago, Hot Mix Asphalt facilities programmable controller (12),which make sure the system is often generated noticeable levels of dust, smoke, performing properly and warns the operator of any failure. odors,and noise. But two things have brought hu., The Batch Mix HMA facility differs from the drum mixer in terms of changes. One was the EPA's New Source where the AC coating takes place. The aggregates are dried in the Performance Standards,which went into effect in drum,but not coated with asphalt cement. Instead,the dried 1973. These required Hot Mix Asphalt producers aggregates are conveyed by a bucket elevator (13) to a mixing to pass strict emission standards and install control tower where they are separated by vibrating screens (14) at the top and dropped into individual storage bins (15) by size. They are systems to prevent the release of dust and smoke dropped from the holding bins to a weigh hopper (18),the amount into the air. A facility must also meet stringent of each size being determined by the type of mix being produced. "visible emissions" tests in order to comply with From the weigh hopper they go to the pugmill (17) where they are coated with asphalt cement which has been weighed separately. regulations. EPA now acknowledges that HMA facilities are not a major source of emissions. The finished product is transferred directly to a waiting truck, although it is becoming more common to transfer the HMA into storage silos like those at a drum mix facility. Batch facilities An even stronger incentive for clean operation is manufactured since 1973 must have a "Fugitive System" (18) economic. It's in the owner's best interest to make which connects the tower to the air pollution control equipment sure that all the equipment is operating at peak (18) to prevent the release of fugitive dust into the atmosphere. efficiency — which means producing very little in 6 .7c,-4` the way of emissions. t Hot Mix Asphalt producers want to be good ,,.%-\\--' os` 0 neighbors. They strive to build clean,quiet facilities 15 1 compatible with the rest of the neighborhood. 1 d 1 l . . 1s It sounds like this would be t, p l , t7 , `. 3, ,. Y � ' : , okay. a, i,.r t it_� �r-- n jec i� � .1p - , . I i' You're right. When people get the facts about • ' - I / modern Hot Mix Asphalt facilities,they understand the need for having one in the community. And i 4 t. 1$' they appreciate their critical role in building and maintaining the nation's infrastructure. •� , NAPA NATIONAL ASPHALT PAVEMENT ASSOCIATION ill r NAPA Building• 5100 Forbes Blvd. • Lanham,MD 20706-4413 Toll-free:888-468-6499 ® " ,'.? $ Tel:301-731-4748 • Fax:301-731-4621 www.hotmix.org - - e-mail:napa@hotmix.org �y7,r x•'� This informational brochure was produced by the National Asphalt n 1�="' w l Pavement Association whose members are dedicated to quality,safes, ' • ID and environmental protection in every phase of Hot Mix Asphalt production and placement LJ `i'Py •", - 6 Sga Printed on recycled paper. IIIIIIIrsir ENVIRONMENTAL ACHIEVEMENT AWARDS YOR4 C it 4 o ,w:y, 00 • 1n „I) #(, c ' I tea Ao4 `Q �. e1) tal Nc COMPANY PROFILES & ENVIRONMENTAL ACHIEVEMENTS Governor's Mansion Denver, Colorado November 19, 2001 ENVIRONMENTAL ACHIEVEMENT AWARD 1sso lr� sr/ SUMMARY OF ACHIEVEMENTS COMPANY PROFILE November 19, 2002 Colorado Asphalt Pavement Association 6880 S.Yosemite Court, Suite 110 Tom Peterson,Executive Director Englewood, CO 80112 Phone: 303-741-6150 The Colorado Asphalt Pavement Association (CAPA) is a nonprofit trade association that represents the hot mix asphalt industry in Colorado. CAPA represents 95 percent of Colorado's asphalt industry with nearly 140 organizations participating as association members. The association includes members from both producer and user organizations, including nearly 40 cities and counties. Working together, the members strive to design, construct and maintain high quality asphalt pavements. CAPA was nominated for an Environmental Achievement Award based on the continued willingness of the association and its members to work with the Colorado Department of Public Health and Environment to address compliance issues in the asphalt industry. Specifically, CAPA is being recognized for its participation in two sector-based projects focused on regulatory innovation. The first of the two projects is an innovative non- regulatory approach to achieving compliance through a Compliance Assurance Pilot Project that focuses on compliance assistance in lieu of conventional enforcement procedures. A total of 19 CAPA members volunteered 44 facilities to participate in this multi-year project. The second innovative project builds on the Compliance Assurance project by agreeing to develop comprehensive performance and measurement tools for the asphalt industry. To date, 11 of CAPA's members are participating in the second phase of the grant project. Participation in sector-based compliance projects illustrates the leadership CAPA is taking to help its members overcome reoccurring compliance issues and to achieve improved environmental performance within the asphalt sector. The results of which are already being witnessed through improved compliance and on-going commitments to support the development of a comprehensive environmental management system for the asphalt industry. The environmental benefit realized from CAPA's leadership is widespread throughout Colorado's asphalt industry. STATE OF COLORADO ft .- Bill Owens,Governor lane E.Norton,Executive Director OQ'coco Dedicated to protecting and improving the health and environment of the people of Colorado #{ �+o,i 4300 Cherry Creek Dr.S. Laboratory and Radiation Services Division Denver,Colorado 80246-1530 8100 Lowry Blvd. 1876 Phone(303)692-2000 Denver,Colorado 80230-6928 TDD Line(303)691-7700 (303)692-3090 Colorado Department Located in Glendale,Colorado of Public Health httpi/www.cdphe.state.co.us and Environment August 28, 2002 Tom Peterson Executive Director Colorado Asphalt and Pavement Association 6880 South Yosemite Court, Suite 110 Englewood, Colorado 80112 Re: U.S. Environmental Protection Agency's Delisting of Asphalt Concrete Manufacturing Dear Tom: Congratulations to the hot mix asphalt industry of Colorado and to the Colorado Asphalt Pavement Association ("CAPA") for the EPA ruling that de-lists hot mix asphalt plants from the list of major polluters. This is a significant announcement and speaks well for the environmental accomplishments of the industry. On February 12, 2002, the U.S. Environmental Protection Agency ("US EPA") issued a decision that deleted asphalt concrete manufacturing as a source type that would require US EPA to promulgate a National Emission Standard for Hazardous Air Pollutants ("NESHAP"). The Clean Air Act requires, under section 112, that EPA list all categories of major sources emitting hazardous air pollutants ("HAPs") and such categories of area sources warranting regulation and promulgate a NESHAP to control, reduce, or otherwise limit the emissions of HAPs from such categories of major and area sources. On December 3, 1993 (58 FR 63941), pursuant to requirements in section 112(e), US EPA published a schedule for the promulgation of emission standards for each of the 174 initially listed source categories. The asphalt concrete manufacturing industry was one of these source categories. The US EPA may, where appropriate, delete categories of sources on the US EPA's own motion or on petition. On February 12, 2002, US EPA deleted the Asphalt Concrete Manufacturing source category on the US EPA's own motion. US EPA included this source category on the initial list notice (57 FR 31576, July 1992), because at the time, US EPA believed there were major sources in each category, either because they were major sources in their own right or because of collocation with other sources of HAPs. This source category was deleted because available data indicate that there are no major sources in any of the source categories. US EPA used emissions data and emission factors to estimate HAP emissions from eleven asphalt concrete manufacturing plants employing various production processes and different fuels. Emissions of total HAPs at the individual plants ranged from 1.5 tons per year("tpy") to 6.4 tpy. In addition, emission factors were used to estimate HAP emissions from a plant with a high annual production of 1.2 million tons of asphalt concrete. US EPA estimated total HAP emissions from that plant to be 6.2 tpy. Based on the above information,US EPA concluded that no asphalt concrete manufacturing facility has the potential to emit HAPs approaching major source levels. As a result of this decision, the US EPA will not develop a specific regulation for the asphalt concrete manufacturing industry that requires affected sources to implement work practices and install control equipment to reduce HAP emissions. This decision does not exempt individual sources that are major sources from potentially having to comply with other regulatory requirements concerning HAP emissions. If a facility is concerned that it might be operating as a major source for HAPs, the Air Pollution Control Division("Division") recommends the facility conduct an emissions inventory and contact the Division's Operating Permit Program. The asphalt industry of Colorado continues to make significant strides towards environmental excellence and we are pleased to be partnering with your industry on the COMPASS Project and the newly initiated COMET project. Thank you for your continued cooperation in the partnership with the Division. Sincerely, NA,4 (Sr- Margie Perkins Director, Air Pollution Control Division cc: Chuck Hix,APCD Jill E. Cooper, Office of Environmental Programs STATE OF COLORADO EXECUTIVE CHAMBERS 6oe•co <- q- 136 State Capitol $, Denver, Colorado 80203-1792 Phone(303)866-2471 1976` Bill Owens Covemor November 13, 2002 Dear Environmental Leader: Thank you for being a member of Colorado's Environmental Leadership Program. You have demonstrated your commitment to the environment by going beyond compliance with environmental laws and regulations. In so doing, your efforts have positively impacted the quality of life for all citizens of the State of Colorado. Your hard work has helped improve the economy and the environment through increasing consumer and shareholder confidence, strengthening employee morale, and operating in a responsible and sensible manner. On behalf of the State of Colorado, I would like to thank you for your commitment to r prove that the establishment and implementation of the voluntary environmental leadership program can make a difference in Colorado. My administration will continue to work with you on other innovative programs and continue its efforts to provide incentives for environmental leaders. • c15c €4 . T STATE OF COLORADO Bill Ovens,Governor Douglas H.Benevento,Executive Director .06. e0F cozo � y Dedicated to protecting and improving the health and environment of the people of Colorado 4300 Cherry Creek Dr.S. Laboratory Services Division '\,:r. 00, Denver, Colorado 80246-1530 8100 Lowry Blvd. •/876. Phone(303)692-2000 Denver.Colorado 80230-6928 T0D Line(303)691-7700 (303)692-3090 Colorado Department Located in Glendale,Colorado of Public Health http://www.cdphe.state.co.us and Environment Executive Summary COMPASS Asphalt Project In 2001 the Colorado Department of Public Health and Environment and Colorado Asphalt Pavement Association began the Compliance Assurance (COMPASS) project. The purpose of COMPASS was to investigate the effectiveness of compliance assistance in improving the overall environmental compliance of participating companies in a specific sector. CDPHE provided the participating companies with a multi-media baseline assessment of each facility. During the 2001 operating season, forty-four asphalt production plants were given a baseline assessment in the regulated mediums of air, hazardous waste and water. The assessment also included pollution prevention options for reducing the impact of the facility. As part of the baseline assessment, each operator was provided with plant specific compliance reports as well as an industry wide assessment. Extensive one-one consulting and industry group training also helped inform the group of their compliance issues. During the 2002 operating season a follow--up assessment was conducted to measure any change in compliance rate. The Compliance Assurance Pilot Project Industry Report addresses the changes observed. A brief summary of those changes is given below. The compliance issues addressed in the study fall into two categories: critical and non-critical. Critical issues, if not complied with, produce violations of permits and/or regulatory requirements. Non-critical issues, indicate good management practices, but generally do not produce violations of permits or regulatory requirements by themselves. The only critical issues identified for the COMPASS project were under the air program. Air Emissions The 2002 follow up assessment showed significant improvements in the air compliance rate when compared to the 2001 baseline assessment. For example, during the baseline assessment only one of the plants had no critical compliance issues. During the follow-up assessment, twenty-two of the forty-two plants had improved to full compliance with the critical items. In general, the compliance rate for both critical and non-critical items improved over the length of the project for all the participants. Hazardous Waste CDPHE also observed significant improvements in Hazardous Waste compliance. During the baseline assessment, five of the plants were observed to be in full compliance with the Hazardous Waste Division's regulations. During the follow-up assessment, the number of plants in full compliance rose to nine, an increase of 80%. Overall scores also improved for the group as a whole. All of the compliance ""' items for Hazardous Waste are non-critical. 12 Water The comparison data obtained from the baseline assessment and the follow-up assessment for water shows two things. First, during the baseline assessment the item of greatest concern was the lack of Storm Water Management Plans (SWMPs). Second, facilities that had SWMPs were not following the plans. Through the course of the COMPASS project, the participating plants improved their understanding of the requirements for obtaining and following their SWMPs. During the follow-up assessment, the overall compliance rate for water improved significantly. All of the compliance items for water were non-critical in nature. Pollution Prevention Pollution Prevention issues addressed in the COMPASS project were not compliance driven. These issues reflect the impact on the environment and best management practices to minimize the impact. While some improvement was observed, the results were not overwhelming. The number of plants showing full "compliance" for these non-regulatory items remained unchanged from 2001 to 2002. This might be a reflection of the lack of a regulatory requirement. Average Score °A° Median Score 2001 2002 2001 2002 Air Emissions critical 76.67 92.15 73.08 81.81 Air Emissions non-critical 74.26 86.06 65.39 65.63 Hazardous Waste 41 58.95 160 62.5 Water 49.06 75.96 52 59 Pollution Prevention critical 83.67 186.59 156.67 76.93 Pollution Prevention non-critical 74.52 180.45 77.03 69.21 Overall, the COMPASS project should be viewed as a highly successful. The participants greatly improved both their compliance rate, and their understanding of environmental compliance issues. Sincerely, 7 Chuck Hix Small Business Assistance Program Air Pollution Control Division Colorado Department of Public Health and Environment 4300 Cherry Creek Drive South Denver, Colorado 80246 (303) 692-3148 • United States Office Of Air Quality EPA-454/R-00-019 Environmental Protection Planning And Standards December 2000 Agency Research Triangle Park, NC 27711 Air �"' EPA HOT MIX ASPHALT PLANTS % • EMISSION ASSESSMENT REPORT Ciean 40. ;NO • 604. and Stso EPA 454/R-00-019 HOT MIX ASPHALT PLANTS EMISSION ASSESSMENT REPORT This document was prepared by: Emissions Monitoring and Analysis Division Office of Air Quality Planning and Standards United States Environmental Protection Agency Research Triangle Park,NC and under contract,by: Midwest Research Institute Kansas City, MO and Cary,NC EPA Contract Number 68D-98-027 and Eastern Research Group, Inc. 1600 Perimeter Park P.O. Box 2010 Moorisville,NC EPA Contract Number 68-D7-0068 U.S. ENVIRONMENTAL PROTECTION AGENCY Office of Air and Radiation Office of Air Quality Planning and Standards Research Triangle Park,North Carolina 27711 December 2000 DISCLAIMER The information in this document has been funded by the Office of Air Quality Planning and Standards,U.S.Environmental Protection Agency(EPA)under contract 68-D-98-027 to Midwest Research Institute and under contract 68-D-70-068 to Eastern Research Group,Inc. The EPA has made additions and revisions to the information submitted by the contractors.This final report has been subjected to the Agency's review,and it has been approved for publication as an EPA document. Mention of trade names or commercial products is not intended to constitute endorsement or recommendation for use. iii PREFACE This report was produced by the Source Measurement Technology Group of EPA's Emissions Measurement Center located in Research Triangle Park,NC. It is one of a series of twelve reports prepared to document an EPA program to characterize emissions to the air from hot mix asphalt plants. These twelve reports and their associated EPA document numbers and publication dates are: EPA Document Publication Date Document Title Number Hot Mix Asphalt Plants Emission Assessment Report EPA 454/R-00-019 December 2000 Hot Mix Asphalt Plants Kiln Dryer Stack Instrumental Methods Testing Asphalt Plant A,Cary,North Carolina EPA 454/R-00-020 April 2000 Hot Mix Asphalt Plants Kiln Dryer Stack Manual Methods Testing Asphalt Plant A, Cary,North Carolina Volume 1 oft EPA 454/R-00-021a April 2000 Volume 2 of 2 EPA 454/R-00-021b April 2000 Hot Mix Asphalt Plants Kiln Dryer Stack Instrumental Methods Testing Asphalt Plant B, Clayton,North Carolina EPA 454/R-00-022 April 2000 Hot Mix Asphalt Plants Kiln Dryer Stack Manual Methods Testing Asphalt Plant B, Clayton,North Carolina Volume 1 of 2 EPA 454/R-00-023a April 2000 Volume 2 of 2 EPA 454/R-00-023b April 2000 Hot Mix Asphalt Plants EPA 454/R-00-0_4 May 2000 Truck Loading and Silo Filling Instrumental Methods Testing Asphalt Plant C, Los Angeles, California Hot Mix Asphalt Plants Truck Loading and Silo Filling Manual Methods Testing Asphalt Plant C, Los Angeles,California Volume 1 of 8 EPA 454/R-00-025a May 2000 Volume 2 of 8 EPA 454/R-00-025b May 2000 Volume 3 of 8 EPA 454/R-00-025c May 2000 Volume 4 of 8 EPA 454/R-00-025d May 2000 Volume 5 of 8 EPA 454/R-00-025e May 2000 Volume 6 of 8 EPA 454/R-00-025f May 2000 Volume 7 of 8 EPA 454/R-00-025g May 2000 Volume 8 of 8 EPA 454/R-00-025h May 2000 Hot Mix Asphalt Plants Technical Systems Audit of Testing at Asphalt Plant C Asphalt Plant C, Los Angeles, California EPA 454/R-00-026 May 2000 iv EPA Document Publication Date Document Title Number Hot Mix Asphalt Plants Truck Loading Instrumental Methods Testing Asphalt Plant D, Bane,Massachusetts EPA 454/R-00-027 May 2000 Hot Mix Asphalt Plants Truck Loading Manual Methods Testing Asphalt Plant D, Bane, Massachusetts EPA 454/R-00-028 May 2000 Hot Mix Asphalt Plants Response to Comments on Testing Program for Asphalt Plants C and D EPA 454/R-00-029 May 2000 Hot Mix Asphalt Plants Stakeholders Opinions Report EPA 454/R-00-030 These documents, including this Emissions Assessment Report document,are available for downloading, on CD-ROM and in paper. Downloads can be made from: http//www.epa.gov/ttn/emeasphalt.html Copies of the CD ROM can be requested by mail at: Emission Measurement Center, MD-19 US Environmental Protection Agency Research Triangle Park,NC 27711 Paper copies of the reports can be obtained from: National Technical Information Service 5285 Port Royal Road Springfield, VA 22161 Phone orders 1-800-553-6847 or(703) 605-6000; FAX orders (703) 605-6900 http://www.ntis.goviproducts/environment.htm v ACKNOWLEDGMENTS Many individuals contributed to the development of this report. Ron Myers of the Emission Measurement Center's Source Measurement Technology Group(SMTG),Brian Slinger, Scott Klamin, Richard Marinshaw,and Amy Marshall of Midwest Research Institute(MRI), are the primary authors of the report. Bob McConnell of EPA's Region I office,David Mobley,Acting Director of EPA's Emissions Monitoring and Analysis Division,Bill Lamason,Mike Toney,Gary McAlister,and Candace Sorrell of EPA's Emission Measurement Center,Ron Ryan and Dennis Beauregard of EPA's Emission Factor and Inventory Group,Laura Autry of EPA's Air Quality Trends Analysis Group,participated in the review. We also acknowledge the contributions of numerous reviewers and advisors from PES,MRI and EPA. vi TABLE OF CONTENTS 1S e 1. EXECUTIVE SUMMARY 1 1.1 INTRODUCTION 1 1.2 OVERVIEW OF HMA INDUSTRY 1 1.3 DEVELOPMENT AND USE OF EMISSION FACTORS FOR HMA FACILITIES 1 1.4 ESTIMATED ANNUAL EMISSIONS FROM TYPICAL HMA FACILITIES 2 2. ASSESSMENT OF HOT MIX ASPHALT EMISSIONS 9 2.1 INDUSTRY OVERVIEW AND PROCESS DESCRIPTION 9 2.1.1 Batch Mix Plants 9 2.1.2 Drum Mix Plants 10 2.1.3 Recycle Processes 10 2.1.4 Emissions and Controls 11 2.2 EMISSION FACTOR DEVELOPMENT FOR AP-42 SECTION 11.1, HOT MIX ASPHALT PLANTS 11 2.2.1 Batch Mix and Drum Mix Dryers 12 2.2.2 Hot Oil Heaters 13 2.2.3 Truck Load-Out 13 2.2.4 Silo Filling 14 2.2.5 Asphalt Storage Tanks 14 2.2.6 Yard Emissions 14 2.3 OTHER APPLICABLE AP-42 SECTIONS 1; 2.4 EMISSION INVENTORY FOR TYPICAL HOT MLX ASPHALT PLANTS 16 2.5 EMISSION ESTIMATES FOR TYPICAL HOT MIX ASPHALT PLANTS 16 APPENDIX A AP-42 Section 11.1,Hot Mix Asphalt Plants, December 2000 APPENDLX B Emission Factor Documentation for AP-42 Section 11.1, Hot Mix Asphalt Production, December 2000 Final Report APPENDIX C Chapter 3: Preferred and Alternative Methods for Estimating Air Emissions from Hot Mix Asphalt Plants. Emission Inventory Improvement Program(EIIP), July 1996. LIST OF FIGURES Number Paee 1. General process flow diagram for batch mix asphalt plants 4 2. General process flow diagram for counter-flow drum mix asphalt plants 5 vii LIST OF TABLES Number FIE 1. ESTIMATED ANNUAL EMISSIONS FOR A TYPICAL BATCH MIX HMA FACILITY 6 2. ESTIMATED ANNUAL EMISSIONS FOR A TYPICAL DRUM MIX HMA FACILITY 7 3. MATRIX OF EMISSION FACTORS DEVELOPED FOR HMA SOURCES 17 4. LOCATIONS OF SUPPORTING DATA FOR EMISSION FACTORS 18 5. ESTIMATED ANNUAL EMISSIONS FOR A TYPICAL BATCH MIX PLANT DRYER, HOT SCREENS,AND MIXER 19 6. ESTIMATED ANNUAL EMISSIONS FOR TYPICAL BATCH MIX PLANT LOAD-OUT OPERATIONS 20 7. ESTIMATED ANNUAL EMISSIONS FOR TYPICAL BATCH MIX PLANT ASPHALT STORAGE TANK 21 8. ESTIMATED ANNUAL EMISSIONS FOR A TYPICAL DRUM MIX DRYER 22 9. ESTIMATED ANNUAL EMISSIONS FOR TYPICAL DRUM MIX PLANT LOAD-OUT OPERATIONS 23 10. ESTIMATED ANNUAL EMISSIONS FOR TYPICAL DRUM MIX PLANT SILO FILLING OPERATIONS 24 11. ESTIMATED ANNUAL EMISSIONS FOR TYPICAL DRUM MIX PLANT ASPHALT STORAGE TANK 25 12. ESTIMATED ANNUAL YARD VOC EMISSIONS FOR TYPICAL BATCH MIX AND DRUM MLX I LMA PLANTS 26 viii LIST OF ACRONYMS ASTM American Society of Testing and Materials Btu British thermal unit CH4 methane CO carbon monoxide(as measured by EPA Method 10) CO2 carbon dioxide(as measured by EPA Method 3) EPA Environmental Protection Agency HAP hazardous air pollutant(listed in or pursuant to section 112(b) of the 1990 Clean Air Act Amendments) ILMA hot mix asphalt NOx nitrogen oxides(as measured by EPA Method 7) PAH polycyclic aromatic hydrocarbon(a class of HAPs) PM particulate matter(as measured by EPA Methods 5 or 17) PM-10 particulate matter less than 10 microns in diameter PM-2.5 particulate matter less than 2.5 microns in diameter RAP reclaimed asphalt pavement RTFOT rolling thin film oven test(ASTM Method D2872-88) SCC source classification code SO2 sulfur dioxide (as measured by EPA Methods 6 or 8) SOx sulfur oxides TOC total organic compounds(as measured by EPA Method 25A) VOC volatile organic compound(refer to 40 CFR 51.100); VOC is TOC plus formaldehyde, less methane,ethane, acetone,and other chemicals listed as negligibly photochemically reactive. ix 1. EXECUTIVE SUMMARY 1.1 INTRODUCTION This report presents an assessment of emissions from hot mix asphalt(HMA)manufacturing facilities. Included in the report is a description of the manufacturing process and the emissions associated with HMA production; the procedures for developing emission factors and emission inventories for the HMA industry; and estimated annual emissions for typical HMA facilities. 1.2 OVERVIEW OF HMA INDUSTRY Hot mix asphalt is used primarily as paving material and consists of a mixture of aggregate and liquid asphalt cement,which are heated and mixed in measured quantities. Hot mix asphalt facilities can be broadly classified as either drum mix plants or batch mix plants,according to the process by which the raw materials are mixed. In a batch mix plant,the aggregate is dried first, then transferred to a mixer where it is mixed with the liquid asphalt. In a drum mix plant, a rotary dryer serves to dry the aggregate and mix it with the liquid asphalt cement. After mixing,the HMA generally is transferred to a storage bin or silo, where it is stored temporarily. From the silo, the HMA is emptied into haul trucks, which transport the material to the job site. Figure 1 presents a diagram of a typical batch mix HMA plant; a typical drum mix HMA plant is depicted in Figure 2. In 1996, approximately 500 million tons of HMA were produced at the 3,600 (estimated) active asphalt plants in the United States. Of these 3,600 plants,approximately 2,300 are batch plants, and 1,300 are drum mix plants. The total 1996 I-L\IA production from batch and drum mix plants is estimated at about 240 million tons and 260 million tons, respectively. Based on these figures. an average batch mix plant produces approximately 100,000 tons of HMA annually,and an average drum mix plant produces about 200,000 tons of HMA per year. Natural gas fuel is used to produce 70 to 90 percent of the HMA. The remainder of the HMA is produced using oil, propane, waste oil, or other fuels. The primary emission sources associated with HMA production are the dryers,hot bins, and mixers, which emit particulate matter(PM) and a variety of gaseous pollutants. Other emission sources found at HMA plants include storage silos,which temporarily hold the HMA; truck load-out operations, in which the HMA is loaded into trucks for hauling to the job site; liquid asphalt storage tanks;hot oil heaters,which are used to heat the asphalt storage tanks; and yard emissions, which consist of fugitive emissions from the HMA in truck beds. Emissions also result from vehicular traffic on paved and unpaved roads,aggregate storage and handling operations, and vehicle exhaust. The PM emissions associated with HMA production include the criteria pollutants PM-10 (PM less than 10 micrometers in aerodynamic diameter)and PM-2.5, hazardous air pollutant(HAP)metals, and HAP organic compounds. The gaseous emissions associated with HMA production include the criteria pollutants sulfur dioxide (SO2),nitrogen oxides (NOx),carbon monoxide(CO),and volatile organic compounds (VOC), as well as volatile HAP organic compounds. 1.3 DEVELOPMENT AND USE OF EMISSION FACTORS FOR HMA FACILITIES An emission factor relates the quantity(weight)of pollutants emitted to a unit of activity of the source. Emission factors for the HMA industry are generally determined in units of pounds of pollutant emitted per ton of HMA produced. These emission factors typically are used to estimate area-wide 1 emissions for a large number of facilities and emissions for specific facilities where source-specific emissions data are not available or where source testing is cost prohibitive. To develop emission factors for the HMA industry, data from more than 390 emission test reports and other documents on the industry were compiled and reviewed. Through a careful screening process, the documents that were determined to be unusable for emission factor development were excluded from further evaluation. The remaining reports were compiled by plant type,emission source,pollutant,and emission control. For each emission test, emission factors were calculated by dividing the measured emission rates by the H vlA production rate measured at the time of the emission test. These emission factors were then grouped by source,pollutant, and control device,and an average emission factor was calculated for each group. Emission factors can be used to estimate emissions from one or more HMA facilities by multiplying the emission factor by the HMA production rate. For example, the emission factor for CO emissions from a natural gas-fired drum mix dryer is 0.13 pounds per ton(1b/ton). If the dryer produces 200,000 tons per year(ton/yr), the estimated CO emissions during that period would be: 200,000 ton/yr x 0.13 lb/ton =26,000 lb/yr or 13 tons/yr. 1.4 ESTIMATED ANNUAL EMISSIONS FROM TYPICAL HMA FACILITIES Annual emissions for a facility can be estimated by summing up the emissions from each emission source over the course of a year. Annual emissions for a specific source can be estimated by multiplying the annual throughput or production rate for that source by its corresponding emission factors. For an HMA facility,annual emissions can be estimated by multiplying the annual HMA production rate by the emission factors for each type of source at the facility. Table 1 summarizes annual emissions for a typical HMA batch mix plant, and Table 2 summarizes annual emissions for a typical drum mix HMA plant. The estimates presented in these tables account for all of the identified emission sources at each type of facility. For both batch mix plants (Table 1) and drum mix plants(Table 2),the estimate includes emissions from the dryer/mixer,load-out operations, asphalt storage, yard(fugitive emissions from loaded trucks), diesel exhaust. paved and unpaved road dust, and aggregate processing(screening,conveyor transfer, and reclaimed asphalt pavement [RAP] crushing). Additionally, for the drum mix plant(Table 2), the estimate includes emissions from silo filling operations. Estimates are presented for criteria pollutants (pollutants for which national ambient air quality standards have been developed) and hazardous air pollutants (HAPs, • as defined in section 112(b) of the 1990 Clean Air Act Amendments). Criteria pollutants include PM-10, VOC, CO, SO2, and NOx. Emissions for three classes of HAPs are presented in Tables 1 and 2: polycyclic aromatic hydrocarbons(PAHs), volatile organic HAPs, and metal HAPs. The emissions were estimated using the emission factors developed for the I-B4A industry and the following assumptions: • Dryers are fueled with natural gas or No. 2 fuel oil(estimates are presented for both types). It is estimated that between 70 and 90 percent of HMA plants use natural gas, although some HMA plants use fuel oil as an alternative to natural gas. • Dryer emissions are controlled with fabric filters. • PM emissions from load-out and silo filling are entirely PM-10. • Annual HMA production rate for a typical batch mix plant is 100,000 ton/yr. • Annual HMA production rate for a typical drum mix plant is 200,000 ton/yr. — • The typical HMA plant has two 18,000-gallon asphalt storage tanks. As indicated in Table 1, a typical batch mix plant using a No. 2 fuel oil-fired dryer emits over .-- 74,000 lb/yr of criteria pollutants. and a typical batch mix plant using a natural gas-fired dryer emits over 2 56,000 lb/yr of criteria pollutants,of which approximately 41,000 lb/yr are CO and approximately 10,700 lb/yr are PM-10; emissions of other criteria pollutants range from about 500 to about 12,000 lb/yr. The same plant would emit about 770 lb/yr of HAPs. A typical drum mix plant using a No. 2 fuel oil-fired dryer emits about 83,000 lb/yr of criteria pollutants,and a typical drum mix plant using a natural gas-fired dryer emits around 75,000 lb/yr of criteria pollutants,of which approximately 28,000 lb/yr are CO, about 10,000 lb/yr are VOC,and around 31,000 lb/yr are PM-10. A typical drum mix plant emits from 1,300 to 2,000 lb/yr of HAPs,depending on the fuel used in the dryer. 3 ) ) COMBINED IXIUUST FROM HOT ELEVATOR, SCREENS,BINS.MIXER.AND DRYER II ISLC 3-05-002 45, Ma, 411 I O e, • ,-3® P i • LOADER i' EXHAUST TO (SCC 3-05002-04) "' A® •``. ATMOSPHERE t t 'I"''I'I"I•I',) lW) O RAP BIN 4 CONVEYOR I+�_ �f a 'ry SECONDARY FINES � �1. FAN • is \ SECONDARY COLLECTOR ;,:..�` ': , r ® ELEVATOR :'r""..n ti :::: �(SGC 3-05002'02)F. -,- • FINE AGGREGATE COURSE AGGREGATE �.�y. i' • • STORAGE PILE (&STORAGE PILE / ,'` (scc3osaMz-m) IS<:caa5m2o3) HOT SCREENS Y---�� (WA (SCC 30500202) 'I' ��.f''�•• STORAGE ', ( : d?!!! a PRIMARY • (OPTIONAL) ' CG LECTOfe sic 3 05 Mt(3) MOTORS 1,.. ....., &WEIGH ( (see 30500202) —.--- WORER� '� A a '' MIW.R {� -' Y ) ( R6T11RN i ' .® , .® (5CC 30500202 t ' 'nNI. • CONVEYOR t, • 1" a � IA �I} 4.-• �, " ]0 S ® ' %. + -- t ti .-. -- _• ROTARY TRUCK '' , 1 CONVEYOR COED30EGATE BINS ; Hi DRYER DRYER (scc If"f LOAD-OUT ''II if�1i f r BURNER (SCC3-&oo2oL.-5)..52,-53) FEEDERS (,Scc 10S0N�) TRUCK LOAD OUT I Z (50C 305-002-14) r- •-` ' r�7 LEGEND + _jl '�{'#If /4 Emission Points - ASPHN.T CEMENT STORAGE ((EATER Q. Ducted Emissions (sec 305-W212) (sec 305-002-05..0).05,00) 0 Process Fugitive Emissbna I 0 Open Dust Emissions Figure I. General process flow diagram for batch mix asphalt plants(source classification codes in parentheses). ) ) ) ►w, PRIMARY pO �t'� \ 1le COLLECTOR ,40 ) LOADER ,-3._, --T1 I { I (— EXHAUST 10 (SCC 3-05-002-04) TO ATMOSPHERE q',,® F lii,� � .® ®K • (J'§:, r r S�J I��.� teal (I, EXHAUST S� �' �� .. t -lI FAN RAP BIN 8 CONVEYOR SECONDARY .; :';,y";., "�3 .ir 4 COLLECTOR z.4:;ilt'.'`r '<'�'?i ,. PF q-, t FINE AGGREGATE COURSE AGGREGATE SECONDARY FINES STORAGE PILE STORAGE PILE Is�A RETURN LINE (SCC 3-05-002-03) (SCC 3-05-002-03) S ORAOE ISM 3054@-13) t.P® u' MUCK • O .® a® AO LOAD-OUT . CONVEYOR • • ` `. r ISM 305 Dot U) ■' ®.-� ��+ ! W � � ��- DRYER _ DRYER �r1\14,i‘ ��/,��{B�---/, \�_ PF BURNER (o , =it— Nil --4----f COUNTER-FLOW CONVEYOR SCALPING COLD AGGREGATE BINS i. ODRUM MIXER SCREEN FEEDERS (SCC 3-05-002-04) (SCC 3-05-002-05,-55,-57, , t� -58,-60.-61,-63) 5. 1, !, LEGEND ` i~ Emission Points + 1LYh(1,'.r.7y,t( I 0 Ducted Emissions AmA3�A� Process Fugitive Emissions ASPHALT CEMENT STORAGE HEATER ft Open Dust Emissions (SCC 3-05-00206,-07,-08,09) (SCC 3-05-002-12) Figure 2. General process flow diagram for counter-flow th'uni mix asphalt planes(source classification codes in parentheses). ) ) ) . TABLE I. ESTIMATED ANNUAL EMISSIONS FOR A TYPICAL I3ATCII MIX IIMA FACILITYa Annual emissions by source,pounds per year Mobile Material No. 2 fuel oil- Natural gas- sources handling fired dryer, fired dryer, Total' Total' (diesel and road hot screens, hot screens, Load- Asphalt (oil- (gas- Pollutant exhaust) dust and mixer' and mixer' out' Storage' Yard' fired) fired) Criteria air pollutants Particulate matter less than 46 7,900 2,700 2,700 52 I0,700 10,700 10 micrometers(PM-10) Volatile organic compounds(VOC) 100 820 820 391 32 110 1,500 1,500 Carbon monoxide(CO) 700 40,000 40,000 135 3 35 41,000 41,000 Sulfur dioxide(SO2) 22 8,800 460 8,800 480 Nitrogen oxides(NO,) 380 12,000 2,500 12,400 2,900 I lazardous air pollutants(IIAPs) m Polycyclic aromatic hydrocarbons 0.035 11 11 2.0 0.12 I 13 13 (PAHs) Phenol 0.40 0.40 0.40 Volatile HAPs 1.9 751 751 6.2 140 1.6 760 760 Metal HAPs 1.4 1.4 1.4 1.4 Total IIAPs' 1.9 760 760 8.6 140 1.6 1770 770 ' Based on an annual IIMA production rate of 100,000 tons per year. s Between 10 and 30 percent of the HMA is produced using fuel oil. ` Between 70 and 90 percent of the HMA is produced using natural gas. ' Loading of IIMA into haul trucks. ' Includes emissions from oil-fired hot oil heaters. r Fugitive emissions from loaded trucks prior to departure to the job site. 'Total expressed using two significant figures. ) ) ) . TABLE 2. ESTIMATED ANNUAL EMISSIONS FOIL A TYPICAL DRUM MIX IIMA FACILITYa Annual emissions by source,pounds per year Mobile Material No. 2 sources handling fuel oil- Natural Total" Total" (diesel and road fired gas-fired Load- Silo Asphalt (oil- (gas- Pollutant exhaust) dust dryer" dryer out° filling' storage' Yard' fired) fired) Criteria air pollutants Particulate matter less than 220 26,000 4,600 4,600 104 I17 31,000 31,000 10 micrometers(PM-10) Volatile organic compounds(VOC) 190 6,400 6,400 782 2,440 64 220 I 10,000 10,000 Carbon monoxide(CO) 1,200 26,000 26,000 270 236 6 72 28,000 28,000 ' Sulfur dioxide(SO2) 26 2,200 680 2,200 710 Nitrogen oxides(NO,) 560 11,000 5,200 12,000 5,800 I lazardous air pollutants(HAPs) v Polycyclic aromatic hydrocarbons 0.13 176 37 4.0 5.8 0.12 190 50 (PAHs) Phenol 0.80 0.80 0.80 Volatile HAPs 6.6 1,560 1,020 12.4 31 140 3.3 11,800 1,200 Metal HAPs 19 16 19 16 Total HAPs" 6.7 1,800 1,100 17 37 140 3.3 12,000 1,300 'Based on an annual HMA production rate of 200,000 tons per year. "Between 10 and 30 percent of the HMA is produced using fuel oil. `Between 70 and 90 percent of the HMA is produced using natural gas. ° Loading of HMA into haul trucks ' Filling of temporary storage silo prior to load-out. 'Includes emissions from oil-fired hot oil heaters. r Fugitive emissions from loaded trucks prior to departure to the job site. h Total expressed using two significant figures. 2. ASSESSMENT OF HOT MIX ASPHALT EMISSIONS This section presents the results of an assessment of emissions from HMA manufacturing. An overview of the HMA industry and process operations is provided first(Section 2.1). Section 2.2 summarizes the methodology used to develop emission factors for the HMA industry. Section 2.3 identifies other sections of AP-42 that apply to HMA plants. An overview of the process for conducting an emission inventory is presented in Section 2.4, and Section 2.5 presents estimates of annual emissions from typical HIvIA facilities. 2.1 INDUSTRY OVERVIEW AND PROCESS DESCRIPTION' Hot mix asphalt paving materials are a mixture of well-graded,high-quality aggregate and liquid asphalt cement,which is heated and mixed in measured quantities. The aggregate often includes RAP. Aggregate and RAP (if used)constitute over 92 percent by weight of the total mixture. Aside from the amount and grade of asphalt cement used, mix characteristics are determined by the relative amounts and types of aggregate and RAP used. A certain percentage of fine aggregate(less than 74 micrometers [µm] in physical diameter) is required for the production of good quality HMA. Hot mix asphalt plants can be classified by their mixing operation as one of the following: (1)batch mix plants,(2)continuous mix (mix outside dryer drum)plants, (3)parallel flow drum mix plants, and(4) counterflow drum mix plants. An HMA plant can be constructed as a permanent plant, a skid-mounted(easily relocated)plant, or a portable plant. All plants can have RAP processing capabilities. In 1996, approximately 500 million tons of HMA were produced at the 3,600 (estimated) active asphalt plants in the United States. Of these 3,600 plants, approximately 2,300 are batch plants. 1,000 are parallel flow drum mix plants, and 300 are counterflow drum mix plants. The total 1996 HMA production from batch and drum mix plants is estimated at about 250 million tons and 260 million tons, respectively. About 85 percent of new plants being constructed today are of the counterflow drum mix design, while batch plants and parallel flow drum mix plants account for 10 percent and 5 percent respectively. Continuous mix plants represent a very small fraction of the plants in use(s0.5 percent) and,therefore, are not discussed further. While most HMA plants have the capability to use both fuel oil and natural gas, it is estimated that between 70 and 90 percent of the HMA in the U. S. is produced using natural gas. The process operations at typical batch mix and drum mix plants are described in the following paragraphs. 2.1.1 Batch Mix Plants2 Processing begins as the aggregate is hauled from onsite storage piles and is placed in the appropriate hoppers of the cold feed unit. The material is metered from the hoppers onto a conveyer belt and is transported into a rotary dryer(typically gas-or oil-fired). As the hot aggregate leaves the dryer, it drops into a bucket elevator, is transferred to a set of vibrating screens,then separated into as many as four different grades(sizes), and dropped into"hot"bins according to size. At newer facilities, RAP may be transferred to a separate heated storage bin. At the same time,liquid asphalt cement is pumped from a heated storage tank to an asphalt bucket,where it is weighed to achieve the desired aggregate-to-asphalt cement ratio in the fmal mix. To control the aggregate size distribution in the final batch mix,the operator transfers material from various hot bins(and RAP bins, if used)to a weigh hopper until the desired mix I See Appendix A, Section 11.1.1, and Appendix B, Section 2.1, for more detailed information. 2 See Appendix A, Section 11.1.1.1, and Appendix B, Section 2.2.1, for more detailed information. 9 and weight are obtained. The aggregate from the weigh hopper is dropped into the mixer(pug mill)and thy-mixed for 6 to 10 seconds. The liquid asphalt is then dropped into the pug mill where it is mixed for an additional period of time. At older plants,RAP typically is conveyed directly to the pug mill from a storage hopper and combined with the hot aggregate. Total mixing time usually is less than 60 seconds. Then,the hot mix is conveyed to a hot storage silo or is dropped directly into a truck and hauled to the job site. Figure I depicts a typical batch mix plant. 2.1.2 Drum Mix Plants3 This process is a continuous mixing type process. The major difference between this process and the batch process is that the dryer is used not only to dry the material but also to mix the heated and dried aggregates with the liquid asphalt cement. In a parallel flow drum mixer,the aggregate is introduced to the drum at the burner end. As the drum rotates,the aggregate, as well as the combustion products from the burner,move toward the other end of the drum in parallel. Liquid asphalt cement is introduced in the mixing zone midway down the drum in a lower temperature zone, along with any RAP and PM from collectors. In a counterflow drum mixer, the material flow in the drum is opposite or counterflow to the direction of exhaust gases. In addition,the liquid asphalt cement mixing zone is located behind the burner flame zone so as to remove the materials from direct contact with hot exhaust gases. After mixing,the mixture is discharged at the end of the drum and is conveyed to either a surge bin or HIvIA storage silos. Figure 2 illustrates a counterflow drum mix plant. In a parallel flow mixer,the exhaust gases also exit the end of the drum and pass on to the collection system. Parallel flow drum mixers have an advantage, in that mixing in the discharge end of the drum captures a substantial portion of the aggregate dust, therefore lowering the load on the downstream • PM collection equipment. For this reason, most parallel flow drum mixers are followed only by primary collection equipment(usually a baghouse or venturi scrubber). However, because the mixing of aggregate and liquid asphalt cement occurs in the hot combustion product flow,organic emissions (gaseous and liquid aerosol) may be greater than in other processes. Counterflow drum mix plants likely will have organic stack emissions (gaseous and liquid aerosol) that are lower than parallel flow drum mix plants because the liquid asphalt cement, virgin aggregate,and RAP are mixed in a zone removed from the exhaust gas stream. A counterflow drum mix plant normally can process RAP at ratios up to 50 percent with little or no observed effect upon emissions. 2.1.3 Recycle Processes4 Reclaimed asphalt pavement significantly reduces the amount of new aggregate and asphalt cement needed to produce II.MA. In the reclamation process,old asphalt pavement is removed from the road base. This material is then transported to the plant,and is crushed and screened to the appropriate size for further processing. The paving material then is heated and mixed with new aggregate(if applicable),and the proper amount of new asphalt cement is added to produce HMA that meets the quality requirements of the customer. 3 See Appendix A, Sections 11.1.1.2 and 11.1.1.3, and Appendix B, Sections 2.2.2 and 2.2.3, for more detailed information. 4 See Appendix A. Section 11.1.1.4, and Appendix B, Section 2.2.4, for more detailed information. 10 2.1.4 Emissions and Controls5 Hot mix asphalt plants have two major categories of emissions: ducted sources(those vented to the atmosphere through some type of stack,vent, or pipe),and fugitive sources(those not confined to ducts and vents but emitted directly from the source to the ambient air). Dryers are the most significant ducted sources of emissions from both batch mix and drum mix HMA plants. Emissions from these sources consist of water(as steam evaporated from the aggregate);PM;products of combustion(carbon dioxide [CO,],NOx, and sulfur oxides [5Ox1); CO; and small amounts of organic compounds of various species (including VOC, methane [CH4], and HAPs). The CO and organic compound emissions result from incomplete combustion of the fiel and also are released from the heated asphalt. At batch mix plants, other potential process sources include the hot-side conveying,classifying, and mixing equipment,which are vented to either the primary dust collector(along with the dryer gas)or to a separate dust collection system. These emissions are mostly aggregate dust,but they also may contain gaseous organic compounds, CO, and a fine aerosol of condensed organic particles. This organic aerosol is created by the condensation of gas into particles during cooling of organic vapors volatilized from the asphalt cement in the mixer. The amount of organic aerosol produced depends to a large extent on the temperature of the asphalt cement and aggregate entering the mixer. Organic vapor and its associated aerosol also are emitted directly to the atmosphere as process fugitives during truck load-out, from the bed of the truck itself during transport to the job site, and from the asphalt storage tank. Both the low molecular weight organic compounds and the higher weight organic aerosol may contain small amounts of HAP. The ducted emissions from the heated asphalt storage tanks may include gaseous and aerosol organic compounds and combustion products from the tank heater. At most H'YL\ facilities. fabric filters are used to control emissions from dryers. Other controls used include mechanical collectors and scrubbers. Emissions from aggregate handling and transfer typically are controlled with fabric filters or scrubbers. Large diameter cyclones and settling chambers also are used as product recovery devices. The material collected in those devices is recycled back into the process. There also are a number of fugitive dust sources associated with batch mix I-L'vlA plants, including vehicular traffic generating fugitive dust on paved and unpaved roads, aggregate material handling, and other aggregate processing operations. 2.2 EMISSION FACTOR DEVELOPMENT FOR AP-42 SECTION 11.1, HOT MIX ASPHALT PLANTS A detailed description of how the emission factors were developed for the HMA industry is provided in Section 4 of Appendix B. The following paragraphs summarize the methodology used. To develop emission factors for the HMA industry,data from about 390 emission test reports and other documents on the industry were compiled and reviewed(a complete list of these references is provided following Section 4 of Appendix B). The majority of these reports documented measurements of emissions from batch plant dryer/mixers and drum plant dryers. Through a careful screening process, 35 of the reports were determined to be unusable for emission factor development and were excluded from further evaluation. About 350 reports remained and were compiled by plant type,emission source, pollutant,and emission control. These emission factors were then grouped by source,pollutant,and 5 See Appendix A. Section 11.1.2, and Appendix B, Section 2.3,for more detailed information. 11 control device,and an average emission factor was calculated for each group. Table 3 presents a matrix of all of the sources and pollutants for which emission factors are presented in AP-42 (Appendix A). While the particulate, CO2,CO, and TOC emission factors are based on over 100 tests, most of the remaining criteria pollutant emission factors are based on between 5 and 10 tests. A few HAP emission factors are based on more than 5 tests, although the majority are based on between 2 and 5 tests. Information on the supporting data for specific emission factors and the quality rating assigned to the emission factor is included in the section or table in Appendices A and B as indicated in Table 4. Column four of Table 4 references the tables in Appendix A that present the emission factors and quality ratings. Column five of Table 4 references the paragraphs in Appendix B that discuss the basis for the emission factors developed for all of the sources and pollutants. Column six of Table 4 references the tables in Appendix B that present the emission factors and the individual data used to develop the emission factors. Generally,the amount of supporting data is typical of many AP-42 sections. However, the amount of data supporting the particulate, CO2, CO, and TOC emission factors is greater than most AP-42 sections. The following paragraphs summarize the procedures followed to develop the emission factors for HblA facilities. 2.2.1 Batch Mix and Drum Mix Dryers The usable data on batch mix and drum mix plant dryer emissions were compiled according to source type, emission control, and pollutant. Data on fuel types,the percentage of RAP used in the mix, and the process operating rate (e.g., dryer production rate)also were recorded. The quality of the emission data was evaluated with respect to the level of documentation in the report, the test methods used, the number of test runs, and any reported problems with the sampling procedures or the operation of the source during the test period. On the basis of this evaluation, data ratings of A, B, C,or D were assigned to each data set. Specific procedures used to evaluate the data are specified in Procedures for Preparing Emission Factor Documents (EPA-454/R-95-015). For each emission test, an emission factor also was calculated for each pollutant sampled. These test-specific emission factors then were grouped according to source type, emission control device, pollutant,and, in the case of combustion sources,fuel type. At this stage in the process,D-rated data sets were discarded,provided there were higher quality data available for that particular group (i.e., that specific combination of source, control, fuel,and pollutant). In addition,where there were data from multiple tests on the same specific emission source,the test-specific emission factors were averaged to yield a source-specific emission factor. In subsequent calculations, this source-specific emission factor was used. A statistical analysis of the data for batch and drum mix dryers was performed to determine the effects of RAP content, fuel type,production rate on emissions of several pollutants. The analysis showed no strong correlation between these parameters and emission factors. Details on the statistical analysis can be found in Section 4.3 of Appendix B. To develop emission factors,the mean of the test-specific emission factors was calculated for each of the emission factor groups discussed above. In some cases,the data for two or more groups were combined and an overall mean emission factor was calculated. For example, if the data indicated that fuel type had no apparent effect on emissions of a specific pollutant, fuel type was ignored and all of the data for that source type and pollutant were combined. The final step in developing emission factors is to assign a quality rating of A. B, C, D, or E. Quality ratings are a function primarily of the number of data points 12 from which a specific emission factor is calculated. Additional information on the rating system used is discussed in Section 3 of Appendix B. 2.2.2 Hot Oil Heaters For hot oil heaters,only a single test report for an oil-fired hot oil heater was available. The report was reviewed and the emission factors compiled using the procedures described previously. Appendix B, Section 4.2.4.2,provides a detailed description of how these emission factors were developed. It should be noted that most hot oil heaters are gas-fired, and the emission factors developed from the available data would not necessarily be representative of gas-fired heaters. 2.2.3 Truck Load-Out Truck load-out emissions were developed from two emission tests sponsored by the U. S. Environmental Protection Agency(EPA)(Appendix B References 355 and 356). In designing,performing and evaluating these two tests, EPA was involved with a number of groups. The groups included citizens, State and local health agencies, State and local air pollution control agencies, and industry associations. These different groups provided input on the selection of facilities for emissions testing,the design of the test program,reviewed the individual site-specific test plans,observed emissions testing,commented on the draft test reports and provided suggestions for analysis of the data to develop emission factors. The procedures used to develop emission factors generally were the same as those described above. However, additional steps were taken to ensure the quality and consistency of the data and the representativeness and universality of the emission factors developed from the data. For example,two quality assurance scientists from Research Triangle Institute were employed to independently audit the test. These additional steps are summarized below. Detailed explanations of the methodology used are provided in Section 4.4 of Appendix B. At one of the facilities the sampling area was enclosed but did not meet EPA requirements for a total enclosure. Consequently, the capture efficiency was quantitatively estimated and the data were corrected for capture efficiency. At one facility,emissions due to diesel truck operation could not be segregated from emissions due to truck load-out. Therefore,background concentrations also were sampled. To account for background levels of various pollutants emitted from truck operation,the as-measured background concentrations were subtracted from the capture efficiency corrected load-out emission concentrations. For the most part, values were treated as zero if the background concentration exceeded the capture-efficiency-adjusted run concentration. Because the asphalt types and temperatures for the two facilities differed, adjustments also were made to normalize the emission data. To account for differences in the volatility of the liquid asphalts used, samples of asphalt were collected during the emission tests and analyzed by ASTM Method D 2872- 88, Effects of Heat and Air on a Moving Film of Asphalt(Rolling Thin Film Oven Test-RTFOT) to determine the "loss-on-heating"values for the asphalts. Additional loss-on-heating data also were obtained from several State departments of transportation laboratories in order to determine a common RTFOT value to use as a default in those situations where no historical information is available. Based upon the RTFOT data collected and the desire to select a default which encourages the use of site-specific data, a default of-0.5 percent was selected as a default value for use in the predictive emission factor equations developed from the data. 13 To account for differences in the load-out temperatures of the two facilities the data were adjusted using the Clausius-Clapeyron equation,which relates vapor pressure and temperature of a substance. This equation and the asphalt laboratory data provide a mechanism to normalize the emissions to a temperature of 325°F,which is the maximum midpoint load-out temperature recommended by the Asphalt Pavement Environmental Council's Best Practices Guide dated March 2000. Using the adjusted data and the temperature and volatility relationship described above, separate predictive emission factor equations were developed for emissions of total PM, organic PM, total organic compounds(TOC),and CO from drum mix and batch mix load-out operations. Additionally, adjusted data for a variety of HAP's were used to develop ratios of the HAP pollutant to either organic PM or TOC (speciation profiles). These speciation profiles are applicable to load-out emissions and yard emissions. 2.2.4 Silo Filling Silo filling emission factors were developed from one of the emission tests described in the previous paragraphs for load-out emissions(Appendix B Reference 355). These data also were collected and evaluated with stakeholder involvement. Additionally, the same basic methodology described in the previous paragraphs for load-out emissions was used to adjust the data on emissions from silo filling operations. Predictive emission factor equations also were developed for total PM,organic PM, TOC, and CO. A detailed explanation of the methodology used to develop these equations is provided in Section 4.4.4 of Appendix B. Speciation profiles for silo filling emissions were also developed using the methodology described for load-out emissions. The speciation profiles from silo filling are applicable to asphalt storage tank emissions. 2.2.5 Asphalt Storage Tanks To estimate emissions from heated organic liquid storage tanks,the methodologies described in Chapter 7 of AP-42 and the TANKS software are generally used. The emissions from these types of tanks depend on the contents of the tank,the volume of gas vented, and the operating temperature range of the liquid in the tank. Emissions during the filling of these tanks(working loss)are governed by the saturation concentration of the liquid stored in the tank and the volume of gas displaced by the addition of liquid to the tank. Emissions during other periods (breathing losses)are governed by the saturation concentration of the liquid stored in the tank and the changes in the volume of the gas caused by temperature variations. Although vapor pressure information on paving asphalt is not available to allow the use of the TANKS program without additional information, information was available from the silo filling test report to infer emissions during the filling of the asphalt storage tank and,by extension,the vapor pressure characteristics of paving asphalt at the typical operating temperatures. Using these data, input values for Antoine's equation and liquid and vapor molecular weight were developed for use with the TANKS program to calculate working and breathing losses for asphalt storage tanks. A detailed explanation of the methodology used to develop these values is presented in Section 4.4.5 of Appendix B. 2.2.6 Yard Emissions At one of the EPA-sponsored emission tests described in the previous paragraphs for load-out emissions(Appendix B Reference 355), data also were collected on fugitive emissions from loaded trucks as they sat in the yard prior to departure for the job site. As with the other data from this reference,these data were evaluated with stakeholder involvement. The data obtained were fitted to a power function in order to develop an equation for these yard emissions as a function of time. A specific emission factor for cumulative emissions over an 8-minute period(which represents the maximum time represented by the 14 • data)was calculated using the power function equation developed from the emission data. A detailed explanation of the methodology used to develop the equations and the emission factor is provided in Section 4.4.6 of Appendix B. 2.3 OTHER APPLICABLE AP-42 SECTIONS Emission factors for other generic sources associated with HMA facilities can be found in other sections of AP-42 (http://www.epa.gov/rm/chiegap42/index.html). As discussed above,methodologies for estimating emissions from asphalt storage tanks can be found in Chapter 7 of AP-42. Methods for estimating fugitive dust emissions from vehicular traffic are presented'in AP-42 Chapter 13 (Sections 13.2.1 and 13.2.2). Material handling emissions and storage pile emissions are addressed in AP- 42 Chapter 11 (Section 11.19.2)and Chapter 13 (Section 13.2.4). Emission factors for truck exhaust are provided in AP-42 Volume II: Mobile Sources(http://www.epa.gov/oms/ap42.htm). To calculate the material handling and mobile source emission estimates presented in Tables 1 and 2 of this report, suitable emission factors for these material handling and mobile sources were determined. The following paragraphs describe the basis for the emission factors that were used: • Receipt of new aggregate—Used equation from AP-42 Section 13.2.4, assuming an average moisture content of 1.5 percent and an average wind speed of 10 miles per hour(mph). The resulting PM-10 emission factor is 0.0041 Ib;ton of new aggregate. The resulting PM-2.5 emission factor is 0.0013 lbiton of new aggregate. • Transfer of aggregate from storage to conveyor belt or between conveyor belts—Used controlled emission factor from.AP-42 Section 11.19.2. The PM-I0 emission factor is 0.000048 lb/ton of new aggregate. • Screening of aggregate—Used controlled emission factor from AP-42 Section 11.19.2. PM-10 emission factor is 0.00084 lb/ton of new aggregate. • RAP crushing—Used controlled tertiary crushing emission factor from AP-42 Section 11.19.2. PM-10 emission factor is 0.00059 lb/ton of new aggregate. • Paved road dust emissions—Used paved roads equation from AP-42 Section 13.2.1, assuming an average vehicle weight of 22 tons and a road silt content of 3 grams per square meter. The resulting PM-10 emission factor is 0.016 lb per vehicle mile traveled. The resulting PM-2.5 emission factor is 0.0040 lb per vehicle mile traveled. • Unpaved road dust emissions—Used unpaved roads equation from AP-42 Section 13.2.2, assuming an average vehicle weight of 6 tons,a road silt percentage of 10 percent, a surface moisture content of 0.7 percent. The resulting PM-10 emission factor is 2.04 lb per vehicle mile traveled. The resulting PM-2.5 emission factor is 0.29 lb per vehicle mile traveled. • Diesel exhaust emissions—Used heavy duty diesel truck emission factors for idling and for an average speed of 10 mph with a 250 brake horsepower engine. The diesel engines get 10 miles per gallon at 10 mph and burn 1 gallon per hour(gal/hr) of fuel at idle. The sulfur content of diesel fuel is 0.05 percent. At idle,the emissions factors for diesel engines are: VOC- 0.208 grams per minute (g/min) (0.00046 pound per minute [lb/min]),CO- 1.57 g/min (0.0035 lb/min),NOx -0.917 g/min(0.0020 lb/min), SO2 -0.157s pounds per gallon of fuel (lb/gal)(where s is fuel sulfur content)and PM-0.043 g/min(0.000095 lb/min). When traveling at an average speed of 10 mph,the emission factors for diesel engines are: VOC - — 3.18 grams per mile (g/mile) (0.0070 pounds per mile [lb/mile]), CO - 18.82 g/mile (0.041 lb/mile),NOx- 8.50 g/mile(0.019 lb/mile), SO2 -0.157s lb/gal fuel (where s is fuel sulfur content),and PM -0.1011 grams per brake horsepower hour(0.00022 pounds per horsepower hour). For organic HAP emissions- Used medium duty diesel truck emission 15 factors from article by Schauer, et. al., in Environmental Science&Technology of May 15, 1999. The volatile HAP emission factors presented were 0.084 grams per kilometer(g/km) (0.00030 lb/mile) and 0.0016 gikm(0.0000057 lb/mile) for PAHs. The ducted and process fugitive emissions estimates presented in Tables 1,2,7,and 11 are based on the following additional assumptions: • 84,800 ton/yr of new aggregate for batch mix plant. • 10,000 ton/yr of recycled pavement for batch plant. • 1.25 million gallons (5,200 tons) of asphalt for batch plant. • 150,900 ton/yr of new aggregate for drum mix plant. • 40,000 ton/yr of recycled pavement for drum mix plant. • 2.5 million gallons (10,400 tons) of asphalt for drum mix plant. • Two 18,000-gallon asphalt storage tanks. • Five open conveyor transfer points for new aggregate. • Front end loader travel over unpaved roads of 0.25 mile per ton of RAP used. • Vehicle travel over paved roads of 1.5 miles per 25 tons of HMA produced. • Vehicle idling time of 128,000 min (an average of 4 trucks in line during the average 8-minute load-out time) for batch plant. • Vehicle idling time of 72,000 min (an average of 6 trucks in line during the average 1.5-minute load-out time) for drum mix plant. 2.4 EMISSION INVENTORY FOR TYPICAL HOT MLY ASPHALT PLANTS To perform an emission inventory for a typical HIvIA plant, the first step is to identify the types of emission sources and to count the total number of each type of source. The next step is to identify the best emission estimation tools, which include: (1) facility-specific emissions test data; (2)source-specific emission factors; (3)other types of source-specific data, such as mass balance data; (4) emission factors for similar sources; (5)emission factors for sources that are believed to be somewhat similar to the source being considered; and(6) engineering estimates. After selecting appropriate emission estimation tools, activity factors, such as production rates, should be determined for each source so that emissions can be estimated for a specified period of time. The emissions over the specified period of time for each source and pollutant then are summed to complete the emission inventory. Appendix C provides more detailed • information on procedures for performing an emission inventory at an HMA plant. 2.5 EMISSION ESTIMATES FOR TYPICAL HOT MIX ASPHALT PLANTS Tables 1 and 2 present annual estimates of emissions of criteria pollutants and HAPs for typical batch mix and drum mix HMA plants,respectively. The estimates presented in these tables account for the most significant emission sources at each type of facility. Tables 5 through 12 present more detailed annual emission estimates for typical batch and drum mix HMA plants. Table 5 summarizes the estimated emissions from a typical batch mix plant dryer,hot screens, and mixer. Lncluded in the table are estimates for criteria pollutants as well as specific PAHs,volatile HAPs,and metal HAPs for which emission factors were developed. Estimated annual criteria pollutant, PAH and volatile HAP emissions from typical batch mix plant load-out operations and asphalt storage tank are summarized in Tables 6 and 7. Tables 8,9, 10, and 11 summarize the estimated annual emissions from a typical drum mix plant dryer,load-out operations, silo filling operations,and asphalt storage tank respectively. These tables includes estimates for criteria pollutants, PAHs,volatile HAPs, and metal HAPs for which emission factors were developed. Finally,Table 12 presents estimates of fugitive emissions from loaded trucks(yard emissions) for a typical 16 batch mix and drum mix plant. The emissions estimates presented in Tables 5 through 12 are based on the emission factors developed for the HMA industry and the following assumptions: • Batch mix plant and drum mix plant dryers are fueled with either natural gas or fuel oil. It is estimated that between 70 and 90 percent of HMA plants use natural gas,although some HMA plants use fuel oil as an alternative to natural gas. As shown in Tables 5 and 8, fuel oil-fired mixers and dryers have higher emissions of SO2,NOx, and some HAPs. • Batch mix plant dryer, hot screens,and mixer and drum mix plant dryer emissions are controlled with fabric filters. • PM emissions from load-out and silo filling are entirely PM-10. (However,the organic portion of these emissions also can be assumed to be PM-2.5. Information is available in AP-42 Appendix B.1,Particle Size Distribution Data and Sized Emission Factors for Selected Sources, for categorizing the inorganic or filterable PM into PM-10 and PM-2.5 fractions.) • Average asphalt loss on heating is-0.5 percent(asphalt volatility). • Average HMA load-out temperature is 325°F. • The typical HMA plant has two asphalt storage tanks that are 50 feet long and 8 feet in diameter. It is estimated that these storage tanks require a total heating capacity of about 200,000 Btu/hr, based on a heat loss of 60 Btu/ft-2 of tank surface area. The asphalt storage tanks are kept at 325°F continuously for the five months the HMA plant operates. As a result, 720 million Btu are used to maintain the temperature of the asphalt in the storage tank. For a gas-fired hot oil heater, 720,000 ft' of gas is combusted. For an oil-fired hot oil heater, 5,100 gallons of fuel oil are combusted. It should be noted that this fuel usage is about 3 percent of the fuel used in a typical batch mix plant and 1.6 percent of the fuel used in a typical drum mix plant. TABLE 3. MATRIX OF EMISSION FACTORS DEVELOPED FOR HMA SOURCES Plant type Source Criteria pollutants HAPs Other pollutants Batch mix Dryer, hot PM-10,NOx, CO. 24 organic HAPs CO, screens, and SO2, VOC 9 metal HAPs 4 other organics mixer 3 other metals Hot oil heaters 22 organic HAPs • Load-out PM, CO, VOC, 41 organic HAPs 3 other organics Yard emissions VOC 19 organic HAPs Drum mix Dryer PM-10,NOx,CO, 58 organic HAPs CO2 SO2, VOC 11 metal HAPs 15 other organics, 6 other metals Hot oil heaters 22 organic HAPs Load-out PM, CO, VOC 41 organic HAPs 3 other organics Silo filling PM,CO, VOC 28 organic HAPs 3 other organics Yard emissions VOC 19 organic HAPs 17 TABLE 4. LOCATIONS OF SUPPORTING DATA FOR EMISSION FACTORS Plant Appendix A Appendix B Type Source Pollutant Table Appendix B Section Table Batch Dryer, PM-10 11.1-1, 11.1-2 4.2.4.3.1-4.2.4.3.6 4-19 Mix hot screens, CO 11.1-5 4.2.4.3.7 4-20 mixer CO2 11.1-5 4.2.4.3.8 4-20 NOx 11.1-5 4.2.4.3.9 4-20 SO2 11.1-5 4.2.4.3.10 4-20 TOCVOC/methane 11.1-6 4.2.4.3.11,4.2.4.3.12 4-20 Speciated organics 11.1-9 4.2.4.3.12-4.2.4.3.15 4-22 Trace metals 11.1-11 4.2.4.3.16 4-21 Drum Dryer/mixer PM-10 11.1-3, 11.1-4 4.2.4.1.1-4.2.4.1.6 4-14 Mix CO 11.1-7 4.2.4.1.7 4-15 CO2 11.1-7 4.2.4.1.8 4-15 NOx 11.1-7 4.2.4.1.9 4-15 SO, 11.1-7 4.2.41.10 4-15 TOC/VOC/methane 11.1-8 4.2.4.1.11 4-15 HCl 11.1-8 4.2.4.1.18 4-17 Speciated organics 11.1-10 4.2.4.1.12-4.2.4.1.15, 4-17 4.2.4.1.19 Dioxin/furans 11.1-10 4.2.4.1.17 4-17 Trace metals 11.1-12 4.2.4.1.16 4-16 Batch Hot oil Organic pollutants 11.1-13 4.2.4.2 4-18 or heater Drum Load-out PM, organic PM, 11.1-14 4.4.4 4-27 to 4-37, Mix TOC, CO,speciated 11.1-15 4-43,4-44 organics 11.1-16 Silo filling PM, organic PM, 11.1-14 4.4.4 4-38 to 4-44 TOC, CO, speciated 11.1-15 organics 11.1-16 Asphalt Speciated organics 11.1-15 4.4.5 4-43,4-44 storage 11.1-16 Yard Speciated organics 11.1-15 4.4.6 4-45,4-46 emissions 11.1-16 — 18 TABLE 5. ESTIMATED ANNUAL EMISSIONS FOR A TYPICAL BATCH MIX PLANT DRYER, HOT SCREENS,AND MIXERa Oil-fired dryer f Natural gas-fired dryer Pollutant Emissions, lb/yr Criteria Pollutants PM-l0 2,700 2,700 VOC 820 820 CO 40,000 40,000 SO2 8,800 460 NO, 12,000 - 2,500 PAHs(semi-volatile HAPs) Naphthalene 3.6 3.6 2-Methylnaphthalene 7.1 7.1 Acenaphthene 0.090 0.090 Acenaphthylene 0.058 0.058 Anthracene 0.021 0.021 Benzo(a)anthracene 0.00046 0.00046 Benzo(a)pyrene 0.000031 0.000031 Benzo(b)fluoranthene 0.00094 0.00094 Benzo(g,h,i)perylene 0.00005 0.00005 Benzo(k)fluoranthene 0.0013 0.0013 Chrysene 0.00038 0.00038 Dibenz(a,h)anthracene 0.0000095 0.0000095 Fluoranthene 0.016 0.016 Fluorene 0.16 0.16 Indendo(1,2,3-cd)pyrene 0.00003 0.00003 ,�. Phenanthrene 0.26 0.26 Pvrene 0.0062 0.0062 Total PAHs 11 11 Volatile HAPs Acetaldehyde 32 32 Benzene 28 28 Ethylbenzene 220 220 Formaldehyde 74 74 Quinone 27 27 Toluene 100 100 • Xylene 270 270 Total Volatile HAPs 751 751 Metal HAPs Arsenic 0.046 0.046 Beryllium 0.015 0.015 Cadmium 0.061 0.061 Chromium 0.057 0.057 Lead 0.089 0.089 Manganese 0.69 0.69 Mercury 0.041 0.041 Nickel 0.3 0.3 Selenium 0.049 0.049 Total metal HAPs 1.35 1.35 ' Dryer,hot screens,and mixer controlled by fabric filter producing 100,000 tons of hot mix asphalt per year. Between 70 and 90 percent of HMA is produced using natural gas;most of the remaining HMA is produced using fuel oil. 19 TABLE 6. ESTIMATED ANNUAL EMISSIONS FOR TYPICAL BATCH MIX PLANT LOAD-OUT OPERATIONSa Pollutant I Emissions,Ib/vr Criteria Pollutants PM-10 52 VOC 391 CO 135 PAHs(semi-volatile HAPs) Acenaphthene 0.089 Acenaphthylene 0.0095 Anthracene 0.0239 Benzo(a)anthracene 0.0065 Benzo(b)fluoranthene 0.0026 Benzo(k)fluoranthene 0.00075 Benzo(g,h,i)perylene 0.00065 Benzo(a)pyrene 0.00078 Benzo(e)pyrene 0.0027 Chrysene 0.035 Dibenz(a,h)anthracene 0.00013 Fluoranthene 0.017 Fluorene 0.26 Indeno(1,2,3-cd)pyrene 0.00016 2-Methylnaphthalene 0.81 Naphthalene 0.43 Pervlene 0.0075 Phenanthrene 0.28 Pyrene 0.051 Total PAFIs 2.02 Other semi-volatile HAPs Phenol I 0.40 Volatile HAPs Benzene 0.22 Bromomethane 0.040 2-Butanone 0.20 Carbon disulfide 0.054 Chloroethane 0.00087 Chloromethane 0.062 Cumene 0.46 Ethylbenzene 1.16 Formaldehyde 0.37 n-Hexane 0.62 Isooctane 0.0075 Methylene chloride 0.00 Methyl tert-butyl ether 0.00 Styrene 0.030 Tetrachloroethene 0.032 Toluene 0.87 1,1,l-Trichloroethane 0.00 Trichloroethene 0.00 Trichlorofluoromethane 0.0054 m-/p-Xylene 1.70 o-Xylene 0.33 Total volatile HAPs 6.18 'Uncontrolled emissions from 100,000 tons of hot mix asphalt per year. 20 TABLE 7. ESTIMATED ANNUAL EMISSIONS FOR TYPICAL BATCH MIX PLANT ASPHALT STORAGE TANKa Pollutant I Emissions,lb/yr Criteria Pollutants PM-10 ND VOC 32 CO 3 PAHs(semi-volatile HAPs) Acenaphthene 0.0027 Acenaphthylene 0.0010 Anthracene 0.00092 Benzo(b)fluoranthene 0.00051 Fluoranthene 0.00022 F1uorene 0.00016 Naphthalene 0.087 Phenanthrene 0.025 Pvrene 0.00016 Total PAHs 0.12 Volatile HAPs Benzene 0.010 Bromomethane 0.0016 2-Butanone 0.012 Carbon disulfide 0.0051 Chloroethane 0.0012 Chloromethane 0.0074 Ethylbenzene 0.012 Formaldehyde 140 • n-Hexane 0.032 Isooctane 0.000099 Methylene chloride 0.000086 Phenol 0.00 Styrene 0.0017 Toluene 0.020 m-/p-Xylene 0.061 o-Xylene 0.018 Total volatile HAPs 140 a Uncontrolled emissions from plant producing 100,000 tons of hot mix asphalt per year. Includes emissions from oil-fired hot oil heaters. All calculated PAH emissions and almost all of the formaldehyde emissions are from the oil-fired hot oil heater. 21 TABLE 8. ESTIMATED ANNUAL EMISSIONS FOR A TYPICAL DRUM MIX DRYERa No.2 fuel oil-fired dryer I Natural gas-fired dryer Pollutant Emissions,lb/vr Criteria Pollutants PM-10 4,600 4,600 VOC 6,400 6,400 CO 26,000 26,000 5O2 2,200 680 NO, 11,000 5,200 PAHs(semi-volatile HAPs) 2-Methylnaphthalene 34 15 Acenaphthene 0.28 0.28 Acenaphthylene 4.4 1.7 Anthracene 0.62 0.044 Benzo(a)anthracene 0.042 0.042 Benzo(a)pyrene 0.0020 0.0020 Benzo(b)fluoranthene 0.020 0.020 Benzo(e)pyrene 0.022 0.022 Benzo(g,h,i)perylene 0.0080 0.0080 Benzo(k)fluoranthene 0.0082 0.0082 Chrysene 0.036 0.036 Fluoranthene 0.12 0.12 Fluorene 2.2 0.76 Indeno(1,2,3-cd)pyrene 0.0014 0.0014 Naphthalene 130 18 Perylene 0.0018 0.0018 Phenanthrene 4.6 1.5 Pyrene 0.60 0.11 Total PAHs 180 37 Volatile HAPs Isooctane 8.0 8.0 Hexane 184 180 Benzene 78 78 Ethylbenzene 48 48 Formaldehyde 620 620 Methyl chloroform 9.6 9.6 Toluene 580 30 Xylene 40 40 Total volatile HAPs 1,568 1,020 Metal HAPs Lead 3 0.12 Mercury 0.52 0.048 Antimony 0.036 0.036 Arsenic 0.11 0.11 Beryllium 0.000 0.000 Cadmium 0.082 0.082 Chromium 1.1 1.1 Manganese 1.5 1.5 _ Nickel 12.6 12.6 Selenium 0.070 0.070 Total metal HAPs 19 16 ' Dryer controlled by fabric filter producing 200,000 tons of hot mix asphalt per year. Between 70 and 90 percent of HMA is produced using natural gas;most of the remaining HMA is produced using fuel oil. 22 TABLE 9. ESTIMATED ANNUAL EMISSIONS FOR TYPICAL DRUM MIX PLANT LOAD-OUT OPERATIONSa Pollutant I Emissions,lb/yr Criteria Pollutants PM-10 104 VOC 780 CO 270 PAHs(semi-volatile HAPs) Acenaphthene 0.177 Acenaphthylene 0.0191 - Anthracene 0.0477 Benzo(a)anthracene 0.013 Benzo(b)fluoranthene 0.0052 Benzo(k)fluoranthene 0.0015 Benzo(g,h,i)perylene 0.0013 Benzo(a)pyrene 0.00157 Benzo(e)pyrene 0.0053 Chrvsene 0.070 Dibenz(a,h)anthracene 0.00025 Fluoranthene 0.034 Fluorene 0.53 lndeno(I,2,3-cd)pyrene 0.00032 2-Methylnaphthalene 1.62 Naphthalene 0.85 Pervlene 0.015 Phenanthrene 0.55 Pyrene 0.10 Total PAHs 4.05 Other semi-volatile HAPs Phenol I 0.80 Volatile HAPs Benzene 0.43 Bromomethane 0.080 2-Butanone 0.41 Carbon disulfide 0.11 Chloroethane 0.0017 Chloromethane 0.12 Cumene 0.91 Ethylbenzene 2.3 Formaldehyde 0.73 n-Hexane 125 Isooctane 0.015 Methylene chloride 0.00 Methyl tert-butyl ether 0.00 Styrene 0.06 Tetrachloroethene 0.064 Toluene 1.74 1,1,I-Trichloroethane 0.00 Trichloroethene 0.00 — Trichlorofluoromethane 0.011 m-/p-Xylene 3.40 o-Xylene 0.66 Total volatile HAPs 12.35 'Uncontrolled emissions from 200,000 tons of hot mix asphalt per year. 23 TABLE 10. ESTIMATED ANNUAL EMISSIONS FOR TYPICAL DRUM MIX PLANT SILO FILLING OPERATIONSa Pollutant I Emissions, lb/yr Criteria Pollutants PM-10 120 VOC 2,400 CO 240 PAHs(semi-volatile HAPs) Acenaphthene 0.24 Acenaphthylene 0.0071 Anthracene 0.066 Benzo(a)anthracene 0.028 Benzo(e)pyrene 0.0048 Chrysene 0.11 Fluoranthene 0.076 Fluorene 0.51 2-Methylnaphthalene 2.7 Naphthalene 0.92 Pervlene 0.015 Phenanthrene 0.91 Pyrene 0.11 Total P_AHs 5.8 Other semi-volatile HAPs Phenol I 0.00 Volatile HAPs Benzene 0.78 Bromomethane 0.12 2-Butanone 0.95 Carbon disulfide 0.39 Chloroethane 0.095 Chloromethane 0.56 Ethylbenzene 0.93 Formaldehyde 17 n-Hexane 2.4 Isooctane 0.0076 Methylene chloride 0.0066 Styrene 0.13 Toluene 1.5 m-/p-Xylene 4.6 o-Xylene 1.4 Total volatile HAPs 31 a Uncontrolled emissions from 200,000 tons of hot mix asphalt per year. 24 TABLE 11. ESTIMATED ANNUAL EMISSIONS FOR TYPICAL DRUM MIX PLANT ASPHALT STORAGE TANKa Pollutant I Emissions, lb/yr Criteria Pollutants PM-10 ND VOC 64 CO 6 PAHs(semi-volatile HAPs) Acenaphthene 0.0027 Acenaphthylene 0.0010 Anthracene 0.00092 Benzo(b)fluoranthene 0.00051 Fluoranthene 0.00022 Fluorene 0.00016 Naphthalene 0.087 Phenanthrene 0.025 Pyrene 0.00016 Total PAHs 0.12 Volatile HAPs Benzene 0.020 Bromomethane 0.0031 2-Butanone 0.025 Carbon disulfide 0.010 Chloroethane 0.0025 Chloromethane 0.015 Ethylbenzene 0.024 Formaldehyde 140 n-Hexane 0.064 Isooctane 0.00020 Methylene chloride 0.00017 Phenol 0.00 Styrene 0.0035 Toluene 0.040 m-/p-Xylene 0.12 o-Xylene 0.036 Total volatile HAPs 140 a Uncontrolled emissions from plant producing 200,000 tons of hot mix asphalt per year. Includes emissions from an oil-fired hot oil heater. All of the calculated PAH emissions and almost all of the formaldehyde emissions are from the oil-fired hot oil heater. 25 TABLE 12. ESTIMATED ANNUAL YARD VOC EMISSIONS FOR TYPICAL BATCH MIX AND DRUM MIX HMA PLANTSa Batch nab Drum mix° Pollutant Emissions, lb/yr Criteria Pollutants PM-10 ND ND VOC 110 220 CO 36 72 PAHs(semi-volatile HAPs) ND - ND Other semi-volatile HAPs Phenol 0.00 I 0.00 Volatile HAPs Benzene 0.057 0.11 Bromomethane 0.011 0.021 2-Butanone 0.054 0.11 Carbon disulfide 0.014 0.029 Chloroethane 0.00023 0.0046 Chloromethane 0.017 0.033 Cumene 0.12 0.24 Ethylbenzene 0.31 0.62 Formaldehyde 0.10 0.19 n-Hexane 0.17 0.33 Isooctane 0.0020 0.0040 Methylene chloride 0.00 0.00 Styrene 0.0080 0.016 Tetrachloroethene 0.0085 0.017 Toluene 0.23 0.46 Trichlorofluoromethane 0.0014 0.0029 m-/p-Xylene 0.45 0.90 o-Xylene 0.088 0.18 Total volatile HAPs 1.6 3.3 a Fugitive VOC emissions from loaded haul truck for eight minutes after completion of load-out. b Uncontrolled emissions from plant producing 100,000 tons of hot mix asphalt per year. c Uncontrolled emissions from plant producing 200,000 tons of hot mix asphalt per year. 26 APPENDIX A AP-42 Section 11.1 Hot Mix Asphalt Plants This page intentionally left blank. • APPENDIX B Emission Factor Documentation for AP-42 Section 11.1 Hot Mix Asphalt Production r This page intentionally left blank. APPENDIX C Chapter 3: Preferred and Alternative Methods for Estimating Air Emissions from Hot Mix Asphalt Plants Emission Inventory Improvement Program(EIIP) July 1996 r f This page intentionally left blank. r. TECHNICAL REPORT DATA (Please read Instructions on reverse before co leting) I.REPORT NO. 2. 3.RECIPIENTS ACCESSION NO. EPA-454/R-00-019 4.TITLE AND SUBTITLE 5.REPORT DATE Hot Mix Asphalt Plants December 2000 Emission Assessment Report b.PERFORMING ORGANIZATION CODE 7.ALTHOR(S) 8.PERFORMING ORGANIZATION REPORT NO. Ron Myers (EPA) Brian Shrager (MRI) Gary Brooks (ERG) 9.PERFORMING ORGANIZATION NAME AND ADDRESS 10.PROGRAM ELEMENT NO. U.S. Environmental Protection Agency 11.CONTRACT/GRANT NO. Office of Air Quality Planning and Standards 68D-98-027 (MRI) Research Triangle Park, NC 27711 68-D7-0068 (ERG) 12.SPONSORING AGENCY NAME AND ADDRESS 13.TYPE OF REPORT AND PERIOD COVERED Office of Air Quality Planning and Standards Office of Air and Radiation 14.SPONSORING AGENCY CODE U.S. Environmental Protection Agency EPA/200/04 Research Triangle Park,NC 27711 15.SUPPLEMENTARY NOTES 16..ABSTR cr The United States Environmental Protection Agency (EPA) Emission Factors and Inventory Group (EFIG) is investigating the Hot Mix Asphalt industry to identify and quantify criteria and hazardous air pollutants(HAP's) emitted from kiln stacks, transport truck loading and silo filling. EFIG obtained over 300 emission tests from kiln stacks that characterize emissions of criteria pollutants and hazardous air pollutants' emissions. EFIG requested that EPA's Emission Measurement Center(EMC)conduct the required testing of the transport truck and silo filling operations. Under separate EPA contracts,Midwest Research Institute (MRI)and Pacific Environmental Services(PES) performed two emissions tests.The primary objective of the testing program was to characterize uncontrolled emissions of the criteria pollutants particulate matter(PM) and total hydrocarbons (THC)and emissions of volatile and semi-volatile organic HAP's including polycyclic organic matter,phenol,benzene,toluene,xylene, ethyl benzene,2-butanone, cumene, formaldehyde, hexane, isooctane and others. The results of the two test reports and responses to comments on these test reports are covered in separate EPA reports(EPA 454/R-00-024, EPA 454/R-00-025 (a through h), EPA 454/R-00-026, EPA 454/R-00-027, EPA 454/R-00-028 and EPA 454/R-00-029). This document characterizes hot mix asphalt plant operations,summarizes emissions from the typical batch mix and drum mix plants,presents emission factors specifically developed for hot mix asphalt plants and presents analyses used to develop the emission factors developed and presents information needed to inventory the emissions at hot mix asphalt plants. 17. KEY WORDS AND DOCUMENT ANALYSIS DESCRIPTORS b.IDENTIFIERS/OPEN ENDED TERMS c.COSATI Field G,o'm Air Pollution control 19.SECURITY CLASS(Report) 21.NO.OF PAGES IS.DISTRIBUTION STATEMENT Unclassified 59_ Release Unlimited 20.SECURITY CLASS(Page) 22.PRICE Unclassified EPA Form 2220.1(Rev.4-77) PREVIOUS EDITION IS OBSOLETE This page intentionally left blank. fy b .j+��, "�K It' lq It W i t , ., , ni Ft `a < a dad < s w, t i''' t, e l 41th._y t a .l rrt v , x tt!. •le ' s El n a� I 1 . By Una Connolly lln art era of communityi contrived, or simply not arc now able to share this nvolvement, it is not unusual for informative. information in ways Thal begin to asphalt plants to be scrutinized by In an effort to clear the air of illustrate just how low they are. the surrounding public. When an misunderstandings, and For instance, a drum mix plant asphalt plant is located close to a communicate more effectively, the producing 200,000 tons of HMA per neighborhood, sometimes neighbors National Asphalt Pavement year was compared to air emissions raise legitimate questions. Although Association's (NAPA) Environmental, from the activities such as the Hot Mix Asphalt (HMA) industry Safety, and Plant Operations following: c,.,s a long record of working with Committee decided to employ a • Residential fireplaces; the U.S. Environmental Protection well-respected firm to compare the • Bakeries; Agency (EPA) to accurately asphalt industry with activities and • Gasoline filling stations; and determine the amount of emissions businesses commonly found in • Fast-food restaurants. from an average asphalt plant, neighborhoods. In an industry with 'these categories were chosen neighbors and others are rarely an enormous amount of sound because of their frequent aware of this effort. technical information, NAPA sought occurrences in neighborhoods and For the past 10 years or more, this an easy to understand way of because well referenced data could industry has worked very hard to communicating this information for he obtained. The data were obtained determine our effects on the those expressing interest. through a variety of sources. environment. (See Chart 1.) It is The analysis of emissions is often including EPA's Clearinghouse for impossible to lay claim to reflected in scientific numbers and Inventories and Emissions Factors environmental stewardship unless methods that are imperative to (CHIEF) on the EPA Technology there has been a sustained and regulators but that have little or no Transfer Network and California diligent effort to understand and meaning to our neighbors or South Coast Air Quality deal effectively with any potential interested others. This often results Management. These types of consequences of our operations on in misinterpretation and references tend to base emission the environment and our neighbors. misperception. NAPA's intent in this estimates on a larger data set than The studies show that 1IMA comparison is to provide emissions would a journal article. facility emissions are typically very information relating to the The study looked at a variety of low and controlled. This statement industry's operations in ways that types and groups of pollutants as a may have little or no validity to a are not misleading, but are accurate basis for comparison. For example, rchbor or others who have both and helpful. Total Organic Compounds (TOC)- legitimate right and a genuine The results are not surprising. any compound that contains a carbon need to be convinced by something This industry already knew that air atom; Volatile Organic Compounds other than technical jargon. In tact, emissions from a properly (VOC)-all organic compounds that some neighbors may perceive that maintained and operated asphalt contribute appreciably to the technical jargon is confusing, plant are low. For the first time. we formation of ozone. NM Mir A.enhall Tnehnnlnnv—.un?weltcr1ST 9nni•91 70f) .. 1 he results of the comparison :: study bring legitimacy to a view k'x° that H`IA facilities typically L 500 PA 'ruck I.4,ithwii Alma JAN) produce very low emissions and are 400 . =r= ` ' well controlled. It Is clear that ini�n r�r,�u r.+�m;ur emissions from HMA facilities are 2(X) .:'i lower than or comparable to many consumer-oriented activities. The f?f) • • / fol[MI rig scenarios represent () • l,47 664.._: - emission levels that are comparable to the yearly releases of one typical 751),(100"funs of Annual Production HMA plant: • VOC emissions from one (1) bakery operating for about two weeks: • VOC emissions from 1:i residential fireplaces during the course of one year; • TOC; emissions from 12 gas filling stations during the course of one year; and • TOC emissions from 27 fast-food restaurants during the course of one year. • -Toluene emissions from one gas filling station operating for five months. .-. One cannot help but be impressed with the fact that the VOC emissions from an I IMA facility producing 2(X), 0(0 tons of 11MA in one year would be equivalent to one bakery operating for about two weeks of that year. I IMA facilities offer a lot to our communities. Hopefully, this kind of information will assist us in our efforts to communicate effectively with our neighbors and others who have a genuine interest in our operations. .after all our neighbors and the public arc the judge as to whether we have truly achieved a level of openness and genuineness in our efforts to demonstrate environmental responsibility including being responsive to their concerns. Contact NAPA's enironmental staff for more information and assistance on this subject. [�kr Ohl[:u1»u)!h•h .\=.-lPA's Director of Environmental and Safe't►'St'rrit C.c. Her e-mall tiililrem i.s ttt'otutollltt'hotifix.ors. r r �A 70. t •I' •t. III $t �� 3( •; i '1 Rll. 10 g '1.'4•:.:i! y# IA ( t s s+ SF ,, ' 1-'a .,p aaiu 4. :T"..;.,: r,'.;r , 3:t.t 2 4 rtt 1 1 p l' t1 `i ' �, ;7•. i• d . •r� < [ ?et yr ;. it ,-.,..!✓i!; r -e �.., r i F•li ,,,,,,v..'„ y , �a r ', 4 . By Mary Stroup Gardiner, Ph.D., Associate Professor of Civil Engineering, and Cliff Lange, Ph.D., Associate Professor of Civil Engineering, Auburn University;Principal Investigators for NCAT on Emissions/Odor Minimization Project. eing a good neighbor and is used to determine the presence of asphalt sample was replaced with IS responsible operator takes more than 70 individual odor grams of 6 mm glass beads that are on new meaning in today's compounds that are then grouped coated with enough asphalt to populous and demanding into one of seven general odor provide an average film thickness audience. In today's groups,each with similar between 10 and 14 microns. operating and business characteristic odors and generally The last column in Table 1 shows environment, any similar odor threshold that there is a wide range of odor perceived impact on our concentrations(Table 1). compound production for each of ,^ neighbors,our employees or the GC testing is traditionally the odor groups. However, when public is serious and must be treated conducted by placing a small bulk the data is viewed on a regional as such. Looking to the future,the sample in a glass vial,brought to basis, the range is typically very National Asphalt Pavement the desired test temperature, and narrow.This suggests that prevalent Association(NAPA)and the State the gaseous material in the odor volatile organic compounds Asphalt Pavement Associations have headspace automatically sampled (VOCs)are most likely dependent set out to provide contractor and analyzed. However, initial GC upon a given crude slate typically members with some problem- investigations showed that the used in each region of the U.S. It is solving tools with the objective of amount of odor compounds also likely that what generates the minimizing odor and emissions. measured at any one of several test perception of odor in one region Ongoing work at Auburn temperatures was dependent upon may or may not be the same in University's National Center for the film thickness of the asphalt. another region. Differences between Asphalt Technology(NCAT)is That is,the smaller molecular sizes asphalt odors in the same region are focused on(1)minimizing visible move more easily through the most probably due to subtle emissions through the development asphalt film than do the larger ones. differences in the concentrations of of practical, reliable test methods, In order to incorporate this factor key individual odor groups for that and contractor tools for optimizing into the testing program,the bulk region. Hot Mix Asphalt temperatures and (2) minimizing odor-causing compounds by the appropriate Table 1—Odor groups,their typical range of odor threshold concentration, selection of odor-reducing additives. and ranges of the groups found in the asphalts tested to date. The approach is to quantify key Odor Group Odor Threshold Concentration Ranges Found in Asphalts Tested source asphalt chemistries related to to Date(Test Temperature 338`F) both visible and odorous emissions, 0G1 0.1 -1 mg/m 11 -68 mg/gram/hour supported by relatively quick and 062 4.5 mg/m' 18 to 82 mg/gram/hour simple process control tests for use 0G3 1 -180mg/m 16 to 40 mg/gram/hour r' in contractor field labs. 0G4 3.200 mg/nv 7-32 mg/gram/hour - - 065 300 mg/m' 0 to 32 mg/gram/hour Odor Groups 066 300-500 mg/m' 9 to 122 mg/gram/hour Gas chromatograph(GC)analysis 067 500 875 mg/m' 122 to 730 mg/gram/hour 20•Hot Mix Asphalt Technology-MARCH/APRIL 2002 Effect of Temperature on Odor Reducers— Odor Compounds Masking or Reactive? •'"^'kolu.rr 1 •'M•`FloWoo B 150 Examples ----- of the effect of test One of the initial , ,, , , temperature 1266, 302, 338,and questions asked at the u 125 r ' gyp_ ,,.,,,, 374'F(130, 150, 170, and 190°C)j beginning of the 1g' - • on the generation of individual odor research was, "Are the X 100 ' R .,..;« c / ki compounds are shown in Figure 1. odor additives being .o E is • -a• For instance, only a limited amount tried by industry simply C El Fr-4 of odor group compound OG-6T is masking the odor or are I a 50 generated at 266`F, but this amount they reacting with the. C = more than doubles once the asphalt?" GC:analyses j 2- • temperature reaches or exceeds of 10 asphalts selected C 0 302.E Further increases in from five regions of the25 50 75 100 125 150 temperature have little effect on the country with a range of amount of the OG-6T compound odor additives and each O61 Rate,No Odor Reducers,up,/gram/ht produced. Some compounds, such of two concentrations as OG7-O, have a threshold typically used in field "'°°°c""`"""a`^"°'Odor A"°°`"' 19a.a Tell Temperature temperature below which little or trials showed that at no detectable amounts of odor least two of the odor additives Figure 2—Examples of the effect of odor compounds are measured. A consistently reduced the production reducers on the production of odor groups. threshold temperature between of odor compounds (Figure 2). In all 302`17 to 338'F is commonly seen. cases, the ability of the odor in the odor group. This reduction in Other compounds appear to be additive to reduce the production of odor compounds through the use of generated at increasingly higher the odor group is dependent on the specific odor additives is typical of rates for incremental changes in initial concentration of the odor the majority of the other odor temperature beyond the threshold group in question. In the case of groups. (OGk-O and O66-BB). Lastly, some OG I, if there is a low amount compounds, such as the O61-BM, produced in the first place, odor Do Odor Reducers Really React have a threshold temperature value additives have little effect. However, With the Asphalt? (usually between 266 and 302'F) an odor group generation rate of A review of the suspected followed by a generally linear 100 mg per grain of asphalt is reactive compounds in the odor increase in generation rates. reduced to about 60 mg per gram reducing additives suggests that per hour when one of two odor they would be more reactive with Figure 1 -Examples of the effect of reducers is used. In general, there is oxygen than asphalt compounds. temperature on the production of individual about a 40 to 50 percent reduction This observation led to the odor V0C compounds. hypothesis that odor reducers are acting as oxygen scavengers. That •374F IN 338F ■302F ■266F is, the odor reducers actually limit 125 oxidation of the asphalt and thereby reduce the production of the odor compounds. This hypothesis was evaluated by 100 conducting the GC analysis both in the presence of air and under a to nitrogen purge. Figure 3 shows that y 75 the production of OG7-O and OG1- E KM under a nitrogen purge are m about half that in air. OG6-X `u 50 production is below the detectable limit while OG6-BB production is reduced by about 25 percent when 25 nitrogen-purged.These reductions 1 ILin odor compound production rates ate similar to those generally seen 0IIII when using the two most effective O66-T OG7-O OG6-BB OG1-BM odor reducers. Further work is in '•Th progress to evaluate this hypothesis. Hot Mix Asphalt Technology-MARCH/APRIL 2002.21 • Emissions continued IInAir eNknpienI'urkr Figure 3- IOU Examples of 170C'Test Tcm}xriiurc reduction in odor .JOiS for Contractors to Use in MO i compound production Minimizing Emissions with and without GC analyses can be useful in "' oxygen in the air. understanding the factors in the generation and minimization of r "' odors during HMA activities. s 20 I towever, (:GC analysis is not useful L for the day-to-day testing needed I 1(i for control of emissions and opacity 0,:74) (166-x O:6.as O(-BM during normal production of HMA. To overcome this obstacle, a simple Figure 4- smoke and emissions potential •' g ..,.. o ' Example of results (SEP)oven prototype was developed from prototype smoke for this study.The oven is capable s t _ and emissions oven of measuring the mass loss of a ,' asphalt with time and s s simultaneously measuring opacity E changes due to smoke production < 1 w / in the oven chamber. Roth of these • _ measurements can provide quick . and simple guidance for the plant operator as to when a critical temperature in HMA production • . has been reached. Figure 4 shows measurements for two asphalts country.The mass loss rate increases /ate mass loss rate and the opacity from the same region of the with increasing temperature for s EMISSio S continued relation to temperature is similar may be helpful in setting process for asphalts from the same region control limits to assist with the but varies widely between parts of problem. For instance,Asphalt it both asphalts but the rate is higher the country,absolute values for generates few complaints when the for Asphalt A as compared to Asphalt mass loss for identifying critical plant is operated at a temperature of B. It was also noted that Asphalt A temperatures cannot be used. 338"F,which corresponds to a has reported odor and visible However, historical information maximum mass loss rate of about emission problems while Asphalt B about odor complaints in a given 0.018 grams;minute. If Asphalt A generates few complaints. locale taken in relation to the were used instead, the plant Since the mass loss rate in characteristics of a given asphalt temperature would need to be reduced by about 10'F to maintain a similar mass loss rate. Using a similar approach to adjust for visible emissions, the plant temperature would need to be reduced by at least 1S"F. Potentially,these tools will provide a basis for identifying effective plant process control parameters that will allow for minimization of visible emissions and odor while producing a quality HMA product. Previous research by BP Amoco has identified the Penske-Marten flash point test as a quick means ot identifying relative emissions potential.A preliminary evaluation of this test indicates it may also he a useful contractor's tool for monitoring changes in emissions potential.Work with this test is promising but inconclusive at this time. Conclusions GC.analyses can he a useful tool in defining source properties of asphalts in relation to odor where the opportunity occurs.Once the candidate odor sources are identified, appropriate odor reducing additives and concentrations may he determined. In addition, the SEP test can be used to help the plant operator identify temperatures that will assist with minimizing smoke or odor emissions.This test can also be used to monitor changes in asphalt character that would substantially impact operations.The Penske- Marten flash point test appears to also hold some promise as a field laboratory tool for purposes of monitoring significant changes in emissions character. It is still under evaluation. OBE Keepiiig • Y fs Iw J . ' .,_.f.. n, t.. .as. .. r .., " *t tt„,I 'r_._,.r . 711'' '''' '). .' ,- / \ ,::.:1 Hy.Mary Lou/cry ,: mericans in communitiesA 4 large and small have _ __ become more concerned ! 1 - ..h about the safety of our land r and of our water supplies. `c' - . rlr, So when it comes to the • .- storage of chemicals or the r ,t_/It/r. recycling of possible contaminants, .m -, -0.4 .d""' .. +". .. they want assurances that these - ajy�' • materials are contained as securely ;. '_ ,F•,•• as possible. Ilot Mix Asphalt, used as untainted s a liner in landfills, drinking water in color, smell, or taste is • servoirs, and sewage treatment essential to a community's peace of iii" ,.omds, provides that protection in mind. :u economical and effective way. HMA is non-reactive, adds Dr. .'%Meth t'j "Asphalt provides an Newcomb. "It's not subject to impermeable surface—liquids are corrosion or reaction with a lot of not going to now through it, so it other materials. It's resistant to precludes any contamination of acid and to sulfate attacks." s....- ground water." explains David E. Asphalt can handle difficult-to- Newcoutb, Pk., Ph.D., NAPA's Vice store toxic materials like sludge, - - President of Research &Technology. brine, and coal slurry. It safely HMA used for liners is made to stores—without chemically different specifications from that altering—whatever materials are produced for highway construction: put into a containment system.the mix includes a higher percentage of asphaltic binder, the material is A Long-Lasting Solution more densely compacted at the site. The initial cost of an HMA and the air voids are kept at less liner is usually greater than than 2.s percent swell within today's natural clay or fabric membrane installation capacities).This virtually liners, but the difference is worth eliminates any porosity. it, as its performance over the Asphalt also makes an especially long run makes clear. HMA is inert good choice for drinking water and stable; clay liners, on the other reservoirs, where keeping water hand, tend to break down and lose Hot Mix Asphalt Technology-SEPTEMBER/OCTOBER 2000.29 1'` KcepiugItClean—• and lagoons, uniformly covering integrity by humps and mounds along the I IMA's adaptability—its ability to bottom and sides without any withstand freeze-thaw cycles in the their leak-proof properties over the problem. That means faster north, perform in blazing hot long term. Membrane liners may installation, with less time required conditions in the south, and survive leak, allowing liquids to leach out. for site preparation work. DMA also the small tremors often felt on the This can encourage vegetation to makes it easier to build reservoirs West Coast •—make it an ideal take root below and behind a liner, with irregular shorelines,giving the material to use in all parts of the eventually causing more leaks and area a more natural look and country, sometimes clogging the interior of making it more aesthetically the pond, lagoon, or reservoir. appealing. (While fabric membranes HMA at Work People who see cracking on can also assume the shape of the 11'hile we may think of asphalt roadways sometimes express ground, over the king term they're as a new invention, builders have concerns about asphalt's longevity much MOW susceptible to puncture actually used sonic form of it for and its ability to prevent leaks, but and to holes caused by constant thousands of years, mostly as a I)r. Newcomb says that's not a abrasion.) water-proofing material. Ancient problem. Traffic and oxidation, Asphalt liners are smooth, boat builders used asphalt in its which cause wear and tear on road making them easy to clean. They're natural form —called pitch —to surfaces, are not factors that have also strong—there's no trouble caulk their vessels; early builders to be considered in liner getting heavy equipment in and out used it to weatherproof the roof applications, of the liners. and caves of their homes. "When the liner is covered with "Another advantage to asphalt is Egyptians used asphalt to mortar water, it's not going to age to any its ability to remain flexible," hr. together rocks placed along the great extent," 17r. Newcomb notes. Newcomb adds. "This allows it to bank of the Nile to prevent conform to things like gradual erosion. Residents of ancient Asphalt Offers Flexibility settlement beneath a pond. When Mesopotamia and the Indus Valley, Unlike rigid liners, DMA literally certain shifts take place in the and later the Romans, used it to "goes with the flow," fitting to the subsoil, asphalt can usually waterproof temple baths and water curves and undulations of ponds accommodate it without losing its tanks, laday,these qualities of asphalt a • in Utah. the have once again made it a prime .L , .:'''+i..'. �1 l)epartnu'nt of choice for communities that want to Transportation keep chemicals contained and water "" has found that pure. The L:1':\ has listed LIMA as an salt detention acceptable liner for sanitary -"--.., basins made of landfills. Trite Ll'A has banned the . dense-graded use of clay as a primary liner for asphalt mixes both sanitary and haiardous waste ensure negligible landfills, however.since it salt intrusion into believes that pollutants enter the the underlying pore structure of the clay and ground water. The eventually work their way through.) utility from ---•,..--..-:,.,, department will be Time and time again, EIMA has refuse.The garbage it uses using this mixture for proven its ability to perform contained so many jagged edges such basins. effectively: and abrasives that other liners There are similar stories all over • In Pennsylvania.where the state soon wore through. When the the country.Taken together, they has been a leader in setting up agency finally tried an asphalt demonstrate that asphalt liners can "closed loop" treatment systems.A liner they found it lasted up to provide what people want —a sate secondary pond collects leachates three tines longer than any other and effective way of keeping their drained from the bottom of the material---and in the long run, it communities fret'from pollution primary pond. l'he leachates are was five tunes less expensive! and contamination. MOM then kept and released from there • Kentucky coal mines use asphalt Mary Lou la}'is a freelance writer .. . or sprayed back over new effluents for coal storage piles at terminals. based in I u,nonivan, Wayland. in the primary pond. I IMA lines The asphalt keeps the coal in, Fora Lope of N.41'.1\brochure, both ponds. prevents it from absorbing Asphalt for Environmental Liners, • In Ames. Iowa, the Solid Waste ground moisture,and provides a contact s'.-LI!a's Publications Resource Recovery System load-bearing surface for trucks to Coordinator at 888-448-6499 or order produces fuel for an electric get in and out. online at wtvmhohni,v,wt, National Asphalt Pavement Association Tests Show Very Low Emissions Le els F Silos and Truck Load - Out Thanks to a proactive response by requested assistance in responding to fugitive emissions from truck load out. NAPA and industry partners. technical issues raised by citizen groups. (The alternative would have been to concerns raised by citizen's groups NAPA agreed to partner with EPA in a test construct a temporary enclosure at a about air emissions during truck program to measure emissions during actual significant cost to the test program.) load-out are being laid to rest.Data from load-out operations. In 1996 and early 1997,NAPAs emissions tests conducted at HMA plants by the U.S. EPA provided state-of-the-art emissions task force visited and reviewed several Environmental Protection Agency(EPA)in testing equipment that can capture, potential test.sites,and proposed a drum )artnership with NAPA prove conclusively collect and measure emissions during mix plant.in Southern California where that truck load-out and silo emissions levels load-out.The test method can search for the load-out facilities are enclosed are very low.Emissions are dramatically up to 110 individual organic compounds uniquely.The task force chose this plant less than estimates by citizen's groups, and quantify total emissions.In order to because it met 15 of 16 U.S.EPA criteria and far beneath the levels that would procltIe'the most accurate results,however, for such testing,because the drum mix automatically trigger EPA regulation under the tests needed to be conducted on an plant design is representative of most the Clean Air Act of 1990(see Figure 1). enclosed truck load-out facility. This plants sold today,and because the In comments on EPAs draft test data would enable the use of standardized majority of U.S.MIA is produced in drum report.NAPA President Mike Acott thanked stack testing procedures to measure mix plants.Choosing this test site allowed EPA for providing the opportunity to prove what would otherwise be uncontrolled. for the most accurate test possible.In that the I lot Mix Asphalt industry is not a"major source"of emissions. EPA is • expected to release the final report on • '-`�; . .. the truck load-out lest.program this ✓"" "w�, winter. NAPA was among about 20 ''.."'" .,� tie industry and citizen groups that filed "'� %.' ± i > pmay.. grow. -oz.-N. : conuurnts on the draft report released a. .. in June lt?99.which contained approxi• iiii\'( �, r7 . _" -'j'.. mately 6.000 pages of test documentation. C.. l• , -Clearly,when issues of public health ' I l l and safety are raised,it is a serious matter I F 4 Is ea and we take it as such."said Gary Fore. 4.l..! `u • . NAPA Vice President,Environment k • - -I. Safety. "We must answer technical t •i quest ions with scientific facts and data ` -.•„w` 'whi rix we ean,;uul be informt,d and -'+ "" '��"0 4,k, 44.istfl filla ow 160 ;7,: • . " responsive to the questions and concerns raised by the public." ve : . ' :..a• p.=•• ._ ' : •_.. 4:11'_1 tx:giilt working on the truck load-outThe unique design of the HMA facility made it an ideal site for the EPA to conduct emissions issue in early 19911,when EPA the air emissions tests. 12 Hot Mix Asphalt Technology—Fall 1999 addition,the site offered climate iuul crews under contract to the P.S. EPA. "G1iea r�l'�f when/ operational advantages that would Approximately 25 people representing support sustained testing over a one-week Pacific Environmental Sciences and 'issues of time period.In 1 Midwest Research Institute seised on t )7, NAPA.through the efforts of the testing crews.Temporary trailers public health Astec. Inc.,performed preliminary testing were set up on site to house the ne'cemauy- to prove the feasibility and usefulness of equipment,instrumentation,and computers. the California facility for future testing. When citizen groups later voiced and safety are The clat.a were shared with both EPA and concerns that batch plants may produce citizen groups.Subsequently, it took about higher emissions than drum mix plants, raised, it is a seven months for EPA and the citizen the Massachusetts Asphalt Pavement groups to agree on testing protocols.After Association assisted in locating a batch se'r'ious matter refinements to the testing protocol,full-scale plant facility in Massachusetts for testing. tests were conducted at the California It was important to test a facility in • facility in July 19f)8. Roth Astec.Inc., Massachusetts,since this would allow and we take i t and Hauck Manufacturing contributed representatives of the concerned citizen ��f crews for a full week's testing. Gail Mize, groups to observe the test.To capture as such. Y Y e Executive Vice President,Astec Inc.,and any uncontrolled load-out emissions at member of NAPA's Emissions Task Force, the Massachusetts site,a tmporaly total MU s t ansi-ver was on site the full week.Gary Fore enclosure and exhaust system was built represented NAPA,and a citizen group around the load-out chute.This temporary technical representative also was present. In enclosure had to meet the same stringent additin, EPA contracted with the design criteria as the California drum mix Research Triangle Institute,a credible facility hi the end,the test data show that questions scientific institution,to provide two emissions from the batch plant were about independent scientists for an on-site the same as from the drumplant(Figure 1). ?.ci th st ies tZfic audit of the entire testing process. The extent and complexity of the mend] The California tests were conducted by colaiuucd on pair 14 facts and data r. 500 where we ca n, Figure 1 400� ___ and be informed and aoo ■ US EPA—Truck = J Load-out(Actual) responsive to H 200�� ■ US EPA — the questions y Silo (Actual) and concerns W •100 ■ Citizen Groups' Estimate Actual Data raised by 0 0.5 1.01 474 Source:D►r{f? ES EPA the public. " 730 K Tons of HMA Produced Annually rest report The tests conducted at HMA plants in partnership with the U.S. Environmental Protection Gary Fore Agency{EPA)prove conclusively that truck toad-out and silo emissions levels are very law. A group of concerned citizens published engineering estimates which projected that an HMA plant producing about 750,000 HMA tons per year would contribute approximately 474 tons of volatile organic compounds(VOCs)annually. The test results show the actual emissions at a 750.000 ton/year production rate are 0.5 tons for truck load-out and 1.01 tons for silos. The average plant in the US produces only 140,000 tons per year, about 19 percent of the 750,000 ton-per-year figure. It follows that the average HMA plant would emit less than 19 percent of the numbers shown above—a very small amount compared to Clean Air Act "Major Source"thresholds of 50-100 tons per year. 13 - National Asphalt Pavement Association continued from pow 1:3 said Gordon[lamer,Barlett Paving Materials, The extent and Inc.,long-standing Chairman of NARA's test effort is unparalleled in the history of Em•ironmental,Safety and Plant Operations our Industry.NAPA estimates that the complex?:ty ('onunittee(ESPO('). entire test.effort cost the government more than$1 million. of the overall In July, 1999, NAPA Emissions Task �1 Force met.to discuss and evaluate the What is a test of f o,�•t is ' recently released draft test data."We were extremely pleased with the test major source?» unparalleled results because they proved what we knew all along—truck load-out opera Title V of the Clean Air Act of 1990 Lions are NOT a source of significant in the levels of emissions,"said Paul Schulz, (CAA)targets the regulation of former NAPA'Task Force Co-Chair.The "major sources"of air emissions. j.� suggest- If a source emits more than the G�is to of Task Force prepared comments threshold quantity,it is termed a ing report improvements,which were "major source."The threshold quantity our ndustl•y. forwarded to EPA in September prior to is spelled out in the('lean Air Act the close of the official comment period. EPA is expected to hold a meeting in based on whether a source of air NAPAestimates emissions is located in a region of December to review the comments the country'that is in attainment with �1 received,after which the final report the entire is to be released.The truck load-out and National Ambient Air Quality(NAAQ) silo data then will be incorporated as standards for a specific pollutant,such test effort cost l'` of EPA's national emissions factors as ozone.For example,in attainment areas where NAAQ standards for ozone guidance document' are met consistently,the threshold for the goventmen t •re a culmination of this test effort volatile organic compounds(VOCs) represents a most significant accomplish- is MO tons per year.In the Northeast Inert.. Not only does it.represent several . (more than years of blood,sweat,and tears on the Ozone Transport Region,most of which is in non-attainment.status.the threshold part of NAPA Members and NAPA staff— $1 million. the effort and the results continue to is 50 tons of VOCs per year. The tests show that we are a responsible Industry." showed that.an Ii14iA plant.producing 750,000 tons of Hot Mix Asphalt per year would emit.0.5 tons per year at !,!.T.: • , ,e1"'4,,..: . ''llarlik. "' 1 t truck load-out and 1.01 tons at the silos. • " Jr, Ni.' ` The primary objective of the truck f/ ' load-out testing was to quantify the h'a �'' 't -`� .. . uncontrolled emissions of VOCs and ` to determine if the levels of truck load- -- Skil ''ns""" out emissions were,in fact,potentially / i.. . •igigi "— •_ high enough to reach"major source" Li:, f thresholds. • As Figure 1 shows,total emissions f VOCs during truck load out.are far .- , , I % �' •l1.et, ' below levels that would qualify HMA I �� z t Plants as a"major source"subject to `"""'° r ,k Fr n°fy}', a , regulation under Title V of the(lean i fix, ;- cy5::±e f r li! _. N� arl. i+ iiL h� t "q; Air Act. 1 :,_ For more information on Clean Air fit# ;. Act issues related to Hot Mix Asphalt • •�. i" +F- i , t' m° .4,:!. Plants,see NAPAs Evaluation of • ;y." '+ Stack f.'nai.rsior)ti f'runt Il:lfA Facility a'-: iflu gp:. . .0 'F°"•"`'. Operations,Special Report 166; c►�R' ,� 4 and Dealing'with Title V Operating ',• ;, ` Permits:the'Synthetic Minor' ,. Alternative,Spwial Report 175; available from the NAPA Publications The EPA utilized state-of-the-art equipment capable of searching for up to Office at 888468-6499. 110 organic compounds and quantifying total emissions. 14 NAPA UPDATE Black enhances green Asphalt association continues to lead environmental crusade By NNlte ACM The National Asphalt Pavement Association ing of seven asphalt plants. Additional tinan- (NAPA) and the hot-mix asphalt (HMA) cial support for the research also came from industry have a track record on environmental HMA producer members whose plants were stewardship that cannot even be approached tested and from equipment manufacturers and by any other industry that I know of. Our other companies in the industry. The EPA- everyday efforts conserve precious natural sponsored testing was estimated to have cost $1.5 million at several HMA facilities around the country. The delisting of asphalt plants was not the first time NAPA and the HMA industry have been recognized in a positive way by our part- • ners at federal regulatory agencies. The National Institute for Occupational Safety and Health (NIOSH) bestowed the first NORA Award on the partnership that put engineering controls on highway-class pavers. NIOSH *,•+► j"fI! h recently affirmed that partnership with a grant - Jot " for the ongoing "phase two' study of the use "" and effectiveness of the systems. Not only does NAPA work effectively with • partners to improve our environmental perfor- i munce, we have a major program within the industry to encourage and recognize continu- ous improvement in this arena. The Diamond Experts say the air quality effects of HMA production hare been Achievement Commendation for Excellence evaluated more thoroughly than those of any other industry. in Hot Mix Asphalt Plant/Site Operations has more than 365 current participants and is resources. minimize the impact of our opera- changing the way America thinks about our tions on the environment and reduce reliance operations. on landfills. Taking a positive approach to potential chal- The continuous process of reducing the lenges,NAPA sponsors research at the Nation- industry's impact on the environment has led al Center for Asphalt Technology on ways to to some astonishing results. For example. in reduce emissions and odors where they may While annual 2002. the I.J.S. Environmental Protection occur. We are gaining new knowledge about Agency declared in two separate actions that asphalt binders and devising new tools for production of HMA production facilities do not have the contractors. HMA paving j potential to be major sources of hazardous air Not only do asphalt pavements provide long- material has pollutants and, further,that all HMA facilities life solutions for highway construction, they together are trivial sources of specific pollu- also are 100% recyclable. In fact, asphalt increased by i tants. These "devsting" actions confirmed pavement is the No. I recycled material in the more than s what we have always believed and what the U.S. Some types of asphalt pavement reduce 250% over the science shows—emissions from HMA plants noise pollution and other environmental con- are very low and well-controlled. cerns. And, while annual production of HMA • past 40 years, Experts say the air quality effects of HMA paving material has increased by more than total emissions production have been evaluated more thor-- 25Oc%c over the past 40 years, total emissions from HMA oughly than those of any other industry in the from HMA plants have dropped by 97%h or country. NAPA. our members and the EPA more in that same period. plants have have funded studies and worked in partnership We have clearly made the case for asphalt as dropped for many years to quantify emissions and add a sustainable material. This is a legacy in by 97% or to the knowledge base about HMA plants. which we can take pride. CO more in that I The investments have been substantial. Over a four-year period in the early 199Os, NAPA ----- same period. itself invested more than $3(X),OO0 in the test- Acott is president of NAPA,Lanham,Md. 24 JANUARY 2003 ROADS B BRIDGES www.ROADS8RIDGES.coM www.beyondroads.com Your complete source of environmental information on asphalt production and use. �^^� _ bevondRoa • s:com --Y. •. R3 t is r h ter,, 2003 Text Site M tdon Contact ar�e (t 8r1F' ` d,41w'Wrtl; A*k s z r ;4 :- `: *'rrevr 'r"E''.., ..! e Asphalt /`� Asphalt Industry ' • Asphalt A phalt Facilities h ' It for ■y� 4e1?Y t : we w:� railbeds are'C851 f tY Nwi i.:44 a ,.._ i �` ` ta�sFoimed into bike and running pati Communities � ;,. - ., Student - Illting hot mix asphalt. r. Teachers y' 7 Legislators e - "+ Ahe... - y'Y.? -. Researchers :b .Journalists beyondRoads.com is your source for information on the asphalt industry,its operations,its products and ik issues,brought to you by the Asphalt Education Partnership(AEP). Take the Quiz New on the Site: Common Myths Tour a Plant Tour an Asphalt Plant-Go on a virtual tour of an asphalt lant and see how as halt is Studies made from start to finish. p p Ask an Expert Desktop Pictures Recipes Asphalt Research Studies-Looking for research data on asphalt?Start with the Studies page under our Explore section. ' UPI Sj jt � ireVls lil )rjl{ )+re} i 1t�,v,it'd ` a" tll } tees" t h<n c ,gig to recewe a T b .R u_ a?r'"' tree newsletter is r -ere re ^'*'."r{g' r*•+ t' rN•Y i T'$; nF"tPi"s' ,. k. em :' ^'I nin t ici 11 T R i e ' ' '5 IP9 '''II' dot enter address tilt a vacy Pr6c fU.MR i : 4. UU 7, T n 4,j ' - Fx l rV t (r yy - r f . CITY OF FORT LUPTON 'e"r CITY COUNCIL s J' Ron Jones,Mayor Phil Jensen,District 3 Carol Mitchell,District 3 David Norcross,District 2 VACANT,District 2 Panama Melly Tear Shannon Crispin,District 1 Darrell Holder,District 1 Artssantentrasses sesta AM 99-015 APPROVAL OF CITY COUNCIL RESOLUTION 99.003, SELECTING THE UPPER FRONT RANGE TRANSPORTATION REPORT AS THE LONG AND SHORT RANGE LIST OF TRANSPORTATION PROJECTS FOR THE CITY OF FORT LUPTON For Mends: Council Workshop- February 17, 1999 Council Meeting - February 24, 1999 Attachments: a. City Council Resolution 99-003 b. Planning Commission Resolution 99-001 c. Upper Front Range Transportation Report Summary Statement: The Fort Lupton Planning Commission voted on February 9, 1999 to recommend to the City Council the approval of the City of Fort Lupton Upper Front Range Transportation Report. Annually the UFR Transportation Board requests a list of future projects in all the upper front-range communities. They use this information to plan for short and long-range projects — that require large amounts of capital and current budget expenditures. Recommended Action: Approve City Council Resolution 99-003, selecting the Upper Front Range Transportation Report as a long and short range list of transportation projects for the City of Fort Lupton. Fiscal Note: A,o g a 2-//- 99 i �aJn 'rector Date Submitted by: (/. - bast1/ Fek q 9 Community Development Director Date Aooroyed: a-lI-fl City Administrator Date EXHIBIT. • a, arravi D e9-24? v/97 RESOLUTION NO.99-003 A RESOLUTION OF THE CITY COUNCIL OF FORT LUPTON APPROVING THE UPPER FRONT RANGE TRANSPORTATION REPORT FOR THE CITY OF FORT LUPTON WHEREAS, the Fort Lupton Planning Commission has discussed the Upper Front Range Transportation Plan for Fort Lupton;and WHEREAS,the Fort Lupton Planning Commission recognize the need for short and long range planning for transportation; and WHEREAS, the UFR Report isn't a contract, it can be revised yearly as certain situations change in the City of Fort Lupton;and WHEREAS, the Fort Lupton Planning Commission has recommended through Planning Commission Resolution P 99-001 recommends to the City Council of Fort Lupton the acceptance of the Upper Front Range Transportation Report. NOW THEREFORE BE IT RESOLVED that the City Council of Fort Lupton hereby approves the Upper Front Range Transportation Report for the City of Fort Lupton. APPROVED AND ADOPTED BY THE FORT LUPTON CITY COUNCIL THIS 24 th DAY OF FEBRUARY, 1999. City of Fort Lupton,Colorado 4O�r Ron loli&.Mayor Approved as to form: Attest: L T. William Wallace Barbara Rodgers,City Clerk AM 99-015 + ®`T2tt% / ettp of fort lupton \^ :►_ ._•. P.O. BOX 148 COUNTY OF WELD 130 S.McKINLEY AVENUE tot mot FT. LUPTON, CO 80621 (303)857-6694 UFR PROJECTS IN FORT LUPTON AREA February 18, 1999 TO: Jenny Halcomb Felsburg, Holt & Ullevig Greenwood Corporate Plaza 7951 E. Maplewood Ave. Ste.200 Englewood, CO 80111 From: Vernon Gantt (,r City of Fort Lupton PO Box 148 130 S. McKinley Ave Fort Lupton, CO 80621 RE: List of projects for Upper Front Range Transportation Plan TRANSIT The City of Fort Lupton has no projects planned for transit at this time. RAIL The need for economical and fast transit will make light-rail a necessity in the near future. I have consulted the Fort Lupton Planning Commission and they have stated that they wish for a Park/ride and future train depot to be on the West side of the Union Pacific tracks and on the North side of Colorado Highway 52. This 300ft. by 300ft location is currently unoccupied except for a vegetable stand. This site would require curb/gutter and sidewalks; adequate turn lanes on Highway 52; storm drainage; water and sewer taps and appropriate buildings and parking to its current needs. In the short-term this site could be used as a park-and-ride and in the medium term it could be used C.- for both the park-and-ride and a train depot. PG2 - UFR REPORT HIGHWAY LONG-RANGE 1. The City of Fort Lupton recommends that the intersection of WCR 8 and U.S. Highway 85 be the future location of a major interchange and overpass that will serve as a South entrance into our City. 2. The City of Fort Lupton recommends that the intersection of 14th street and U.S. Highway 85 be the future location of a major interchange and overpass to serve as the North entrance into Fort Lupton. BOTH WCR 8 AND 14.5 HAVE BEEN RECOMMENDED BY THE U.S. HIGHWAY 85 ACCESS STUDY TO BE THE LOCATIONS OF THE NORTH AND SOUTH ENTRANCES INTO THE CITY OF FORT LUPTON. THESE CHOICES ARE CONSISTANT WITH THE LONG TERM PLAN OF MAKING HWY 85 AN EXPRESSWAY FROM I-76 TO NORTH OF FORT LUPTON. 3. Colorado Highway 52 needs to be widened from the Union Pacific Railroad tracks to U.S. 85. Due to incredible amounts of traffic currently using this stretch of road, without widening, the turning movements become more dangerous day by day. It will be very difficult to widen the North side of the street, but the South side could be widened by one lane width without removing current buildings. This project would require obtaining right of way; new curb, gutter, and sidewalk; relocation of light poles; signs; storm water drainage piping; and possibly the replacement of water and sewer taps on the South side of the street. SHORT-TERM The following intersections are currently in need of extensive improvements to make them safe: 1. Colorado Highway 52 and Denver Ave. — Due to the drastic increase in traffic in Fort Lupton; this intersection is has become extremely dangerous. It is the main intersection in town and almost everybody in the City must pass intersect this location to enter or leave Fort Lupton. PG 3 - UFR REPORT 2. Colorado Highway 52 and Grand Ave. - Due to its proximity to U.S. Highway 85, less then 100 ft. from the North bound off ramp, the Grand Ave intersection has become very dangerous due to congestion of all types of traffic converging oti this area. This situation has been looked at repeatedly by CDOT and it may need further study. CDOT and the City have discussed in the past putting lights at U.S. Highway 85 and State Highway 52. This project would require extensive engineering to formulate the best option. 3. Colorado Highway 52 and Rollie Ave— Due to the new subdivisions that have recently added homes and a new school in the Northeast section of Fort Lupton, Rollie Ave.has become a major congestion area. The situation will only get worse as Coyote Creek and Chestnut Ridge subdivisions continue to build out. Coyote Creek will add 750 new homes over 4 years and Chestnut Ridge will add 59 new homes in 1999 and 2000. This project will require the widening of State Highway 52, four-way lights with turn signals, and adequate striping. Please give me a call at(303)857-6694 if you have any questions or need 4 ttification on any of the projects. Cr- (r1pfpcfrd is a map of the projects listed in this report) Respectfully Vernon Gantt Community Development Coord. City of Fort Lupton •• f . PLANNING RESOLUTION P 99-001 A RESOLUTION OF THE FORT LUPTON PLANNING COMMISSION RECOMMENDING THE APPROVAL 1'Ht UPPER FRONT RANGE TRANSPORTATION REPORT FOR Mt CITY OF FORT LUPTON WHEREAS, the Fort Lupton- Planning Commission have discussed the Upper Front Range Transportation Projects Report; and WHEREAS,the UFR Report has long and short range goals for transportation; and WHEREAS, the UFR Report helps the City and CDOT planners prepare for the future; and WHEREAS, the UFR Report is not a contract, it can be revised every year as the situation changes THEREFORE,the Fort Lupton Planning Commission recommends that the Upper Front Range Transportation Report for Fort Lupton be accepted and sent to Felsburg, Holt, and Ullevig. The following information is a list of long and short-term projects sent to the Upper Front Range Transportation Board: LONG RANGE PROJECTS 1. A major intersection at Weld County Roads and State Highway 85 2. A major intersection at Weld County Road 14.5 and State Highway 85 3. The widening of State Highway 52 from the Union Pacific Railroad tracks to Highway 85 ,SHORT TERM PROJECTS 1. A future location for a park&ride/Train Depot on the Northwest-side of the Union Pacific Railroad tracks at State HWY 52. 2. The following intersections need to have new street lights: a.) Denver Ave and State HWY 52 b.) Rollie Ave and State Highway 52 c.) Grand Ave and State Highway 52 APPROVED AND PASSED BY A MAJORITY VOTE OF THOSE APPOINTED TO THE FORT LUPTON PLANNING COMMISSION ON THIS DAY OF 9 FEBRUARY, 1999. CITY FOR ,UPTON, COLORADO AT T: eyn d , hairperson Vernon Gantt Community Dev Coord. 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NOTICE OF SITE CONDITIONS AND DECLARATION OF RESTRICTIONS This instrument is made and executed this 26th day of May, 1981, by COLORADO LANDFILL, INC. , a Colorado cor- poration, hereinafter called "Declarant". RECITALS A. Declarant is the owner of that certain real property legally described in Exhibit "A" which is attached hereto and incorporated herein by this reference. The entire parcel described in Exhibit "A" is hereinafter called "the property". B. Several years prior to the date hereof, portions of the property were open pit mined for gravel deposits. Some time subsequent to completion of gravel mining, the portions of the property which were mined were filled with trash while the property was operated as a designated sanitary landfill. C. In late 1980, the portions of the property which were used as a sanitary landfill were completely filled and covered with a porous overburden and the landfill was closed in compliance with regulations of the State of Colorado and Weld County. D. The portions of the property which were not mined and filled with trash are described in Exhibits "B" and "C" attached hereto and incorporated herein by this reference. Said portions of the property described in Exhibits "B" and "C" are hereinafter referred to as "the undisturbed property". • The portion of the property not within the boundaries of the undisturbed property is hereinafter called "the encumbered property". • E. Declarant is aware that the encumbered property poses special difficulties with regard to future use and development. Any improvements constructed on or under the encumbered property will have to be designed and constructed to allow for potential surface subsidence and venting of gases (primarily methane) which may form in the subsurface. F. Declarant intends hereby to give notice to future owners and users of the encumbered property of the facts recited herein and to impose certain restrictions on the future development of the encumbered property so that anyone who desires to construct improvements thereon will design and construct such improvements in such a manner that gas and subsidence conditions will be provided for. NOW, THEREFORE, Declarant does hereby give notice of the matters recited above and does impose the following res- trictions as covenants which shall run with and be a burden upon the encumbered property. 1. The foregoing recitals are incorporated herein as if set forth at length. 2. No owner, lessee, permitee or licensee shall cause improvements to he placed in, or or under the encumbered pro- perty without first submitting an application for a building permit to the county or municipality having jurisdiction. Such •„_,, permit application shall be accompanied by a certificate from a registered professional engineer certifying that the construction or development plans include allowances for subsidence and underground gas and shall detail what those allowances are. 3. Upon receipt of the building permit application and engineer's certificate, the governmental agency having jurisdiction ' 945 1867133 BOOK....._._.. REC€PTION...._....._..--- 7-((' i-- may refer the application to other appropriate governmental agencies for review and comment and may withhold issuance of a building permit until it is reasonably satisfied that appro- priate provisions have been made in the plans with respect to subsidence and gas conditions at the site. A decision of the building authority to withhold issuance of a permit or impose conditions unacceptable to the applicant may be appealed according to the appeal process in the building code then applicable; or, if none, to the Board of County Commissioners or City Council having jurisdiction. 4. The foregoing covenants and restrictions shall be enforceable by any owner of any portion of the property, by the Board of County Commissioners of Weld County, and by the City Council of any municipality to which the property might • hereafter be annexed. IN WITNESS WHEREOF, Declarant has caused this instru- ment to be executed by its proper officers the day and year first above written. COLORADO LANDFILL INC. , a Colorado corporation By ‘7 C. L n Keirnes ATTEST: Secretary STATE OF COLORADO ) ) ss. COUNTY OF WELD The foregoing document was acknowledged before me this day of Suty, 1981, by C. LYNN KEIRNES as President, and as Secretary of COLORADO LANDFILL, INC. , a Colorado corporation. WITNESS my hand and official seal. My commission expires: 2 (f— Z (-4 7--/ffrez ' � C/t Yry Pug�ic ` 1 rug�\- • • ,.r -2- • q 1867133 BOOR'45 RECEPTION..._.._............._._ 7.3" R. NB9'f/2.4r7 72 51". EXHIBIT A a F 0 r� ti t^ 1 > 4 A 3 /.A.7.90.r F In �' �/ gcres ti . % �\JJ .41 v 3 F a M 0-\ % o 'el fl3c V 8; �'s 8 sew/P./._Ste' 8 miries'm'N 630.as' ` -es/ 4ne P/9 JJ' of 6E6/NN/NG ,,A .J£r./9 8p /.e/NT ei BE6/NN/NG LEGAL DESCRIPTION 8` SA-Ca- /9 A parcel of land located in the Southeast Quarter (SF1L) of II � /Ny�.GLW. Section 19, Township 1 North, Range 66 West of the 6th P.M., II Weld County, Colorado being more particularly described as follows: Beginning at the Southeast Corner (SE COR) of said Section 19 and considering the East line of said 5511 as bearing North 00°00'00" East, with all other bearings contained herein relative thereto; Thence North 00°00'00" East, 1340.00 feet; Thence North 89°45'00" West, 1630.03 feet to the True Point of Beginning; Thence North 89°45'00" West, 219.77 feet; Thence North 00°15'00" East, 501.80 feet; Thence North 89°45'00" West, 423.66 feet to a point on the East R.O.W. line of U.S. Highway 85; Thence North 05°46'27" West, along said R.O.W. line, 775.18 feet; Thence North 89°21'24" East, 725.29 feet; Thence South 00°00'00" West, 1283.37 feet to the True Point of Beginning. Said described parcel of land contains 14.730 acres, more or less, and is subject to any rih[s-of-way or other easements as granted or reserved by instruments of record ,or as`now., e ting on said described parcel of land. SU,..nYOR's CERTIFICATE: I hereby certify that this plat was prepared-'under my supervision; andt that the same is correct to the best of my knosl�.dg`e and belief.(\\ /�� Yy: `Y:•-.n P d`�y;5,a-k1. `i ._ _ Jaspei, Neese\ Colorado PEE. & L.S. No. 4392 1867133 I BOOK945 RECEPTION EXHIBIT B N B9'2/'24 E 723.29 h A N h Zil N 4 0 N S. o .�/B9'45'00"N , W 0 ' . 423.66 MV 0 C AN p ° .8 $ Parcel #/ ,, Scale lr�"Soo `o o°o .°°h o cn h 2 8M ',' ni Br 45'00. -° /630.003' 2/977' ,rnie erb of N69'4500"W f Be;.,w7.9 tag,' /i,C Sec. /9 W 8C :$4I . 8i. Ppr:,t Of Bey:.-,:9 aE Car see 19 LEGAL DESCRIPTION - Parcel #1 k II T/x! 1744 w A parcel of land located in the Southeast Quarter (SEI/4) of Section 19, Township 1 North, Range 66 West of the 6th P.M. , Weld County, Colorado being more particularly described as follows: Beginning at the Southeast Corner (SE COR) of said Section 19 and considering the East line of said SE1/4 as bearing North 00°00'00" East, with all other bearings contained herein relative thereto; Thence North 00°00'00" East, 1340 feet; Thence North 89°45"00" West, 1630.03 feet to the True Point of Beginning; Thence North 89°45'00" West, 90 feet, more or less; Thence North 00°00'00" West, 345 feet, more or less; Thence South 44° East, 130 feet, more or less; Thence South 00°00'00" East, 250 feet, more or less; to the True Point of Beginning; said parcel containing 0.61 acres, �-e or less. •p0 �•1N, C.NF4, a SURYEYOR's CERTIFICATE: I hereby certify that this plat was preparediun -gr mh er4,ision and that the same is correct to the best of my k)�Jn ,,/�]/��d�gge and belief c-p p: La ern C. Nelson c Io�4" Colorado P.E. E L.S. No. 2683 The foregoing certification was acknowledged before me this e6.t6 day of 41e2 / , A.D., 1981. Witness my hand and seal. // /7 — // My commission expires: /1/pV /O, /x/87 (1 N•t a y Public 945 1867133 BOOK.,..._..__ RECEPTION ......._..____._._. EXHIBIT C '7-7 MTrue /30,0*NB9'l/I4"5 725 29' f aey.hn;r 30Z3, 44 P. .8 4 q° Sarre/ 2 t 8 .' h. n 1 ro I n/89.21' 0) ra^e p V a 0 .k I2 NBT3.64aW Q 0 Scale r. 500 U, O co °o �a a h 8 A✓B9v5'aa"w /6So 03' 2/9.77 NB9•e6'00-0v ' o Ease [me . Sec..9 o o� .C)I Ira/rain/ of Berlin, SE Cer Sec/q LEGAL DESCRIPTION - Parcel #2 I T/N, IR 66 W A parcel of land located in the Southeast Quarter (SEl/4) of Section 19, Township 1 North, Range 66 West of the 6th P.M. , Weld County, Colorado being more particularly described as follows: Beginning at the Southeast Corner (SE COR) of said Section 19 and considering the East line of said SEI/4 as bearing North 00°00'00" East, with all other bearings contained herein relative thereto; Thence North 00°00'00" East, 1340.00 feet; Thence North 89°45'00" West, 1630.03 feet; Thence North 00°00'00" West, 1283.37 feet to the True Point of Beginning; Thence South 89°21 '24" West, 130.00 feet, more or less; Thence South 00°00'00" East, . 0.00 feet, more or less; Thence North 89°21'24" East, 130.00 feet, more or less; ,nce North 00°00'0Q" East, 280.00 feet, more or less; to the True Point ads t•eiaaing; said parcel containing 0.814 e� acres, more or less. ^4,�_ 'NNFy • *4, iosi EREp it., SURVEYOR's CERTIFICATE: I hereby certify that this plat was preparedt v er my supee*" on; and that the same is correct to the best of my o e.'.e and belief. : Lii- 2683 z 'fJf&4Ja�. e L. ern C. Ne son `ter ej�n . �S.v• Colorado P.E. & L.S. No.°2 nFeco V'e0 0°G The foregoing certification was acknowledged before me this aG Mday of /✓/cty ,A.D. , 1981. Witness my hand and seal. My commission expires:: Nov. /0, /98Z l( ��"""i"""09l"id/Note y •ublic Hello