Hot Mix Asphalt Plants - Emission Assessment Report

1 United StatesOffice Of Air QualityEPA-454/R-00-019 Environmental ProtectionPlanning And StandardsDecember 2000 AgencyResearch Triangle Park, NC 27711 AirHOT MIX Asphalt PLANTSEMISSION Assessment REPORTThis page intentionally left 454/R-00-019 HOT MIX Asphalt PLANTSEMISSION Assessment REPORTThis document was prepared by:Emissions Monitoring and Analysis DivisionOffice of Air Quality Planning and StandardsUnited States Environmental Protection AgencyResearch Triangle Park, NCand under contract, by:Midwest Research InstituteKansas City, MO and Cary, NCEPA Contract Number 68D-98-027andEastern Research Group, Perimeter Box 2010 Moorisville, NCEPA Contract Number ENVIRONMENTAL PROTECTION AGENCYO ffice of Air and RadiationOffice of Air Quality Planning and StandardsResearch Triangle Park, North Carolina 27711 December 2000iiThis page intentionally left information in this document has been funded by the Office of Air Quality Planning andStandards, Environmental Protection Agency (EPA) under contract 68-D-98-027 to MidwestResearch Institute and under contract 68-D-70-068 to Eastern Research Group, Inc.

2 The EPA has madeadditions and revisions to the information submitted by the contractors. This final Report has been subjectedto the Agency s review, and it has been approved for publication as an EPA document. Mention of tradenames or commercial products is not intended to constitute endorsement or recommendation for Report was produced by the Source Measurement Technology Group of EPA s EmissionsMeasurement Center located in Research Triangle Park, NC. It is one of a series of twelve reportsprepared 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.

3 Document TitleEPA DocumentNumberPublication DateHot Mix Asphalt PlantsEmission Assessment ReportEPA 454/R-00-019 December 2000 Hot Mix Asphalt PlantsKiln Dryer Stack Instrumental Methods TestingAsphalt Plant A, Cary, North CarolinaEPA 454/R-00-020 April 2000 Hot Mix Asphalt PlantsKiln Dryer Stack Manual Methods TestingAsphalt Plant A, Cary, North CarolinaVolume 1 of 2 EPA 454/R-00-021aApril 2000 Volume 2 of 2 EPA 454/R-00-021bApril 2000 Hot Mix Asphalt PlantsKiln Dryer Stack Instrumental Methods TestingAsphalt Plant B, Clayton, North CarolinaEPA 454/R-00-022 April 2000 Hot Mix Asphalt PlantsKiln Dryer Stack Manual Methods TestingAsphalt Plant B, Clayton, North CarolinaVolume 1 of 2 EPA 454/R-00-023aApril 2000 Volume 2 of 2 EPA 454/R-00-023bApril 2000 Hot Mix Asphalt PlantsTruck Loading and Silo Filling Instrumental Methods TestingAsphalt Plant C, Los Angeles, CaliforniaEPA 454/R-00-024 May 2000 Hot Mix Asphalt PlantsTruck Loading and Silo Filling Manual Methods TestingAsphalt Plant C, Los Angeles.

4 CaliforniaVolume 1 of 8 EPA 454/R-00-025aMay 2000 Volume 2 of 8 EPA 454/R-00-025bMay 2000 Volume 3 of 8 EPA 454/R-00-025cMay 2000 Volume 4 of 8 EPA 454/R-00-025dMay 2000 Volume 5 of 8 EPA 454/R-00-025eMay 2000 Volume 6 of 8 EPA 454/R-00-025fMay 2000 Volume 7 of 8 EPA 454/R-00-025gMay 2000 Volume 8 of 8 EPA 454/R-00-025hMay 2000 Hot Mix Asphalt PlantsTechnical Systems Audit of Testing at Asphalt Plant CAsphalt Plant C, Los Angeles, CaliforniaEPA 454/R-00-026 May 2000 Document TitleEPA DocumentNumberPublication DatevHot Mix Asphalt PlantsTruck Loading Instrumental Methods TestingAsphalt Plant D, Barre, MassachusettsEPA 454/R-00-027 May 2000 Hot Mix Asphalt PlantsTruck Loading Manual Methods TestingAsphalt Plant D, Barre, MassachusettsEPA 454/R-00-028 May 2000 Hot Mix Asphalt PlantsResponse to Comments on Testing Program for Asphalt PlantsC and DEPA 454/R-00-029 May 2000 Hot Mix Asphalt PlantsStakeholders Opinions ReportEPA 454/R-00-030 These documents, including this Emissions Assessment Report document, are available for downloading,on CD-ROM and in can be made from: of the CD ROM can be requested by mail at: Emission Measurement Center, MD-19US Environmental Protection AgencyResearch Triangle Park, NC 27711 Paper copies of the reports can be obtained from.

5 National Technical Information Service5285 Port Royal RoadSpringfield, VA 22161 Phone orders 1-800-553-6847 or (703) 605-6000; FAX orders (703) 605-6900 individuals contributed to the development of this Report . Ron Myers of the EmissionMeasurement Center s Source Measurement Technology Group (SMTG), Brian Shrager, Scott Klamm,Richard Marinshaw, and Amy Marshall of Midwest Research Institute (MRI), are the primary authors ofthe Report . Bob McConnell of EPA s Region I office, David Mobley, Acting Director of EPA s EmissionsMonitoring and Analysis Division, Bill Lamason, Mike Toney, Gary McAlister, and Candace Sorrell ofEPA s Emission Measurement Center, Ron Ryan and Dennis Beauregard of EPA s Emission Factor andInventory Group, Laura Autry of EPA s Air Quality Trends Analysis Group, participated in the review.

6 We also acknowledge the contributions of numerous reviewers and advisors from PES, MRI and OF CONTENTSPage1. EXECUTIVE OVERVIEW OF HMA DEVELOPMENT AND USE OF Emission FACTORS FOR HMA ESTIMATED ANNUAL EMISSIONS FROM TYPICAL HMA Assessment OF HOT MIX Asphalt INDUSTRY OVERVIEW AND PROCESS Batch Mix Drum Mix Recycle Emissions and Emission FACTOR DEVELOPMENT FOR AP-42 SECTION ,HOT MIX Asphalt Batch Mix and Drum Mix Hot Oil Truck Silo Asphalt Storage Yard OTHER APPLICABLE AP-42 Emission INVENTORY FOR TYPICAL HOT MIX Asphalt Emission ESTIMATES FOR TYPICAL HOT MIX Asphalt AAP-42 Section , Hot Mix Asphalt Plants , December 2000 appendix BEmission Factor Documentation for AP-42 Section , Hot Mix Asphalt Production.

7 December 2000 Final ReportAPPENDIX CChapter 3: Preferred and Alternative Methods for Estimating Air Emissions from HotMix Asphalt Plants . Emission Inventory Improvement Program (EIIP), July OF FIGURESN umberPage1. General process flow diagram for batch mix Asphalt Plants ..42. General process flow diagram for counter-flow drum mix Asphalt OF ANNUAL EMISSIONS FOR A TYPICAL BATCH MIX HMA ANNUAL EMISSIONS FOR A TYPICAL DRUM MIX HMA OF Emission FACTORS DEVELOPED FOR HMA OF SUPPORTING DATA FOR Emission ANNUAL EMISSIONS FOR A TYPICAL BATCH MIX PLANT DRYER,HOT SCREENS, AND ANNUAL EMISSIONS FOR TYPICAL BATCH MIX PLANT ANNUAL EMISSIONS FOR TYPICAL BATCH MIX PLANT ASPHALTSTORAGE ANNUAL EMISSIONS FOR A TYPICAL DRUM MIX ANNUAL EMISSIONS FOR TYPICAL DRUM MIX PLANT ANNUAL EMISSIONS FOR TYPICAL DRUM MIX PLANT SILOFILLING ANNUAL EMISSIONS FOR TYPICAL DRUM MIX PLANT ASPHALTSTORAGE ANNUAL YARD VOC EMISSIONS FOR TYPICAL BATCH MIX ANDDRUM MIX HMA OF ACRONYMSASTMA merican Society of Testing and MaterialsBtuBritish thermal unit CH4methaneCOcarbon monoxide (as measured by EPA Method 10)CO2carbon dioxide (as measured by EPA Method 3)

8 EPAE nvironmental Protection AgencyHAPhazardous air pollutant (listed in or pursuant to section 112(b) of the 1990 Clean Air ActAmendments)HMAhot mix asphaltNOxnitrogen oxides (as measured by EPA Method 7)PAHpolycyclic aromatic hydrocarbon (a class of HAPs)PMparticulate matter (as measured by EPA Methods 5 or 17)PM-10particulate matter less than 10 microns in matter less than microns in diameterRAPreclaimed Asphalt pavementRTFOT rolling thin film oven test (ASTM Method D2872-88)SCCsource classification codeSO2sulfur dioxide (as measured by EPA Methods 6 or 8)SOxsulfur oxidesTOCtotal organic compounds (as measured by EPA Method 25A)VOCvolatile organic compound (refer to 40 CFR ); VOC is TOC plus formaldehyde, lessmethane, ethane, acetone, and other chemicals listed as negligibly photochemically page intentionally left EXECUTIVE INTRODUCTIONThis Report presents an Assessment of emissions from hot mix Asphalt (HMA) manufacturingfacilities.

9 Included in the Report is a description of the manufacturing process and the emissions associatedwith HMA production; the procedures for developing Emission factors and Emission inventories for theHMA industry; and estimated annual emissions for typical HMA OVERVIEW OF HMA INDUSTRYHot mix Asphalt is used primarily as paving material and consists of a mixture of aggregate andliquid Asphalt cement, which are heated and mixed in measured quantities. Hot mix Asphalt facilities can bebroadly classified as either drum mix Plants or batch mix Plants , according to the process by which the rawmaterials are mixed. In a batch mix plant, the aggregate is dried first, then transferred to a mixer where itis mixed with the liquid Asphalt .

10 In a drum mix plant, a rotary dryer serves to dry the aggregate and mix itwith 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 thematerial to the job site. Figure 1 presents a diagram of a typical batch mix HMA plant; a typical drum mixHMA plant is depicted in Figure 1996, approximately 500 million tons of HMA were produced at the 3,600 (estimated) activeasphalt Plants in the United States. Of these 3,600 Plants , approximately 2,300 are batch Plants , and1,300 are drum mix Plants . The total 1996 HMA production from batch and drum mix Plants is estimatedat about 240 million tons and 260 million tons, respectively.