-, ,

l

Project No. 1725

Crisdel Group. Inc. Rubber Mix Asphalt Production

Emission Compliance Test Program

APC 10 No. 45031 NJ Stack 001

RevIewed by. Robert E. CUtler. P.E

Prepared for:

Mr. Willl8fTI Werwer Crisdel Group. Inc. 240 Ryan Street

South Plainfield, New Jersey 07080

June 1994

·,

Table of Contents

Page - ,

,.0 Introduction " . . , : ... ... . " . . . ... . , 2.0 Facility Oescriptlon , . . .. . . . 2

3.0 Test Results 3

4 0 Sampling and Anarytical Methodologies . '2

Appendix A Reid Data

Appendix B Calculations

Append!)( C Laboretol"'f Data

Appendix 0 Calibration Data

Appendix E NJOEPE Process log

.. 1

,

1.0

AirNova. Inc. conducted en emission compliance test program at the Trap Rock Industries

facility located in Florence, New Jersey for the purpose of demonstrating compliance with applicable

NJDEPE regulations regarding the production of rubber mix asphalt at this facility. Emission sampling

was conducted at the oudet of a baghouse which serves as the emission control device for en asphalt

hot-rnix plant. One test set was conducted for each of two [2l operating conditions. The first test set

was co!1ducted while the plant was processing recycled asphalt pavement. The second test set was

conducted while the plant was feeding liquified rubber into the preheated aggregate to produce a

MJbber m ix asphalt. The first test set was conducted while the plant was processing recycled asphalt

pavement. The specific parameters determined as part of this test program included the following:

Particulate Matter Total ~droc8rbonS Camon Manmade Nitrogen Olcicles Opacity Qdo,

A descnption of the source which was evaluated. the results of the evaluation. and the test

"''i methodologies which were utilized in the perfonT\ance 01 the program is pl'OVIded herein.

AirNova. Inc. - 1 -

.. '

2.0 Facility Description

The fac ility under evaluation produces asphaltic hot mix utilizing a batch process. The hot mix

is a paVIng maten al consisting of a combination of graded aggregate that is dried. heated and evenly

coated With hot asphalt cement. The aggregate is dried and heated in a rotal')' dryer which is fired by

natural gas. After further cJasstiication. the aggregate is mixed with asphalt pumped from heated

storage tanks and the final product is loaded onto tn./cks. During I'\ibber mix production. liquid I'\ibber

is added In conjunction with the hot asohalt cement. Particulate emissions from the dryer are

controlled by a fabnc fi lter baghouse operated at apprOJumately 1.4 in. WG pressure drop.

All emiSSion determinations were conducted at the baghouse exhaust. Slmpling was conducted

In a vertical section of emaust duct 36 Il'IChes by 31 inches In dimension. Four {.:I I test peru located

1 7 eqUIValent duct diameters downstream and 5 8 eqUIValent duct diameters upstream from the

nearest flow disturbance were utilized for all sampling .

AirNova. Inc. ·2 .

3.0 Tast Aaatim

The n!sults ot the test program 8n! presented in this section. The following tables present

summarized results for each emission parameter:

Table Parameters Page

3-1 NO .. OJ, THe Emission SummaI)' • 4 Recycle t..'.:..

3-2 Particu:dte Emission SummaI)" 5 Recycle Mix

3-3 Visual Opacity SummaI)' • 6 Recyc!e Mix

3-4 Odor Survey SummaI)" Recyc!e Mix 7 3-5 NO •• CO. THe: Emission SummaI)' • 8

Rubber Mix 3-6 Particulate Emission SummaI)' . 9

Rubber Mix 3-7 Visual Opacity SummaI)' • Rubber Mix 10 3-6 Odor Survey SummaI)" Rubber Mix n

Average emiSSion values as detemuned for each test series are as fol lows:

., Emission Test Averege (!b/hr j

Parameter Recycle Mix Rubber M"x

Total Hydrocarl:>ons 1.72 9 .6 £ Csrbon Monoxide 4.42 5 .74 Nitrogen Oxides 12.6 9 .74 Particulate 24.7 109.2

AirN0Y8. Inc. -3 .

...,

-.

,

...,

!I"

Table J.1

Nitrogen Oxides. Carbon Monoxide and Total Hydrocarbon Emission Surrmary

Recycle Mix Trap Rock Industries Aorence, New Jersey

Run No. 1 2 O.te 05/ 18/94 05/18/94 Test Period 2C0J.2102 2111-2216

Totel ttdrocartJons las CH.l

ppmV-d1')' 24.1 24.1 ppmV-d1')' a 7% o~ 78.2 70.7 Ib/hr 1.80 1.73

Carton MoflolClde

ppmV-d1')' 33.0 36.0 ppmV-d1')' a 7% O2 107 100 Ib/hr 4 .30 4 .53

N 'troqen Oxides las N02l

ppmV-d1')' 64.5 59.3 ppmV-d1')' D 7% O2 209 17",

Ib/hr 13.8 12.3

Stendard Conditions: 7[1' F, 29.92 in. Hg.

AirNova. Inc. - 4 -

3 05/ 18/94 2227-2330

21.7 66.3 1.62

34.0 104

4,42

54.3 166 11 .6

~

.<

,

Run No. D.", Test Period

Temperature (Of] Moisture Content {%J Molecular Wt (Ib/molel Velocity {(psi Aow Rate (OSCFM) Isokinetic Rate (%1

Oxygen (%1

carbon Dioxide (%)

PartJculate Concentration [gr/ DSCFJ Emlssillfl Rate Ub/ hrJ

Tabla 3-2

Particulate Emission SummaI)' Recycle Mix

Trap Rock. Industries Aorence, New Jersey

1 2 05/ 18/ 94 05/ 18/ 94 2cx:::0-21 02 2111·2216

178 189 •• 0 16.9

27.60. 27.33 89.7 9O.S

29,991 28.963 106 109

16.61 16.17

3.30. 3.64

0.092 0.0.91 23.6 22.5

Standard Con<!lt:ons: 7[f F, 29.92 in. Hg.

AirNova. Inc. ·5·

3 05/18/94 2227-2330

186 15.8

27.44 92.5

29,939 106

16.34

3.48

0.109 27.9

.,

Run No. oa" Test Period

Minimum Opacity (%J Max,imum Opacity [%) Average Opacity [%]

Table 3·3

Visual Emission Summary Recycle Mix

Trap Rock. Industries Rorence, New Jersey

1 05/ 18/ 94 2COJ.-21 02

10 25

19.2

2 05/1 8/ 94 2111-02216

• Unable to conduct measurements due to dark.ness

AirNova, Inc. ·6·

3 05/1 8/ 94 2227·2330

:1

-,

.,

"

Run No. O,te

Location . Plant

50 feet upwind 50 feat downwind Fencelina downwind

Intensity. a . none. 5 . very strong

Table 3·4

Odor Survey Summary Recycle Mix

Trap Rock Industries Aorence. New Jersey

2 05/1 8/94 05/18/94

<1 a 1.4 1.4 <1 1.2

• Application Point Odor Survey not required by NJDEPE

AirNova. Inc. · 7 .

3 05/ 18/94

a 1.7 1.1

.;

Table 3 - 5

Nitrogen Oxide. Carbon MonoKide and Total HydrocartlOn Emission SummaI)'

Rubber Mix Trap Rock Industries Aorence. New Jersey

Run No. 1 2 3 O,te 0.5/20./ 94 0.5/20./94 0.5/20/94 Test Penod 2003-2105 2116-2218 2224-2326

Total Hydrocarbons [as CH.l

ppmV-(1)' 168 123 107 ppmVodl)' (gI 7% 02 417 362 307 Ib/hr 11 .9 9 .16 8.DO

Carbon Monoxide

ppmV-(1)' 600 35.0 40..0. ppmV-<lry 0 7% ~ 148 104 115 Ib/hr 7.41 4 .57 525

Nitrogen Q,:;ldes [as NO,I

ppmV-<lry 51 .6 41 .0. 46.0 ppmV-(1)' 0 7% 02 128 121 132 Ib/hr 10.5 8 .80 9.91

Standard Conditions: 7r:f F. 29.92 In. Hg.

AirNova. Inc. · 8 -

4

. ,

Run No. Date Test Period

T empereture ("F] Moisture Content [%J Molecular Wt. (Ib/mole] Velocity (lpsJ Row Rate (DSCfM]

Isokinetk Rate (%]

Oxygen (%]

Carbon Oio;(Jde (%]

Particulate Concentratlon (gr/OSCFJ Emission Rate (Ib/hr]

Table 3-0

Particulate Emission SummalY Rubber Mix

Trap Rock Industries Aorence, New Jersey

1 2 OS/ 20/ 94 OS/20/94 2OJ3.2105 2116-2218

186 181 18.3 14.0

27.21 27.56 90.1 89.8

28.457 30,086 104 96

15.28 16.20

4.14 2.95

0.366 0 .500 89.4 129.0

Standard Conditions: 7r1' F, 29.92 in, Hg.

AirNova, Inc. ·9·

3 OS/20/94 2224-2326

181 15.6

27.43 91 .9

30,208 97

16.70

3.34

0.422 109.3

Run No,

D'te Test Penod

Minimum Opacity (%] Malimum Opacity (%] Average Opacity (%]

Table 3 - 7

Visual E;, li5slon Summary Rubber Mil

Trap Rock Industnes Florence, New Jersey

1 OS/20/94 2003-2105

20 3D 24

2 OS/20/94 2116·2218

• Unab'e to conduct measurements due to dari<ness

AlrNova, Inc - 10 -

3 OS/20/94 2224-2326

Run No. 0o",

Location • Plant

50 feet upwind 50 feet downwind Fenceline downwind

Location - Application Point

Upwind Oownwlnd 50' Behind Truck

IntenSIty: 0 - none. 5 - vel)' sU'Ong

AirNova. Inc.

Table3·e

Odor SummaI)' Rubber M ix

Trap Rock Industries Aorence. New Jersey

1 2 OS/20/94 OS/20/94

<1 <1 1.7 <1 <1

a 1.7 2.3

• 11 •

3 OS/20/94

<1 1.5 <1

'.

4.0 Sampling and Analytical Met:hoddogie&

The emission test program was conducted utilizing the methodologies specified below:

EPA Method 1

EPA Method 2

EPA Method 3A

EPA Method 4

Nu- I"~ Test Method 1

NJ Air Test Method 3.7

EPA Method 7E •

NJ Air Test Method 2

EPA Method 10

NJ Odor Survey Protocol

Sample and Velocity Tra\lerse for Stationary Sources

Determination of Stack Gas Velocity and Volumetric Row Rate

Gas Analysis for the Determination of Dry Molecular Weight

Determination of Moisture Cllntent in Steck Gases

Sampling and Analytical Pn..,~dures for Determining Emissions of Particles from Manufac:uring Processes and from Combustion of Fuels

Procedure for the Direct Measurement of Volatile Organic Substances Using a Rame Ionization Detector (AD). a Photoionization Detector (PIDl. or a Non.Qispersive Infrared Analyzer (NDIR)

Determination of Nitrogen Oxide Emissions from Stationary Sources: Instrumental Analyzer Procedure

Visual Determination of the OpaclI:y of Emissions from Stationary Sources

Determination of CartxJn MonOXide Emissions from Stationary Sources

Determination of Odor Emissions from Stationary Sources

Triplicate test runs were conducted in determinau .. m of total hydrocarbons, nitrogen oxides.

cartlon dioxide, oxygen and cartlon monoKide concentrations. particulate matter and opacity with each

being a minimum of 1·hour in duration. EPA Methods 1 through 4 were conducted concurrent with

all test runs for the purpose of determming the stack gas moisture content. Odor Oeterminatmns were

also perfonned at the production site and the point of application.

A complete description of each test methodology is presented below.

AirNova, Inc. - 12 .

,.

4 .1 Vritot:iOt rod VoIc.macric Raw RatII

The velocity profile was determined in accordance with guidelines oLJtjined in EPA Method 2,

'Determination of Stacl: Gas Velocity and Volumetric Row Rate". The gas Yelocity and volumetric flow

rate was determined from velocity pressure and gas temperature data. An '5' type pitot tube and

thermocouple were used. The pitot tuOe was connected to en inclined manometer and the

thenTl()l;QUple to e pyrometer. The velocity pressure was measured on the manometer and the gas

temperature on the pyromster. These readings were taken and recorded for each traverse point.

4 .2 QrtIon [)imide and ClicygBn

Caroon diOXIde (m~l and oxygen Oz) concentrations were determined by EPA Method 3A. The

sampling train consisted of a stainless steel probe pack.ed with a plug of glass wool for particulate

filtration. The sampling probe was attached to an ice-cooled condenser used to remove excess

moisture from the sample stream. The oxygen concentration was determined using a paramagnetic

oxygen analyzer The oxygen analyZer was operated in the 0-25% range. A non--dispersive infrared

analyzl:r was utilized to measure carbon diOXIde concentrations. Calibration gases which were used

are as follows: OItrogen as a zero gas and three (3) upscale span gases of aJZ/02 in nitrogen. Zero

and rrudspan bIas checks were performed before and after each run. Carton dioxjde and oxygen

samples were collected simultaneously during all sampling events. The results of the CO~ and Oz

analysis are reporteu in percentage by volume.

4 .3 Moisa.Jra Content

MOIsture content was determined in accordance WIth EPA Referenc'J "Ilethed 4 . Sampling was

conducted UtIlizing large capaCIty Implngers while collecting a minimum sample volume of 30 OSCF.

4 .4 TotaI~B

Total hydrocarbons were measured continuously using a heated total hydrocarbon analyzer.

Sample gas was transported from the test location through a heal2d glass fiber filter and heated

AirNova. Inc. • 13 -

Teflon sample line and directed to the instrument. This instrument uses a Rame Ionization Detector

(AD] and a heated sample oven maintained at 320'F to prevent the condensation of high molecular

weight hydrocarbons. The detector is fueled with hydrogen and uses blended air as the oxidant. The

instrument was initia lly calibrated with NIST tracsable mixtures of methane In air of 25%. Scm.. and

90% of instrument span and zeroed with hydrogen free air (cO.1 ppmC]. System bias checks were

conducted before and after each test n.m utilizing the zero and midpoint calibration standard. The

instrument was operated in the Q.5OJ ppmV range.

4 .S Carbon Monaxide

Exhaust gas concentrations of carbon monolOde were determined by utilizing EPA Reference

Method 10. This method allowed for the continuous instrumental analysis of source gas

concentrations by employing a gas filter correlation analyzer. Exhaust gas sample was extracted from

the emissIon source through a Tefton sample line and filter and passed through a chilled condenser

for moisture removal pnor to being Introduced to the Instrument for immediate analysis. Instrument

calibrations were Inttlally performed by Introducing zero and NIST traceable upscale gases of 25%.

SO%. and 90*! of the Instrument. System bias checks were conducted before and after each test run

utilizing the zero and midpoint calibration standard. The instrument was operated In the 0.1 CXXJ ppmV

range. Source concentratlons were permanently recorded by a stnp cha~ recorder. A leak check was

pprfomled from the sample probe prior to the sta~ of testing to ensure the integrity of all system

components.

4 .6 Cbides of Nitrogen

A chemiluminescence analyzer With a thennal conve~r was employed for the analysis of nitric

olOde INO] and total Clades of nitrogen (NO.) in accordance with EPA Reference Method 7E. Exhaust

samples were transport.ed to the dr alyzer through a heated filter and heated 1320'F) Teflon sample

line. A thermal conve~r IS used to conve~ nitrogen diolOde (N~] to nttnc OXIde (NO) so that total

AirNova. Inc. - 14 -

oKides of nitrogen (NO,) could be measUt'ed. The converter can be switched in and out of the system

using solenoid valves permitting selective operation in the NO or NO, mode. The instrument was initially

calibrated using NIST tt'8Ceable NO in nitrogen standards of 25%. 50%. and scm of instrument span

and zeroed with zero grade nitrogen. System biBS checks were performed before and after each

sampling run utilizing zero and midspan calibration gases. Source concentrations were permanently

recorded by a strip chart recorder. (See Figure 4-1)

4.7 Total fIartX:UatrB MICer

The emission rate of total particulaU\ matter was determined in accordance with those

procedures outlined in NJ Air Test method 1. Gas samples were isokineticaHy extracted from the

exhaust stack and passed tIvough a stainless steel sample nozzfe. 8 glass lined probe and a glass fiber

filter. all maintained at 225°F. The gas sample was then passed through an impinger train consisting

of four glass implngers immersed in an ice bath. The first. a modlfief1 Greenburg-Smith. and the

second. a Greenburg-Smith each contained 100 mf of distilled water. A third impinger was initially dr,'.

The fourth implnger contained silica gel for final drYing of the gas sample. The sample volume is

subsequently measured by passing through a calibrated dry gas meter. An '5' type pitot tube is

attached to the sample probe to mOflitor the stack gas velocity in order to maintain isokinetic sampling

conditions. Also attached was a type OK' thermocouple to measure the emaust gas temperature.

(Figure 4-2)

After each run. the probe, nozzle. and atl connecting glassware ahead of the filter were bnJshed

and rinsed with acetone and the washings retained in a high density polyethylene container for analysis.

The glass fiber fitters were placed in petn dish containers after each test run and retumed to the

laborator,' for later analysis. The Silica gel was retumed to ItS original tared container and reweighed

to determined moisture gain.

After retuming the samples to the laborator,'. the glass fiber filters were deSiccated for 24

AirNova. Inc. - 15 -

••

••

. " , .

. .

. . . . . ... ... .. . ... . . . . . ... ••• •••••••• AirNava • Inc. " ........ : ' " ...... .

. . . . . . " .. . . .

I. '~n._._IIt __

=e~-.J. C:aYtCr. Avenue. ~!'InSaUIW1. New .Je~ev wS 1 as (E~SJ 458_ ~ =~~ . ~AX ~6E-=c:==

I I I I

g. ...... I i ..

I g.. ...... I 101

, I

••• _.. _w.&&.".. , _ flUUI

,~ _ " i. , . ,.-:r.. ~_...,.._" •• ' __ .n tv. , ...

figure 4- 1 Instrumental Analysis Syste~

- 16 •

'"

l

I

I

l

.. . . . . . . . . . . : ....... . . . . . . . . . . ••••••••• • •

AirNova , Inc . .. . . . . . . . . ' " ....... ' ...... . . . . . .

RIYIIt!I ·nPl! lITaTTDla

5845-A Clayton Avenue. Pennsauken. New Jersey 08 109 16091 486-1 500 • FAX 486-9896

1""'111 rnA'. D"rD'UU .MA" .r "rnACID If AN IOU,VAUlr CD.alllllll

mlm Ami IRIft RR /

~....:...,.,'Iln ........ ---------.... ',,,;-cnlCI VAL VI

PlTar IlUGlllTER n"AIIVaLv.

CRIJrCl

r..,,;:; -

ICE 11111

VA_ aAU ••

..,ACDDII UHI

-¥r n --n .. /- ( ) Tnl*_.

IMIaVALVI ,

I

"""aRT ,-

' jr-----------------------------------I Figure 4-2 NJ Air Test Method 1 Sampling System

- 17 -

hours and reweighed to determine weight gain. The &Ci!tone samples were evaporated in tared

beakers, desiccated for 24 hours ancl reweigheo In order to determine total particulate content. A

minimum sample volume of 30 OSCF were collected during each test run. The dry gas meter was

calibrated in accordance with EPA Reference Method 5, Section 5.3.

4 .8 ~ Maastrement (NJ p,jr Test Mldod 2)

The opacity Ipel"C8tlt) of the pltrne from the baghouse exhaust was determined by NJ Air Test

Method 2. The obserwtions were made by a certified observer. The obseJVer was positioned with the

sun oriented in a 140' degree sector WlV1 the su.. to his back. conditions permitting. Observations

were directed to the point of the greatest percent opacity. Obserwtions were made at 60 second

intervals . The obserwtions were perlormed simultaneously with the emission sampling.

4 .9 Odor-

The odor emiU:ed during production and application was determined in accordance with the

Odor Survey Protocol outlined by the NJDEPE Bureau of Technical SeNlces. The determination was

made by the odor observer at the point of production and applicatbn and 50 feet upwind, 50 feet

dcmnwind and at the fence line of each location. The observer judged the odor on a scale of 0-5 with

-, 0 being nondetectable anu 5 being very strong, In addition, sampling tin Ie. weather conditions, wind

direction and wind speed were recorded for each observetion, Dbserwtions were made concummtly

: 1 with each test run,

4 .10 Cyclonic Raw OetarminaOons

A cyclonic flow determination was conducted prior to the start of sampling to ensure that the

test location met acceptable cntena. This infomlatlon was immediately available to the on-sice DEPE

observer.

AirNova. Inc. - 18 .