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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
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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
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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.
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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 .
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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
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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.
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3 05/ 18/94 2227-2330
21.7 66.3 1.62
34.0 104
4,42
54.3 166 11 .6
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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.
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3 05/18/94 2227-2330
186 15.8
27.44 92.5
29,939 106
16.34
3.48
0.109 27.9
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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
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3 05/1 8/ 94 2227·2330
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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
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3 05/ 18/94
a 1.7 1.1
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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.
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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.
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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
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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
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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
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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.
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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
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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
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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
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figure 4- 1 Instrumental Analysis Syste~
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5845-A Clayton Avenue. Pennsauken. New Jersey 08 109 16091 486-1 500 • FAX 486-9896
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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.
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