oEFA
United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 79-NMM-11C
April 1980
Air
Non Metallic Minerals
Stone Processing
Emission Test Report
Brannan Sand and Gravel
Company
Jefferson County
(Denver), Colorado
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SET 1838/18U* 01 0180
VISIBLE EMISSIONS FROM
NON-METALLIC MINERAL PROCESSING
BRANNAN SAND AND GRAVEL
DENVER, COLORADO
79-NMM-ll-C
EPA Contract No. 68-02-2813
Work Assignments 39 & HO
Prepared For:
Emission Measurement Branch
United States Environmental Protection Agency
Attn:: Mr. J. E. McCarley
Mail Drpp 13
Research Triangle Park, NC 27711
January 1980
SCOTT ENVIRONMENTAL SERVICES
A Division Of
SCOTT ENVIRONMENTAL TECHNOLOGY, INC.
Plumsteadville, Pennsylvania 189^9
Scott Environmental Technology Inc.
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TABLE OF CONTENTS
1.0 INTRODUCTION
2.0 SUMMARY OF RESULTS, BRANNAN SAND AND GRAVEL, COLORADO.
1
6
APPENDIX A - FIELD DATA SHEETS
APPENDIX B - FIELD TEST LOG
a
APPENDIX C - LABORATORY .DATA SHEETS - STONE MOISTURE DETERMINATIONS
APPENDIX D - EPA CERTIFICATION FOR METHOD 9 OBSERVERS
APPENDIX E - EPA REFERENCE METHODS 9 AND 22.
APPENDIX F. - PROCESS DATA
Scott Environmental Technology Inc.
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SET 1838/18M 01 0180 Page 1
1.0 INTRODUCTION
The Clean Air Act of 1971 mandates that Standards of Performance
"be established for new stationary air pollution sources. Establishment of
these standards requires that an emission data base be developed for each
source category. This data base is used as a guide for the establishment
of Performance Standards which will minimize air quality degradation and
yet not be impossible to attain.
One stationary source category for which standards are being
developed is non-metallic mineral processing. This industry is engaged in
the processing of mineral ores obtained from open pit surface mining. The
ores are transferred, crushed and screened to produce specific size grades
of roch which is used primarily in highway construction.
The crushing, screening and material transferring operations
generate fugitive mineral dust emissions which, because they are fugitive,
are difficult to quantify at their source by existing air sampling methods.
Visual determination of the opacity of the released dust, however, are a
workable means of estimating fugitive dust emission generation.
Under work assignment from the Emission Measurement Branch of
the United States Environmental Protection Agency, Scott Environmental
Technology, Inc. participated in a test project which consisted of visible
emission observations conducted at various emission points in five non-
metallic mineral processing facilities. Visible emissions observations at
each of the subject emission points were conducted according to EPA Reference
Methods 9 and 22, "Visual Determination of the Opacity of Emissions from
Stationary Sources" and "Visual Determination of Fugitive Emissions from
Material Processing Sources", respectively. The actual parameters under
which each 'emission point observation was conducted were varied to accommo-
date process and weather variables. Method 9 was used without any modifica-
tion. The only modification used with Method 22 consisted of changing the
observational threshold from zero opacity as specified in the method to a
suitable upscale opacity threshold at 5% increments. A set of readings for
a minimum of 20 minutes was made at every test point with a zero visible
threshold for EPA-22. In those instances where essentially constant
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SET 1838/18M* 01 0180 Page 2
emissions were observed at a zero threshold during the first set of obser-
vations, a higher threshold was selected for subsequent observation sets.
The test plan specified visible observations by both test methods
for two hours at each test point. Since Method 22 requires constant obser-
vation by the reader it was decided to limit reading time to individual
sets no longer than 30 minutes. This was done in order to prevent observer
eye fatigue from adversely affecting visible emissions determinations.
Observations by both EPA Method 9 and EPA Method 22 were conducted
simultaneously at all test locations.
Non-metallic mineral processing is not typically a continuous
operating process. Lapses in material processing are most frequent at the
primary crusher. In order to assure realistic emissions observations,
actual material processing was required to be in progress for a minimum
of 75% of the visible emissions observational periods. Material processing
was timed separately and any data set failing to meet the minimum 75% time
requirement was considered invalid.
Simultaneous visible emissions observations were made at the Vulcan
plant in Helena, Alabama by a plant employee and by contract personnel from
TRC at all five plants tested.
The TRC testing was requested by the industry association. Copies
of this test information are available upon request.
The non-metallic mineral processing plants, the test points
observed and test dates were as follows:
Program A
Plant: Vulcan Materials
Location: Helena, Alabama
Product: Crushed Stone
Dates: October 2 through U, 1979
Test Points: 1. Primary Crusher
2. Untested (Surge Conveyor)
3. Impact Crusher Screen
k. • Impact Crusher
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Page 3
Program A - Continued
Program B
Plant:
Location:
Product:
Dates:
Test Points:
Program C
Plant:
Location:
Product:
Dates:
Test Points:
Program D
Plant:
Location:
Product:
Dates:
Test Points:
5. Final Screens
6. Cone Crusher
7. Transfer Point
Castle Concrete Company
Colorado Springs, Colorado
Crushed Limestone
October 8 through 11, 1979
1. Primary Crusher
2. Initial Screens.
3. Transfer Point
1*. Untested (Reclaim Tunnel)
5. Secondary Screens
6. Cone Crusher •
7. Final Screens.
Brannan Sand and Gravel Company
Denver, Colorado
Sand and Gravel
October 11, 15 & l6, 1979
1. Initial Screens
2. Primary Crusher
3. Transfer Point
U. Secondiary Screens
5. Cone Crusher
6. Final Screens
7A & 7B Transfer Points
Vulcan Materials
Garrisonville, Virginia
Crushed Granite
October 22 through 25, 1979
1. Primary Crusher
2. Initial Screens
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Page It
Program D - Continued
3. U.5 ft. Cone Crusher
it. Secondary Screens
5. 5.5 ft. Cone Crusher
6. Transfer Point
7. Transfer Point
Program E
Plant:
Location:
Product:
Dates:
Test Points:
Flintkote Corporation
Frederick, Maryland
Crushed Limestone
October 26, 29 & 30, 1979
1. Primary Crusher
2. Transfer Point
3. Initial Screens
U. Cone Crusher
5. Storage Bin.
The participants in each of the programs consisted of the U. S.
Environmental Protection Agency (EPA), Scott Environmental Technology, Inc.
(SET), The Research Corporation (TRC), G-CA and representatives of the subject
plants. The SET personnel on site during all programs vere under the direction
of Mr. Joseph Wilson, Field Supervisor. The balance of the Scott test crew
were Mr. Jeff Castor (Programs A, B & C), Mr. David Combe (Programs A, B, C,
D & E), Mr. Joseph Marino (Programs A, B, C, D & E), and Mr. Bruce Markley
(Programs B, C, D & E).
' Other participants were::
Vulcan - Ala: Vulcan - Allen Blake
GCA - Bob Greenberg
TRC - Louis Clark, Randall Kauffman
EPA - Roy Neulicht, John Brown
Castle Concrete & GCA - Bob Greenberg
Brannan Sand & Gravel ___ _ , _, , _. „ ,
TRC - Louis Clark, Jim Nedry
EPA - John Brown
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Vulcan - VA.
Page 5
GCA - Bob Greenberg, Tom Henderson
TRC - Louis Clark, Jim Nedry
EPA - John Brown
Flintkote: GCA - Tom Henderson
TRC - Louis Clark, Jim Nedry
EPA - John Brovn.
The results of the test program at Brannan Sand and Gravel,
Colorado are summarized in this report.
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SET 18.38/18UU 01 0180 Page 6
2.0 SUMMARY OF RESULTS - BRANNAN SAND & GRAVEL, COLORADO
This facility processes primarily bank run non-metallic minerals.
The process equipment, mounted on trailers and portable, was at a site just
northwest of Denver near Golden, Colorado. The entire process is powered
by diesel engine generators. • The Oj.e was being removed from a gravel bank
and trucked to the bank top for dumping into the initial screens before
the primary crusher. A schematic of the process is shown in Figure 2.A.
The plant produced two grades; approximately three-quarter inch stone and
gravel fines, used for road construction and as a concrete component.
Seven test points were selected by the Project Officer as follows:
TP-1 Initial Screens
TP-2 Primary (Jaw) Crusher
TP-3 Transfer Point
• TP-lt Secondary Screen
TP-5 Cone Crusher
TP-6 Final Screen
TP-TA & 7B Transfer Points
Test Point 7 was a combination of two conveyor transfer points
(A&B) in c?ose proximity. Observational interferences experienced at this
plant included gusty winds which kicked up dust at intermittent intervals.
Sun angle conditions limited the tim^ available for some test point obser-
vation sets, and minor delays resulted from spotty rains.
Summaries of the test data are presented in the following tables.
Table 2.1 summarizes the results of the Method 9 and Method 22 observa-
tions. The data in Table 2.2 represents Method 9 data expressed as the
percent of observation time that emissions exceeded various opacity levels.
Conventional Method 9 six-minute opacity averages are shown in Table 2.3.
Table 2.4 presents the moisture content of non-metallic mineral samples
collected during the test program. Observational parameters are illustrated
in Figures 2.B through 2.H.
Scott Environmental Technology Inc.
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TP-1 Initial Screens
TP-2 Primary Crusher
TP-3 Transfer Point
TP-4 Secondary Screens
TP-5 Cone Crusher
TP-6 Final Screens
TP-7a Transfer Point
TP-7b Transfer Point
• Indicates Spray Bars
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Page 8
TABLE 2.1
'VISIBLE EMISSION SUMMARY
BRANNAN SAND AND GRAVEL COMPANY ..
DENVER, COLORADO
Percent 'of Time Emissions
, ' Exceeded "X" Percent Opacity
Method 22
Time
Period
Test Point 1,
0720-0750
0800-0830 .
0840-0910 '
0920-09411
0722-0732J
Avg.
Test Point 2,
0740- 0810
0815-0845
0850-0920
0930-1000
Observed
Time (min)
Initial Screens,
30
30
30
30
Primary Crusher,
30
30
30
30
Observer
"X" 1 2
10/12/79,
0 .2
0 1
0 2
0 • 2
0 2
10/15/79
0 93
15 42
15 20
15 30
10/15/79
1
<1
1
4
2
92 :
40
12
48
Method 9
Observer
3
«.
23
20
19
13
19
91
17
25
'7
4
4
7
7
, 0
5
93
18
18 .
10
Average
Opacity
Method 9
Observer
3
1
1
1
• <1
1
14
11
13
8
4
<1
<1
<1
0
<1
.12
14
13
10
Avg. (X = 15)
15
31 33
16 15
Test Point 3, Transfer Point, 10/16/79
11 12
0731-0801
1110-1140
Test Point 4,
0907-0937
0945-1015
1035-1105
1310-1340
Avg.
1345-1405
30
30
Secondary
30
30 '
30
• 30
20
0
10
Screens,
0
0
0
0
0
10
6
3
10/16/79
5
1
42*
5
4."
3
12
33
15
1
4*
10
9
12
12
0
3
0
. 56
0
15
0
12
0
16
0
0
0
4
0
<1
2
<1
0
3
0
1
2
<1
4
1
0
0
0
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SET 1838/1844 01 0180
TABLE 2.1 (Continued)
VISIBLE EMISSION SUMMARY
BRANNAN SAND AND GRAVEL COMPANY (CONTINUED)
DENVER, COLORADO
Page 9
Percent of Time Emissions Average
Exceeded "X" Percent Opacity Opacity
Method 22
Time
Period
Test Point 5,
1342-1412
1420-1450
1455-1525
1530-1600
Avg. (X = 15)
Test Point 6,
1020-1050
1055-1125
1130-1200
1303-1333
Avg.
Test Point 7A
1610-1640
1646-1716
Avg.
Test Point 7B
1415-1455
1455-1525
Ava.
Observed
Time (rain)
Observer
"X"
1
2
Method 9
Observer
3
4
Method 9
Observer
3
4
Cone Crusher, 10/15/79
30
30
30
30
0
15
15
15
.15
93
14
6
2
,7.
99
0
1
0
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Page- 10
TABLE 2.2
METHOD 9/TIME CORRELATION
BRANNAN SAND AND GRAVEL COMPANY
DENVER, COLORADO
Percent of Time
Emissions Exceeded "X" Opacity
Test Period Observer Notes
Ti=st Point 1, Initial Screens, 10/12/79,
0720-0750 3
4
0800-0830 3
4
0840-0910 3
4
0920-0941 _
T
0722-0732 (10/15/79)
4
Test Point 2, Primary Crusher, 10/15/79
0740-0810 3.
4
0815-0845 3
4
0850-0920 3
4
0930-1000 3
4
Test Point 3, Transfer Point, 10/16/79
0731-0801 3
4
1110-1140 - 3
4
Test Point 4, Secondary Screens, 10/16/79
0907-0937 3
4
0945-1015 3
4
1035-1105 3
4
1310-1340 3 ' .
4
1345-1405 3
4
-"X"
0 5 10 15 20 25 30 35
10/15/79
23
42
20 •
7 1
19 • -
7 •
.
0
91 77 46 36 20 4
93 88 52 13 ,
95 68 35 17 8 1
100 98' 65 18 '
99 83 50 25 10 2
100 93 48 18
85 51 19 7 1
87 63 28 10
12
12
42
71 3
3
16 -
0
0
56*
0*
0
o
43 *Data omitted - wind interference
18 " . .
£y) Scott Environmental Technology Inc.
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Page 11 '
.TABLE 2.2 (Continued)
METHOD 9/TIME CORRELATION
BRANNAN SAND AND GRAVEL COMPANY (CONTINUED)
DENVER, COLORADO
Test Period
Observer
Notes
Percent of Time
Emissions Exceeded "X" Opacity
"X"
0 5 10 15 20 25 30 35
Test Point
1342-1412
1420-1450
1455=1525
1530-1600
Test Point
1020-1050
1055-1125
1130-1200
1305-1335
Test. Point
1610-1640
1046-1716
Test Point
1415-1445
1455-1525
5, Cone Crusher, 10/15/79
.3
4
3
4
3 •
4
3
4
6, Final Screens, 10/15/79
3
4
3
.4
3
4
3
4.
7A, Transfer Point, 10/15/79
3
4
3
4
7B, Transfer Point, 10/16/79
3
4
3
4
100 67
100 98
100 95
100 100
98 73
100 95
99 98
100 96
3
. 2
0
0
2
. 0
0
0
,
.0
0
0
0
0
0 .
7 2
8 4
•
23 1
78 18
42 • 5
83 19
11 2
74 36
40 3
23
1
2 1
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Page 12
TABLE 2.3
METHOD 9 - SIX MINUTE AVERAGES
Brannan Sand, and Gravel Company
Denver, Colorado
TP-1
TP-2
TP-3
TP-4
TP-5
TP-6
TP-7
Initial
Screens
Observer
Run 3 4
1 <1
2 0
• 3 2
4 1
5 3
6 1
7 1
8 1
9 1
10 1
11 3
12 1
13 <1
14 <1
15 <1
16 0 '
17 0 -
18 0
19 2
20 2
0
0
0
1
1
<1
0
0
<1
1
<1
0
<1
1
<1
0
0
Q
0
Primary Transfer
Crusher Point
Observer Observer
343 4
14
16
16
16
12
9
13
9
13
12
17
9
14
13
15
8
6
7
10
0 9
|jy) Scott Environmental
13 0 0
14 0 1
14 2 1
9 <1 <1
13 0 0
15 1 U
14 2 4
14 <1 3
15 3 4
13 4 5 '
16
13
11
12
13
9
6
9
11
12
Technology Inc.
Secondary Cone
Screens Crusher
Observer Observer
3434
0
<1
<1
0
0
0
0
0
0
0
0
<1
4
5
5
0
0
0
0
0
<1
3
1
0
0
0
0
0
0
0
0
0
0
.0
0
0
0
0
0
0
8
9
9
12
13
11
13
12
13
12
12
10
9
7
8
12
13
11
11
12
12
14
17
15
15
15
16
14
16
14 .
17
17
17
10
15
10
11
11
11
11
Final
Screens
Observer
3 4
0
0
<1
1
0
0
0
0
0
0
0
<1
0
0
<1
0
0
0
0
0
0
0
0
<1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Transfer
Points
Observer
3 4
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
<1
<1
0
0
2
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
0
0
3
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Page 13
TABLE 2.4
ROCK SAMPLE MOISTURE CONTENT
Brannan Sand and Gravel Company
Denver, Colorado
Sample
No.
15
16
17
18
19
20
21
22
Sample
Date
10/12/79
10/15/79
10/16/79
10/16/79
10/15/79
10/15/79
10/15/79
10/15/79
Sample Source
Initial Screens
(TP-1)
Primary Crusher
(TP-2)
Transfer Point
(TP-3)
Transfer Point
(TP-3)
Secondary Screens
(TP-4)
Cone Crusher
(TP-5)
Final Screens
(TP-6)
Transfer Point
Gross
Weight
(g)
632.6
830.1
403.2
383.6
383.6
482.2
752.6
316.9
% Moisture
0.83
1.7
1.4 (before rain)
1.4 (after rain)
1.4
0.99
2.5
3.9
(TP-7)
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Pace lU
Plan
WD - Variable
WS - 0-3 mph
Clear
Test Point Ht.
- 20'
TT
ID
Elevation
Background - Sky
Key
X- point of emissions
- observer location
r sun position
Inc.
FIGURE 2.B
Test Point #1 Initial Screens
Brannan Sand and Gravel. Co. Denver, Colorado
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Page.15
to
O
Plan
WD - Variable
WS - 0-2 mph
Clear
Test Point Ht.
-3'
Elevation
Background - sky at
horizon, truck trailers
Key
X - point of emissions
£?- observer location
J(\- syn position
Inc.
FIGURE 2.C
Test Point #2 Primary Crusher
Brannan Sand and Gravel Co. Denver, Colorado
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SET 1838/18W 01 0180
Page 16
W
o
\'
n
Plan
WD - Variable
WS - 0-2 mph
Partly Cloudy
Test Point Ht.
- 6'
Elevation
Background - Sky,
truck -trailer
Key
X- point of emissions
?- observer location
- sun position
ii«« Inc.
FIGURE 2.D . , :/
Test Point #3 Transfer Point
Brannari Sand and Gravel Co. Denver, Colorado
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Page 17
••BP» !fry»
Plan
WD - East
ws - 0- 15 mph, gusty
Partly Cloudy
Test Point Ht. - 20'
Elevation
Background - Sky with
gray cloudc.
Key
X - point of emissions
?- observer location
- sun position
Inc.
FIGURE 2.E • .
Test Point $4 Secondary Screens
Brannan Sand and Gravel Co. Denver, Colorado
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Page 18
Plan
WD - Variable
WS - 0- 10 raph, 'gusty
Partly Cloudy
Test Point Ht. - 4'
Elevation
Background - Earth
"bank and gray trailer
Key
X- point of emissions
?- observer location
,- sun position
^li Inc.
FIGURE 2.F .
Test Point #5 Cone Crusher
Brannan Sand and Gravel Co,. Denver, Colorado
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Page 19
Plan
o
WD - Variable
WS - 0-2 mph
Clear
Test Point Ht.
- 10'
Elevation
Background. - Sky,
gray
Key
X - point of emissions
- observer location
r sun position
environmental
Technology
Inc.
FIGURE 2.G '' ' •
Test Point #6 Final Screens
Brannan Sand and Gravel Co. Denver, Colorado
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Page 20
w
Plan
o
WD - Variable
WS - 0- 5 mph
Partly Cloudy
7A Test Point Ht.
7B Test Point Ht.
- 6'
- 5'
X-B
a:
~tr
Background:
A - Sky at horizon
B - earth bank vith
scattered shrubs
Elevation
Key
- point of emissions
- observer location
- sun position
Inc.
FIGURE 2.H
Test Points 7A and 7B Transfer Points
Brannan Sand and Gravel Co. Denver, Colorado
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