United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 79-NMM-110
April 1980
Air
Non Metallic Minerals
Stone Processing
Emission Test Report
Vulcan Materials
Company
Garrisonville, Virginia
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SET 1838/18M 01 0180
VISIBLE EMISSIONS FROM
NON-METALLIC MINERAL PROCESSING
VULCAN MATERIALS,
GARRISONVILLE, VIRGINIA
79-NMM-ll-D
EPA Contract No. 68-02-2813
Work Assignments 39 & ^0
Prepared For:
Emission Measurement Branch
United States Environmental Protection Agency
Attn: Mr. J. E. McCarley
Mail Drop 13
Research Triangle Park, NC 27711
January 1980
SCOTT ENVIRONMENTAL SERVICES
A Division Of
SCOTT ENVIRONMENTAL TECHNOLOGY, INC.
Plumsteadville, Pennsylvania 189^9
Scott Environmental Technofosy Inc
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TABLE OF CONTENTS
Page
1.0 INTRODUCTION 1
2.0 SUMMARY OF RESULTS, VULCAN MATERIALS, VIRGINIA 6
APPENDIX A - FIELD DATA SHEETS
APPENDIX B - FIELD TEST LOG
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
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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 rock 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 determinations 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 accommodate process and weather variables. Method 9 was used
without any modification. The only modification used with Method 22 con-
sisted of changing the observational threshold from zero opacity as speci-
fied 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
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SET 1838/181+U 01 0180 Page 2
every test point with a zero visible threshold for EPA-22. In those instances
where essentially constant emissions were observed at a zero threshold
during the first set of observations, 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 ob-
servation 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
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Page 3
Program A - Continued
Test Points: 1. Primary Crusher
2. Untested (Surge Conveyor)
3. Impact Crusher Screen
U. Impact Crusher
5. Final Screens
6. Cone Crusher
7. Transfer Point
Program B
Plant:
Location:
Product:
Dates:
Test Points:
Program C
Plant:
Location:
Product:
Dates:
Test Points:
Castle Concrete Company
Colorado Springs, Colorado
Crushed Limestone
October 8 through 11, 1979
1. Primary Crusher
2. Initial Screens
3. Transfer Point
U. 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 & 16, 1979
1. Initial Screens
2. Primary Crusher
3. Transfer Point
h. Secondary Screens
5. Cone Crusher
6. -Final Screens
7A & 7B Transfer Points
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Page
Program D
Plant:
Location:
Product:
Dates:
Test Points:
Program E
Vulcan Materials
Garrisonville, Virginia
Crushed Granite
October 22 through 25, 1979
1. Primary Crusher
2. Initial Screens
3. U. 5 ft. Cone Crusher
U. Secondary Screens
5. 5.5 ft. Cone Crusher
6. Transfer Point
7. Transfer Point
Flintkote Corporation
Frederick, Maryland
Crushed Limestone
October 26, 29 & 30, 1979
1. Primary Crusher
2. Transfer Point
3. Initial Screens
IK 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), GCA and representatives of the subject
plants. The SET personnel on site during all programs were 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).
Plant:
Location:
Product:
Dates:
Test Points:
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Other participants were:
Vulcan - Ala. Vulcan - Allen Blake
GCA - Bob Greenberg
TRC - Louis Clark, Randall Kauffman
EPA - Roy Neulicht, John Brown
GCA - Bob Greenberg
TRC - Louis Clark, Jim Nedry
EPA - John Brown
GCA - Bob Greenberg, Tom Henderson
TRC - Louis Clark, Jim Nedry
EPA - John Brown
GCA - Tom Henderson
TRC - Louis Clark, Jim Nedry
EPA - John Brown
i
The results of the test program at Vulcan Materials, Virginia are
summarized in this report.
Castle Concrete &
Brannan Sand & Gravel
Vulcan - VA.
Flintkote:
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SET 1838/18M 01 0180 Page 6
2.0 SUMMARY OF RESULTS - VULCAN MATERIALS, VIRGINIA
The Vulcan Materials operation is situated in Garrisonville, just
west of Stafford, Virginia. This plant is new, having been in operation
approximately one year. The processing equipment is all at ground level
and is permanently installed about 1/U mile from the open pit quarry. A
schematic of the process is shown in Figure 2.A.
This facility processes granite in two grades, "clean stone" and
"crusher run". Both grades are produced during typical operations. Emission
level differences between the two products were not discernable by the
observation team.
Upon completion of the required safety indoctrination, the test
personnel conducted a preliminary site inspection. Seven test points were
selected for observation:
TP-1 Primary (Jaw) Crusher
TP-2 Initial Screens
TP-3 U.5 ft. Cone Crusher
TP-lj Secondary Screens
TP-5 5.5 ft. Cone Crusher
TP-6 Intermediate Transfer
TP-7 Screens Return Transfer
No interference from water spray mist was evident at any of the
test points. The only observational difficulties were the result of dust
leaks whose emissions interfered with test point emission observations.
Rain and process shutdowns resulted in significant delays in the testing.
The testing was accomplished between 10/22/79 and 10/29/79.
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 opactiy 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. Diagrams of the observational parameters
are presented in Figures 2.B through 2.H.
Scott Environmental Technology Irx.
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Q
o 3
(O
C I-1 H
I- ,O J VJQ
rt H L
O PJ •**
H 3
H-
O
n
o
P-
M
O
H-
P.
Ol
TP-1
TP-2
TP-3
TP-4
TP-5
TP-6
TP-7
Primary Crusher
Initial Screens
4^ Cone Crusher
Secondary Screens
5% Cone Crusher
Transfer Point
Transfer Point
O Indicates Spray Bars
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Page 8
TABLE 2.1
VISIBLE EMISSION SUMMARY
VULCAN MATERIALS
GARRISONVILLE, VIRGINIA
Percent 'of Time Emissions
Exceeded "X" Percent Opacity
Method 22
Time
Period
-t Test Point 1,
".1342-1412
1435-1505
Avg.
1515-1545
1605-1635
Avg.
Test Point 2,
1516-1546
1558-1628
1100-1130
1302-1332
Avg.
Test Point 3,
0925-0955
1008-1038
1045-1115
1125-1155
Avg. (X = 15)
Test Point 4,
1108-1138
1143-1158
0745-0805
0810-0840
0845-0915
Avg.
Observed
Time (rain)
Primary Crusher
30
30
30
30
Initial Screens
30
30
30
30
4*5 Cone Crusher
30
30
30
30
Observer
"X"
, 10/25/79
0
0
0
10
10
10
, 10/24/79
0
0
0
0 .
0
, 10/23/79
0
10
15
15
15
1
.1
9
5
0
0
0
0
0
0
0
0
68
8
10
0
5
Secondary Screens, 10/22/79,
30
15
15
30
30
f
0
0
0
0
0
0
1
1
1
1
1
1
2
5
5
5
0
0
0
0
0
0
0
0
49
14
2
0
1
10/23/79
10
13
5
' 6
7
8
Method 9
Observer
3
•
23
17
20
0
0
0
0
0
'0
0
0
70
0
0
0
0
33
0
0
0
0
7 .
4
19
30
25
0
0
0
0
0 '
0
0
0
68
0
0
0
0
8
4
0
0
0
2
Average
Opacity
Method 9
Observer
3
1
1
1
1
2
2
0
0
0
0
0
4
4
5
3
4
2
0
0
0
0
4
1
2
2
1
1
1
• '
0
0
0
0
0
4
3
3
2
3
<1
<1
0
0
0
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TABLE 2.1 (Continued)
VISIBLE EMISSION SUMMARY
VULCAN MATERIALS (CONTINUED)
GARRISONVILLE, VIRGINIA
Page 9
» Percent of Time Emissions
, ' Exceeded "X" Percent Opacity
Method 22
Time
Period
Test Point
0830-0900
0908-0938
0945-1007
1008-1018
1025-1055
Observed
Time (min)
5, 5h Cone Crusher
30
30
22
10
30
Observer
"X"
, 10/22/79
0
10
15
15
15
1
11
37
7
h6
1
2
25
36
6
10
7
Method 9
Observer
3
47
40*
0
0 ,
0
4
67
2*
0
. 0
o-
Average
Opacity
Method 9
Observer
3
2
12
10
10
6
4
3
10
10-
13
9
Avg. (X = 15)'
15
20
Test Point 6, Transfer Point, 10/23/79, 10/24/79
Avg.
Test Point 7, Transfer Point, 10/25/79
Avg.
<1
11
1257-1327
1335-1350
1338-1353
1355-1425
1433-1503
30
15
15
30
30
0
0
0
0
0
0
0
0
0
0
0
1 .
0
0
0
0
3
0
0
0
0
4
0
0
0
0
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Page 10
TABLE 2.2.
METHOD 9/TIME CORRELATION
VULCAN MATERIALS
GARRISONVILLE, VIRGINIA
Test Period
Test Point 1,
1342-1430
1435-1505
1515-1601
1605-1635
Test Point 2,
1100-1130
1303-1332
1516-1546
1558-1628
Test Point 3,
0925-0955
1008-1038
1045-1116
1125-1155
Observer
Primary Crusher,
3
4
3
4
3
. 4
3
4
Initial Screens,
3
4
3
4
3"
4
3
4
Notes
10/25/79
10/24/79
4.5' Cone Crusher, 10/23/79
3
4
3
4
3
4
3
4
•
Percent of Time
Emissions Exceeded "X" Opacity
"X"
5 10 15 20 25 30 35
23
19
17
30
16
13
29
23
0
0
0
0
0
0
0
0'
69
68
75
59
84
64
58
30
3 1
6
4
2
4
1
3
12
2
7
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TABLE 2.2. (Continued)
METHOD 9/TIME CORRELATION
VULCAN MATERIALS (CONTINUED)
GARRISONVILLE, VIRGINIA
Percent of Time
Emissions Exceeded "X" Opacity
Test Period
Observer
Notes
T<=st Point 4,
1108-1138
1143-1158
0745-0805
0810-0840
0845-0915
Test Point 5,
0830-0900
0908-0938
0945-1007
1008-1018
1025-1055
Test Point 6,
1257-1327.
1335-1350
1338-1353
1355-1425
1433-1503
Secondary
3
4
3
4
• 3
4
3
4
3
4
5.5' Cone
3
4
3
4
3
.4
3
4
3
4
Transfer
3
4
3
4
3
4
3
4
3
4
Screens, 10/22/79, 10/23/79
33
8
0
4
0
0 -
0
0
0
o
Crusher, 10/22/79
47
67
100
100
95
94-
100
100
98
98
Point, 10/23/79, 10/24/79
0
0
3
4
0
0
0
0
0
0
1
1
98
93
95
91
97
100
51
90
•
10
-"X"
15 20
25 30 35
40
2
23
24
13
38
10
14
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TABLE 2.2 (Continued)
METHOD 9/TIME CORRELATION
VULCAN MATERIALS (CONTINUED)
GARRISONVILLE, VIRGINIA
i
* '
Percent of Time
Emissions Exceeded "X" Opacity
"X"
Test Period Observer Notes _0 __5_ JLO_ 15^ 20 25_ _30
Test Point 7, Transfer Point, 10/25/79 .
0750-0820 .3 5
'4 0
0826-0906 3 .0
4 -0
0915-0945 .3 0 '
4 . 0 •
0955-1025 3 0
4 0
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Page 13
TABLE 2.3
METHOD 9 - SIX MINUTE AVERAGES
Vulcan Materials Company
Garrisonville, Virginia
TP-1
TP-2
TP-3
TP-4
TP-5
TP-6
TP-7
Primary Initial
Crusher Screens
Observer Observer
Run 3434
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
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Page
TABLE 2.3
ROCK SAMPLE MOISTURE CONTENT
Vulcan Materials
Garrisonville, Virginia
Sample
No.
23
24
25
26
27
28
29
30
31
32
33
Sample
Date
10/25/79
10/25/79
10/25/79
10/25/79
10/23/79
10/22/79
10/22/79
10/23/79
10/24/79
10/25/79
Sample Source
Primary Crusher
(TP-1)
Primary Crusher
(fine particles)
Initial Screens
(TP-2)
Initial Screens
(TP-2)
4 1/2' Cone Crusher
(TP-3)
Secondary Screens
(TP-4)
5 1/2' Cone Crusher
(TP-5)
Transfer Point
(TP-6)
Transfer Point
(TP-6)
Transfer Point
(TP-7)
10/25/79 Transfer Point
(TP-7)(fine particles)
Gross
Weight
(g)
642.7
140.04
576.1
681.0
554.8
756.7
662.5
580.0
528.92
564.4
224.3
% Moisture
2.7
8.9
3.4 (be
1.4 (af
0.59
0.42
0.58
0.51
0.55
0.81
5.1
Vftv
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Page 15
Plan
WD - South
WS - 5 mph
Overcast
Test Point Ht.
- 61
Elevation
Background - Trees at
horizon & structural
support.
Key
X- point of emissions
?- observer location
- sun position
Inc.
FIGURE 2.B .
Test Point #1 Primary Crusher
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Page 16
Plan
WD - Northwest
WS - 5 mph
Overcast
Test Point Ht.
- 1*0'
Elevation
Background - 'Sky
Key
X - point of emissions
£?- observer location
.- sun position
Inc.
FIGURE 2.C . '••'.-. • -'• :; / '•• '
Test Point #2 Initial Screens
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Page 17
Cat
Plan
WD - South
WS - 0-5 mph
Overcast
Test Point Ht.
Background - Gray
support structure
Elevation
X -
Key
point of emissions
- observer location
- sun position
Inc.
FIGURE 2.D
Test Point #3 4^ Cone Crusher
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Page 18
©
Plan
WD - Southeast
WS - 0-5 mph
Clear 10/22/79
Overcast 10/23/79
Test Point Ht. -
Elevation
Background - Conveyor
"belt & support
structure
Key
X - point of emissions
- observer location
- sun position
»!« U Inc.
FIGURE 2.E
Test Point #4 Secondary Screens
Vulcan Materials Co. Garris'onv'ille, Virginia
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Page 19
&
Plan
WD - Variable
WS - 0-5 mph
Clear
Test Point Ht.
Elevation
Background - Grassy
bank at horizon with
trees & support
structure.
Key
X - point of emissions
- observer.location
- sun position
FIGURE 2.F
/
Test Point #5 5h Cone Crusher
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Page 20
Plan
WD - 10/23 South
10/24 North
WS - 5-10 mph
Overcast
Test Point Ht. - 40'
Background - Sky
Key
X - point of emissions
£?- observer location
- sun position
Elevation
Inc.
FIGURE -2.G .
Test Point #6 Transfer Point
Vulcan Materials Co. Garrisonv.ille, Virginia
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Page 21
Plan
o
WD - Variable
WS - 0-5 mph
Partly Cloudy
Test Point Ht.
- 50'
Elevation
Background - Sky
Key
X - point of emissions
?- observer location
- sun position
FIGURE 2.H •
Test Point #7 Transfer Point
Vulcan Materials Co. Garrisonville, Virginia
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