United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 79-NMM-11E
April 1980
Air
Non Metallic Minerals
Stone Processing
Emission Test Report
Flintkote Corporation
Frederick, Maryland
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SET 1838/18M 01 0180
VISIBLE MISSIONS FROM
NON-METALLIC MINERAL PROCESSING
FLINTKOTE CORPORATION,
FREDERICK, MARYLAND
79-HMM-ll-E
EPA Contract No. 68-02-28.13
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.
Plumsteadvilie, Pennsylvania 189^9
Scott Environmental Technology inc.
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TABLE OF CONTENTS
Page
1.0 INTRODUCTION , 1
2.0 SUMMARY OF RESULTS - FLINTKOTE CORPORATION, MARYLAND . . 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
consisted of changing the observational threshold from zero, opacity as
specified in the method to a suitable upscale opacity threshold at 5%
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SET 1838/18M 01 0180 Page 2
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 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 observation 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 con-
ducted 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 process-
ing 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 v
• Location: Helena, Alabama
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Page 3
Program A - Continued
Product: Crushed Stone
Dates: October 2 through U, 1979
Test Points:!. 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: Castle Concrete Company
Location: Colorado Springs, Colorado
Product: Crushed Limestone
Dates: October 8 through 11, 1979
Test Points:!. Primary Crusher
2. Initial Screens
3. Transfer Point
1*. Untested (Reclaim Tunnel)
5. Secondary Screens
6. Cone Crusher
7. Final Screens
Program C
Plant: Brannan Sand and Gravel Company
Location: Denver, Colorado
Product: Sand and Gravel
Dates: October 11, 15 & 16, 1979
Test Points:!. Initial Screens
2. Primary Crusher
3. Transfer Point
1*. 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:
Vulcan Materials
Garrisonville, Virginia
Crushed Granite
October 22 through 25, 1979
1. Primary Crusher
2. Initial Screens
3. ^-5 ft. Cone Crusher .
h. Secondary Screens
5. 5-5 ft. Cone Crusher
6. Transfer Point
T. 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
k. 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).
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Page 5
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 Bro wn
The results of the test program at Flintkote Corporation,
Maryland are summarized in this report.
Castle Concrete &
Brannan Sand & Gravel
Vulcan - VA.
Flintkote:
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2.0 SUMMARY OF RESULTS - FLINTKDTE CORPORATION, MARYLAND
The Flintkote facility, located approximately a mile south of
Frederick, Maryland is a large mineral processing operation. The process
tested, the #2 limestone plant, was one segment of the operation. The
plant was receiving the raw rock from large banks of what appeared to be
previously quarried stone, and was producing large-size grades of crushed
limestone. The process equipment arrangement was semi-portable, with some
of the components on trailers. Figure 2.A presents a schematic of the
operation. •
Upon their arrival on 10/26/795 the test team was given a
safety orientation and process inspection. Some of the anticipated test
points were deemed untestable bacause they were indoors, and a total
of 5 testable points were identified:
TP-1 Primary Crusher
TP-2 Conveyor Transfer
TP-3 Initial Screens
TP-H Cone Crusher
TP-5 Storage Bin.
No significant interferences were encountered at this site,
and the major problems were the result of process breakdowns and rock
jams. One jam occurred in the primary crusher which required explosive
charges to dislodge. The testing on the five points was completed on
10/30/79-
Summaries of the test data are presented in the following
tables. Table 2.1 summarizes the results of the Method 9 and Method
22 observations. The data in Table 2.2 represents Method 9 data ex-
pressed 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 for each of the test points are diagrammed in.
Figures 2.B through 2.F.
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Page 8
.TABLE 2.1
VISIBLE EMISSION SUMMARY
FLINTKOTE COMPANY
FREDERICK, MARYLAND
Percent of Time Emissions Average
. Exceeded "X" Percent Opacity Opacity
Method 22
Time
Period
Test Point 1,
* .
" 0945-1015
1048-1118
1126-1156
Avg. (X = 10)
1209-1239
Test Point 2,
1353-1427
1428-1458
1533-1603
1125-1155
Avg.
Test Point 3,
1300-1330
1336-1406
1412-1542
1450-1520
Avg.
Test Point 4,
1530-1600
1023-1053
1110-1140
1151-1221
Avg. (X = 20)
Observed
Time (rain)
Primary Crusher
30
30
30
30
Transfer Point,
30
30
30
30
Initial Screens
30
30
30
30
Observer
"X"
, 10/26/79
0
10
10
10
15 .
10/26/79,
0
0
0
0
0
, 10/29/79
0 .
0
0
0
6
1
65
8
10
.9
1
2
58
11
10
11
2
Method 9
Observer
3
72
16
•23
20 •
10
4
78
7
13
10.
0
Method 9
Observer
3
5
8
10
9
Q
4
6
6
7-
7
5
10/29/79
0
4
3
2
2
,
0
0
0
0
0
1
2
1
0
1
10/30/79'
0
0
0
0
0
0
1
0
0
.
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Page 9
TABLE, 2.1 (Continued)
VISIBLE EMISSION SUMMARY
FLINTKOTE COMPANY
FREDERICK, MARYLAND
Percent of Time Emissions
Exceeded "X" Percent Opacity
Time
Period
Test Point
0755-0825
1023-1053
0908-0938
0947-1017
Observed
Time (min)
5, Storage Bin,
30
30
30
. 30
"X"
10/29/79,
0
0
0
0
Method 22
Observer
1 2
10/30/79
• 0 0
0 0
0 0
0 0
Method 9
Observer
3
0
0
' 0
0
4
0
0
1 .
. '1
Average
Opacity
Method 9
Observer
3 4
0
0
0
0
0
0
Avg.
-0
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Page 10
TABLE 2.2 .
METHOD 9/TIME CORRELATION
FLINTKOTE COMPANY
FRED ERICK, MARYLAND
Percent of Time
Emissions Exceeded "X" Opacity
Test Period
Test Point 1,
0945-1015
1048-1113
1126-1156
' 1209-1239
Test Point 2,
1353-1427
1428-1458
1533-1541
1059-1120
1125-1155
Test Point 3,
" 1300-1330
1336-1406
1412-1442
1450-1520
Observer ... Notes
Primary Crusher, 10/26/79
3
4
o
4
3
. 4
3
4
Transfer Point, 10/26/79,
4
3
4
3
10/26/79
4 10/29/79
3
.4
3
Initial Screens, 10/2-9/79
4
3
4
3
4
3
4
3
"X"
0 5 .10 15 20
72 29 12 3 1
78 37 92
84 38 16 7 3
78 32 7-3
91 53 23 12 ' 8
83 38 13 6 2
96. 53 20 10"6
79 25 6
10/29/79
0
0
0
1
t
0
0
o .
0
0
0
0
0
0
0
0
0
25 30
1 1 '
4 2
2 1
.
«^?Vv
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Page 11
TABLE 2.2 (Continued)
METHOD 9/TIME CORRELATION
FLINTKOTE COMPANY (CONTINUED)
FREDERICK, MARYLAND
Percent of Time
Emissions Exceeded "X" Opacity
Test Period
Test Point 4,
1530-1600
1023-1053
1110-1140
1151-1221
Test Point 5,
0755-0825
1025-1053
0908-0938
0947-1017
Observer Notes
Cone Crusher, 10/29/79
4 '
3
4 10/30/79
3
• 4
3
4
3
Storage Bin, 10/29/79,
3
4
3
4
3 10/30/79
4
3
4 '
0
, 10/30/79
100
100
93
98
90
93
97
98
10/30/79
0
0
0
0
i 0
1
.0
1
•5
100
100
73
93
72
.' 78
90
81
10
64
100
26
76
44
50
• 68
70
- "X"
15 20 25 30
21 18
78 29 3 .
0 •
53' 18
•14
38 18 . 1
.33 1
45 20 3 1
1
•
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Page 12
TABLE 2.3
METHOD 9 - SIX MINUTE AVERAGES
Flintkote Company
Frederick, Maryland
TP-1
Primary
Crusher
Run
I
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Observer
3 4
. 4
6
9
3
5
10
4
9
8
7
8
8
8
13
10
13
10
9
10
6
8
7
8
3
5
8
3
5
7
7
8
8
6
8
6
8
5
4
6
5
TP-2
Transfer
Point
Observer
3 4
0
0
0
0
0
0
4
0
0
0
0
0
0
0
0
0
o x
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
•0
0
TP-3
Initial
Screens
Observer
3 4
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
TP-4
Cone
Crusher
Observer
3 4
18
21
22
23
19
17
20
15
15
16
6
10
18
17
19
18
15
16
18
13
15
14
111
15
13
11
13
8
8
9
6
7
ll"
16
16
15
15
13
16
14
TP-5
Storage
Bin
Observer
34
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
<1
0
<1
0
0
0
<1
0
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Page 13
TABLE 2.4
ROCK SAMPLE MOISTURE CONTENT
Flintkote Company
Frederick, Maryland
Sample
No.
34
35
36
37
38
Sample
Date
10/26/79
10/26/79
10/29/79
10/29/79
10/29/79
Sample Source
Primary Crusher
(TP-1)
Transfer Point
(TP-2)
Initial Screens
(TP-3)
Cone Crusher
(TP-4)
Storage Bin
(TP-5)
Gross
Weight
(g) % Moisture
522.1
452.8
327.0
510.9
528.6
1.4
3.4
2.4
0,89
0.28
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Plan
I!
(
WD - Northwest
WS - 5-10 mph
Cloudy
Test Point Ht.
- 4'
Elevation
Background - Conveyor
and equipment
structure
X - point of emissions
£?- observer location
-O- sun position
.
'ia/'Wiiiti Inc.
FIGURE 2..B
Test Point #
Flintkote Co.
Primary Crusher
Frederick, Maryland
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SET 1838/18UH 01 0180
Page 15
Plan
WD - Northwest
WS - 5 mph
Cloudy
Test Point Ht.
- 10'
Background - Sky &
gray storage shed
Elevation
Key
X - point of emissions
?- observer location
- sun position
Inc.
FIGURE 2.C
Test Point #2 Transfer Point
Flintkote Co. Frederick, Maryland
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Page 16
Plan
N
WD - Northwest
WS - 0-5 mph
Clear
Test Point Ht.
- 20'
Elevation
'Background - Sky
Key .
X - point of emissions
?- observer"location
- sun position
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FIGURE 2.D
Test Point S3 Initial Screens
Flintkote Co. Frederick, Maryland
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17
N
Plan
WD - Northwest
WS - 0-5 mph
Clear
Test Point Ht. - 6'
QZZZD
Elevation
Background -
Equipment structure
Key
X- point of emissions
?- observer location
- sun position
Inc.
FIGURE 2.E
Test Point #4 Cone Crusher
Flintkote Co. Frederick, Maryland
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SET l833/l8Mi 01 0180
P:,."" 1.8
Plan
WD - Variable
WS - 0-5 mph
Clear
Test Point Ht.
-20'
Elevation
'Background - Sky .
Key
X- point of emissions
i^- observer location
- sun position
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