SEPA
United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 83-ASP-4
May 1934
Air
Asphalt Concrete
industry
Emission Test
Report
T.J. Campbell
Company
Oklahoma City,
Oklahoma
Volume 1
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DCN 222-078-03-15
EMISSION TEST REPORT
T.J. CAMPBELL ASPHALT CONCRETE PLANT
OKLAHOMA CITY, OKLAHOMA
Final Report 83-ASP-4
Volume 1
Prepared for:
Mr. Clyde E. Riley
Task Manager
Emissions Measurement Branch
Office of Air Quality Planning and Standards
U.S. Environmental Protection Agency
Research Triangle Park, North Carolina 27711
EPA Contract No. 68-02-3850
Work Assignment 03
ESED Project No. 83-05
Prepared by:
M.R. Fuchs
E.P. Anderson
L.-A. Rohlack
A.E. Behl
Radian Corporation
Revised May 84
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This report has been reviewed by the Emission Standards
and Engineering Division, Office of Air Quality Planning
and Standards, Office of Air, Noise and Radiation,
Environmental Protection Agency, and approved for pub-
lication. Mention of company or product names does not
constitute endorsement by EPA. Copies are available
free of charge to Federal employees, current contractors
and grantees, and nonprofit organizations - as supplies
permit - from the Library Services Office, MD-35, Environ-
mental Protection Agency, Research Triangle Park, NC 27711
Order: EMB Report 83-ASP-4, Volume 1
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PREFACE
The work reported herein was performed by personnel from Radian
Corporation, Midwest Research Institute (MRI), and the U.S. Environmental
Protection Agency (EPA).
Radian's Project Director, Michael Fuchs, directed the field sampling
and analytical effort and was responsible for summarizing the test and
analytical data presented in this report. Sample analysis was performed
by Radian Corporation in Austin, Texas. The test work was performed under
EPA Contract No. 68-02-3850, Work Assignment No. 3.
MRI Project Monitor, William Terry, was responsible for monitoring
process operations during the emissions testing program, and for reporting
those data to EPA. Radian was responsible for incorporating the process
data into report form (Section 3.0). The assistance of T.J. Campbell Company
personnel contributed substantially to the success of this emission test
program. T.J. Campbell Construction Company personnel included Mr. Ted
Campbell, President, and Mr. O'Flynn Sewell, Plant Manager.
Mr. Jeffrey Telander, Office of Air Quality Planning and Standards,
Industrial Studies Branch, EPA, served as Project Lead Engineer and was
responsible for coordinating the process operations monitoring.
Mr. Clyde E. Riley, Office of the Air Quality Planning and Standards,
Emission Measurements Branch, EPA, served as Task Manager and was responsible
for overall test program coordination.
iii
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TABLE OF CONTENTS
Section Page
1.0 INTRODUCTION 1-1
1.1 Background -.- 1-1
1.2 Ob j ectives 1-2
1.3 Brief Process Description 1-2
1.4 Emissions Measurement Program 1-4
1.5 Description of Report Sections 1-7
2.0 SUMMARY AND DISCUSSION OF RESULTS 2-1
2.1 Particulate Emission Results 2-2
2.2 Total Organic Carbon Results. . . 2-13
2.3 Extractable Organics Emission Results 2-14
2.4 Comparison of TOC and Extractable Organics
Emission Results 2-18
2.5 Trace Metal Emission Results 2-22
2.6 Polynuclear Aromatic Hydrocarbons Emission
Test Results 2-25
2.7 Particle Size Distribution Results 2-27
2.8 Visible Emissions Results 2-32
2.9 Scrubber Water Grab Sample Measurements 2-38
2.10 Scrubber Water Analytical Results 2-41
2.11 Process Sampling Results 2-46
3.0 PROCESS DESCRIPTION AND OPERATION 3-1
3.1 Process Description.. 3-1
3.2 Process Operation 3-6
3.3 Process Monitoring During the Emission
Test Program 3-8
3.4 Emission Control System Monitoring During the
Emission Test Program/
3.5 Summary of Pertinent Plant Operation Information
During the Emission Test Program 3-12
4.0 SAMPLING LOCATIONS 4-1
4.1 Venturi Scrubber Inlet Sampling Locations „. 4-1
4.2 Venturi Scrubber Outlet Sampling Locations....... 4-5
4.3 Visible Emission Observation Locations 4-9
4.4 Venturi Scrubber Water SAmpling Locations „. 4-9
4.5 Venturi Scrubber Process Monitoring Locations.... 4-9
4.6 Asphalt Concrete Process Sampling Locations 4-13
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TABLE OF CONTENTS (continued)
Section PajL£
5.0 SAMPLING AND ANALYSIS 5-1
5 . 1 Sampling Procedures . 5-1
5.2 Analytical Methodology 5-19
5.3 Data Reduction 5-31
6. 0 QUALITY ASSURANCE 6-1
6.1 Standard Quality Assurance Procedures.. 6-1
6.2 Test Program Specific Quality Control/
Quality Assurance Procedures 6-9
vi
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LIST OF TABLES
Table Page
2-1 Summary of Particulate and Total Organic Carbon
Emissions during Conventional Operation
(English Units) 2-3
2-2 Summary of Particulate and Total Organic Carbon
Emissions during Conventional Operation
(Metric Units) 2-4
2-3 Summary of Particulate and Total Organic Carbon
Emissions during Recycle Operation
(English Units) 2-5
2-4 Summary of Particulate and Total Organic Carbon
Emissions during Recycle Operation
(Metric Units) ' 2-6
2-5 Comparison of Particulate Emissions Calculated by
the Concentration Method vs. Area-Ratio Method 2-10
2-6 Aggregate Additions for Typical Mixes at
T.J. Campbell Construction Company, Oklahoma City,
Oklahoma 2-12
2-7 Summary of Uncontrolled Particulate and Extractable
Organics Emissions 2-15
2-8 Summary of Controlled Particulate and Extractable
Organics Emissions 2-16
2-9 Comparison of Uncontrolled TOC and Extractable
Organics Emissions 2-19
2-10 Comparison of Controlled TOC and Extractable
Organics Emissions 2-21
2-11 Summary of Trace Metal Emissions during Conventional
Operation 2-23
2-12 Summary of Trace Metal Emissions during Recycle
Operation 2-24
2-13 Summary of Polynuclear Aromatic Hydrocarbon Emissions
during Conventional Operation 2-26
2-14 Summary of Polynuclear Aromatic Hydrocarbon Emissions
during Recycle Operation 2-28
VII
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LIST OF TABLES (continued)
Table Page
2-15 Summary of Uncontrolled Particle Size Distribution
Tests . „ 2-31
2-16 Summary of Visible Emission Observations during
Conventional Operation 2-33
2-17 Summary of Visible Emission Observations during
Recycle Operation 2-35
2-18 Summary of Scrubber Water pH and Temperature
Measurements for Conventional Operation..... 2-39
2-19 Summary of Scrubber Water pH and Temperature
Measurements during Recycle Operation 2-40
2-20 Summary of Scrubber Water Analytical Results during
Conventional Operation . 2-42
2-21 Summary of Scrubber Water Analytical Results during
Recycle Operation 2-44
2-22 Summary of Process Sample Measurements for
Conventional Operation. 2-47
2-23 Summary of Process Sample Measurements for Recycle
Operation 2-47
3-1 Technical Data on the Asphalt Concrete Plant Operated
by the T.J. Campbell Construction Company,
Oklahoma City, Oklahoma 3-2
3-2 Technical Data on the Wet Venturi Scrubber at the
T.J. Campbell Construction Company, Oklahoma
City, Oklahoma 3-5
3-3 Aggregate Additions for Typical Conventional Mixes
Produced at the T.J. Campbell Construction Company,
Oklahoma City, Oklahoma. 3-7
3-4 Aggregate Additions for Typical RAP Mixes Produced at
the T.J. Campbell Construction Company, Oklahoma
City, Oklahoma 3-7
viii
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LIST OF TABLES (continued)
Table Page
3-5 Process Information during Emission Testing,
T.J. Campbell Construction Company, Oklahoma
City, Oklahoma 3-9
3-6 Summary of Venturi Scrubber Operating Data Collected
during Conventional Operation at T.J. Campbell
Construction Company, Oklahoma City, Oklahoma 3-13
3-7 Summary of Venturi Scrubber Operating Data Collected
during Recycle Operation at T.J. Campbell
Construction Company, Oklahoma City, Oklahoma 3-14
3-8 Average Production and Mix Type during Testing
Period—T.J. Campbell Construction Company,
Oklahoma City, Oklahoma 3-15
5-1 Summary of Source Sampling Parameters and Methodology.... 5-2
5-2 Polycyclic Aromatic Hydrocarbons Determined by GC-MS 5-28
5-3 GC-MS Conditions 5-28
6-1 Summary of Calibrated Equipment Used in Performing
Source Sampling 6-2
6-2 Summary of Total Organic Carbon Audit Sample
Measurements 6-15
6-3 Summary of Cleanup Results 6-16
ix
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LIST OF FIGURES
Figure Page
1-1 Schematic of asphalt concrete plant process and
emission control equipment 1-3
2-1 Particle size distribution curves of uncontrolled
emissions collected during recycle and
conventional operation 2-30
2-2 Six-minute averages of November 12, 1983. Opacity
readings on the venturi scrubber stack during
conventional operation 2-34
2-3 Six-minute averages of November 10, 1983. Opacity
readings on venturi scrubber stack during
recycle operation 2-36
2-4 Six-minute averages of November 11, 1983. Opacity
readings on venturi scrubber stack during
recycle operation 2-37
3-1 Wet venturi emissions control scrubber operated by the
T.J. Campbell Construction Company, Oklahoma City, OK..
3-4
4-1 Schematic of asphalt concrete process including
sampling point locations and sampling matrix 4-2
4-2A Side View of Inlet Duct Sampling Ports 4-3
4-2B Top View of Inlet Duct Sampling Ports 4-3
4-3 Venturi scrubber inlet sampling location for gas
flow rate, particulate mass, condensible
hydrocarbons, trace metals, and polyaromatic
hydrocarbons emissions sampling 4-4
4-4 Venturi scrubber inlet sampling location for the
collection of particle size distribution samples 4-6
4-5 Venturi scrubber outlet sampling location for
particle size distribution sampling 4-7
4-6 Venturi scrubber outlet sampling location for gas
flow, particulate mass, condensible hydrocarbons,
trace metals, and polyaromatic hydrocarbons
emission sampling 4-8
xi
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LIST OF FIGURES (continued)
Figure
4-7 Locations of visible emission observations at the
T.J. Campbell asphalt plant, Oklahoma City.
Oklahoma • • . 4-10
4-8 Layout of effluent and influent scrubber ponds
including sampling locations • • • 4-11
4-9 Venturi scrubber pressure drop monitoring location........ 4-12
4-10 Location of Flosensors® used to monitor the flow
rate of water to the T.J. Campbell wet venturi
scrubber 4-14
5-1 Modified EPA Method 5E sampling train designed to
collect particulate and condensible hydrocarbon
samples at the venturi scrubber inlet and outlet 5-7
5-2 Sampling train designed to collect trace metals
samples at the venturi scrubber inlet and
outlet 5-9
5-3 Sampling train designed to collect polynuclear Aromatic
hydrocarbon samples at venturi scrubber inlet
and outlet 5-11
5-4 In-stack Andersen high capacity stack sampler sampling
train used to determine the particle size distribution
at the venturi scrubber inlet 5-13
5-5 In-stack Andersen Mark III Cascade impactor sampling
train used to determine the particle size distribution
at the venturi scrubber outlet 5-14
5-6 Schematic of the Andersen Model HCSS high grain-loading
impactor 5-15
5-7 Particulate and condensible hydrocarbons sample
recovery analytical matrix 5-21
5-8 Particulate, extractable hydrocarbons, and trace
metals sample recovery analytical matrix................ 5-22
5-9 Polynuclear aromatic hydrocarbons sample recovery
analytical matrix 5-23
5-10 Scrubber water samples analytical matrix 5-24
5-11 Gas flow rate at stack conditions and stack
temperature. 5-35
xii
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SECTION 1
1.0 INTRODUCTION
Section 111 of the Clean Air Act of 1970 charges the Administrator of
the U. S. Environmental Protection Agency (EPA) with the responsibility for
establishing Federal standards of performance for new stationary sources
which may significantly contribute to air pollution. When promulgated,
these new source performance standards (NSPS's) are to reflect the degree of
emission limitation achievable through application of the best demonstrated
emission control technology. Emission data, obtained from selected indus-
trial sources, are used in the development and/or review of NSPS regula-
tions. Information is presently being collected and analyzed for the NSPS
review of the asphalt concrete industry.
1.1 BACKGROUND
An NSPS for asphalt concrete plants was promulgated March 8, 1974 and
established a particulate limit of 0.04 grains per dry standard cubic foot
and a visible emission limit of 20 percent opacity. Following a review of
this NSPS in 1979, no revisions to the standard were proposed; however, a
second review of the asphalt concrete NSPS was initiated in November of
1982. As part of this review, particulate and opacity limits are being
evaluated for plants utilizing recycle asphalt pavement (RAP). The review
of the NSPS was requested by the National Asphalt Pavement Association
(NAPA). The request was made from the concern that possible higher emis-
sions (particulate and visible) were being generated during asphalt concrete
production utilizing RAP. Increased hydrocarbon emissions during RAP utili-
zation are considered to result in greater plume opacity due to the genera-
tion of a "blue haze" created by condensed hydrocarbons.
1-1
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coofKMurrtOM
EPA's Office of Air Quality Planning and Standards selected the T. J.
Campbell Construction Co. asphalt concrete plant in Oklahoma City, Oklahoma,
as an emission test program site. Selection was based upon (1) utilization
of RAP, (2) prior results obtained during NSPS compliance testing, and (3)
suitability for testing.
1.2 OBJECTIVES
The purpose of the test program was to obtain and evaluate emission
data (particulate matter, hydrocarbons, and visible emissions) from an
asphalt concrete plant processing RAP. The plant was tested during conven-
tional and recycle operations to provide a basis for comparison of the two
operational modes to the promulgated NSPS.
1.3 BRIEF PROCESS DESCRIPTION
Figure 1-1 presents a schematic of the asphalt concrete process.
Following are descriptions of conventional and recycle operations at the T.
J. Campbell plant.
1.3.1 Conventional Operation
Conventional operation is the term used to denote process operation
when feeding only virgin aggregate, i.e., unused aggregate material, to the
drum mixer. The virgin aggregate is loaded into the natural gas-fired
rotary drum mixer via a belt conveyor. The quantity and mix of virgin
aggregate is fed from four bins and controlled by a computer located in the
control room. Liquid asphalt is injected into the drum about three-fourths
of the distance of the drum from the burner end. The asphalt concrete falls
from the drum onto a conveyor and is transported to any of three storage
silos for truck load-out.
Gaseous emissions from the drum enter a knockout box which reduces the
gas velocity to allow further reduction of particulate matter by settling.
1-2
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U)
AGGREGATE
FEED BINS
BURNER
RAP
FEED PORT"
VENTURI
PRESPRAYS
STACK
Figure 1-1. Schematic of asphalt concrete plant process and emission control equipment.
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RAOSAH
From the knockout box, the emissions are ducted to a wet venturi scrubber.
In the duct work between the knockout box and venturi are water sprays to
cool the emission gases. Water is also injected at the venturi throat.
Additional water is flushed through a collection box below the venturi.
Scrubber water is contained in two earthen ponds totaling about 120 feet by
24 feet with an effective depth of 3 to 6 feet. Scrubber effluent flows
into the end of one pond while scrubber supply water is pumped from the end
of the other pond. The ponds are divided by a dike which serves as a weir
to reduce the suspended particulate matter in the scrubber water supply
pond.
1.3.2 Recycle Operation
Recycle oepration differs from conventional operation in that RAP
replaces a portion of the virgin aggregate in the rotary drum mixture. The
remainder of the RAP or recycle process is as described in Section 13.1.
The advantages of recycle operation include use of less virgin aggregate,
usually in areas with a limited supply of virgin aggregate, and the use of
less asphalt cement due to the inclusion of asphalt material in the RAP.
1.4 EMISSIONS MEASUREMENT PROGRAM
The measurement program was conducted at the T. J. Campbell Construc-
tion Co. asphalt concrete plant in Oklahoma City, Oklahoma, November 7-15,
1983. The emission tests were designed to characterize and quantify uncon-
trolled (venturi scrubber inlet) and controlled (venturi scrubber outlet)
emissions from the conventional and recycle asphalt operations.
Radian personnel were responsible for sampling and analyzing process
emissions. Midwest Research Institute (MRI) was responsible for coordina-
ting the test program with plant officials and for assuring that operating
conditions for process and control equipment were suitable for the test
program. MRI was also responsible for monitoring and recording all neces-
sary process and control equipment operating parameters.
1-4
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CORPORATION
1.4.1 Test Parameters of Interest
1.4.1.1 Particulate Mass Loading—
Total particulate loading measurements were performed simultaneously at
the scrubber inlet (uncontrolled) and outlet (controlled) using a modified
version of EPA Method 5E. Three particulate mass test runs were conducted
during conventional operation and three were conducted during recycle
operation.
1.4.1.2 Total Organic Carbon and Extractable Organics—
Total organic carbon (TOC) and extractable organics samples were col-
lected at the scrubber inlet and outlet simultaneously during the EPA Method
5E determinations described in Section 1.4.1.1. Each sample consisted of
organics that condensed on the glassware downstream of the filter holder and
in the first two impingers containing 0.1N NaOH. TOC impinger samples (0.1N
NaOH impinger solutions) were analyzed to determine the total organic carbon
and the extractable organics content. Three test runs were conducted during
both conventional and recycle operation.
1.4.1.3 Trace Metals—
During one recycle and one conventional particulate and TOC/extractable
organics test run, a pair of nitric acid (HNOo) impingers were incorporated
in the sampling train to collect volatile trace metals samples. Particulate
matter collected during the respective runs was also analyzed for trace
metals. Both uncontrolled and controlled emissions were characterized for
trace metals.
1.4.1.4 Gas Stream Analysis—
The COo and Oo concentrations of the inlet and outlet flue gases were
determined during recycle and conventional operations using an Orsat 02/C02
apparatus as specified in EPA Method 3.
1-5
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1.4.1.5 Particle Size Distribution—
Three particle size distribution (PSD) test runs were performed for uncon-
trolled emissions during conventional operation, and one inlet PSD run was
performed during recycle operation. The presence of a water mist in the
scrubber outlet gas stream prevented the collection of acceptable PSD data
for controlled emissions.
1.4.1.6 Polynuclear Aromatic Hydrocarbons—
One inlet sample and one outlet sample were collected during conven-
tional and recycle operations for polynuclear aromatic hydrocarbons (PAH).
1.4.1.7 Scrubber Water Samples and Operations Monitoring—
The two process waters sampled were scrubber water to the venturi and
scrubber water from the venturi. Grab samples of process waters were col-
lected during each recycle and conventional particulate/TOC and PAH run.
All samples were composited and analyzed for total dissolved solids, total
suspended solids, and total organic carbon. Selected samples were analyzed
for polynuclear aromatic hydrocarbons and trace metals.
The temperature and pH of water entering and exiting the scrubber were
measured at the respective sampling locations coincident with the conven-
tional and recycle process sampling.
Scrubber water flow rates to the venturi were monitored at two loca-
tions: total flow to the venturi and flow to the venturi throat. Flow rate
data were recorded during each emission test run.
1.4.1.8 Process Samples and Production Monitoring—
Grab samples of the three process solids streams virgin aggregate, RAP,
and asphalt cement were obtained during the test program. Virgin aggregate
and RAP were analyzed for moisture content. No analyses were performed on
the asphalt cement samples.
1-6
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MRI monitored and recorded the process operations data presented in
this report.
1.5 DESCRIPTION OF REPORT SECTIONS
The remaining sections of this report present the Summary and Discus-
sion of Results (Section 2), Process Description and Operation (Section 3),
Location of Sampling Points (Section 4), Sampling and Analytical Methodology
(Section 5), and Quality Assurance Procedures (Section 6). Detailed des-
criptions of methods and procedures, field and laboratory data, and calcula-
tions are presented in the various appendices, as indicated in the Table of
Contents.
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SECTION 2
2.0 SUMMARY AND DISCUSSION OF RESULTS
This section includes a presentation and discussion of the results of
emission and process characterization tests conducted at the T. J. Campbell
asphalt concrete plant in Oklahoma City, Oklahoma. Uncontrolled and con-
trolled emission streams were tested. Process characterization included
testing of scrubber waters and feed materials. Testing was conducted during
both conventional and recycle operation.
Particulate mass, total organic carbon, and extractable organics test
results are presented in Sections 2.1, 2.2, and 2.3, respectively. A com-
parison of total organic carbon emissions and extractable organics emissions
during conventional and recycle operation is presented in Section 2.4.
Sections 2.5 and 2.6 present trace metal and polynuclear aromatic hydrocar-
bon results, respectively. Particle size distribution data and visible
emission results are presented in Sections 2.7 and 2.8. Scrubber character-
ization results and process sampling results are presented in Sections 2.9
through 2.11.
Difficulties encountered in either sample collection or process con-
trol during testing are discussed as applicable to data interpretation.
The test results are also discussed and comparisons made, when applicable,
to help explain variabilities or discrepancies within the test results.
Additional field data may be found in Appendices A and C. Additional
analytical data may be found in Appendix E.
2-1
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2.1 PARTICULATE EMISSION RESULTS
A modified version of EPA Method 5E was used to collect particulate
mass samples during conventional and recycle operation. Particulate emis-
sion results, identified in the data tables as the "front-half catch," are
presented and discussed in this section.
2.1.1 Conventional Operation Particulate Emission Results
Table 2-1 (English units) and Table 2-2 (metric units) present results
of the uncontrolled and controlled particulate emission tests performed
during conventional operation. Three uncontrolled and controlled particu-
late emission sampling runs were conducted simultaneously during conven-
tional operation. The three conventional operation runs are designated as
C-l, C-2, and C-3.
Uncontrolled particulate loadings were 7.60, 8.49, and 5.58 grains per
dry standard cubic feet (gr/DSCF) for Runs C-l, C-2, and C-3, respectively.
The corresponding controlled particulate emiss-ions were 0.0550, 0.0814, and
0.0332 gr/DSCF for Runs C-l, C-2, and C-3, respectively. The average con-
trolled particulate mass loading was 0.0565 gr/DSCF, which is above the
present NSPS standard of 0.04 gr/DSCF. The particulate (front-half catch)
collection efficiency of the wet venturi scrubber was 993, 99.1, and 99.4
percent for Runs C-l, C-2, and C-3, respectively.
2.1.2 Recycle Operation Particulate Emission Results
Table 2-3 (English units) and Table 2-4 (metric units) present results
of the uncontrolled and controlled particulate emission tests performed
during recycle oepration. Three uncontrolled and controlled particulate
emission sampling runs were conducted simultaneously during recycle opera-
tion. The three recycle operation runs are designated as R-l, R-2, and R-3,
2-2
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TABLE 2-1. SUMMARY OF PARTICULATE AND TOTAL ORGANIC CARBON EMISSIONS
DURING CONVENTIONAL OPERATION (ENGLISH UNITS)
NJ
I
Date 11/12 11/13
Run Number C_l C-2
Type Emissions Uncontrolled Controlled Uncontrolled Controlled
Scrubber Pressure Drop (in. H,0) 13.5 13.4
Scrubber Water Flow Rate (GPM) 219 219
Production Rate (ton/hr) 244 235
Process Mix Type B-Mix B/C Mix
Average Opacity (Percent) Mean ,
Range 0 (0-1.5) 0 (-0-)
Particulate and Total Organic Carbon (TOO Results
Front Half Catch - Particulate
(probe, cyclone, and filter)
mg-mass 9360 172 10,800 244
gr/DSCF 7.60 0.0550 8.49 0.0814
Ibs/hr* 762 5.53 9101 8.29
Ibs/ton production 3.12 0.0226 3.87 0.0353
Collection Efficiency Percent** 99.3 99.1
Back Half Catch - TOC
(impinger solutions and rinses)
mg-mass 253 166 553 417
gr/DSCF 0.205 0.0532 0.434 0.139
Ibs/hr* 20.5 5.34 43.6 14.2
Ibs/ton production 0.0840 0.0219 0.186 0.0604
Collection Efficiency Percent** 73.9 67.5
Total Catch
mg-mass 9610 338 11,400 661
gr/DSCF 7.80 0.108 8.92 0.220
Ibs/hr* 782 10.9 954 22.5
Ibs/ton production 3.20 0.0445 4.06 0.0957
Collection Efficiency Percent** 98.6 97.6
11/14
r-1 Averaee
Uncontrolled Controlled Uncontrolled Controlled
13.5 13.5
215 218
213 231
M-Hix
N/A 0
6950 104 9040 173
5.58 0.0332 7.22 0.0565
599 3.45 757 5.76
2.81 0.0162 3.27 0.0247
99.4 99.2
370 405 392 329
0.297 0.129 0.312 0.107
31.8 13.4 32.0 11.0
0.149 0.0629 0.139 0.0476
57.8 65.7
7320 509 9430 502
5.88 0.162 7.53 0.164
631 16.8 789 16.7
2.96 0.0791 3.41 0.0731
97.3 97.9
N/A - not available
*lbs/hr controlled emission rate based on gas flow rate using saturation volume for the moisture content of the gas
**Collection efficiency percent determined using Ibs/hr values
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TABLE 2-2. SUMMARY OF PARTICULATE AND TOTAL ORGANIC CARBON EMISSIONS
DURING CONVENTIONAL OPERATION (METRIC UNITS)
Date 11/12
Run Number C-l
Type Em i an ion e Uncontrolled Controlled
Scrubber Pressure Drop (in. H,0) 34.3
Scrubber Water Flow Rate (GPH) (3.8
Production Rate (ton/hr) 61.5
Process Mix Type B-Mix
Average Opacity (Percent) Mean,
Range 0 (0-1.5)
Particulate and Total Organic Carbon (TOC) Results
Front Half Catch - Particulate
(probe, cyclone, and filter)
mg-masa 9360 172
mg/DSCH 17, AGO 126
g/8* 96.1 0.697
g/kg production 1.56 0.0)13
Collection Efficiency Percent** 99.3
Back Half Catch - TOC
(impinger solutions and rinses)
mg-mass 253 166
mg/DSCH 470 122
g/s* 2.59 0.673
g/kg production 0.0420 0.0109
Collection Efficiency Percent** 73.9
Total Catch
ing-mass 9610 338
mg/DSCH 17,900 248
g/s* 98.7 1.37
g/kg production 1.60 0.0222
Collection Efficiency Percent** 98.6
11/13 H/14
C-2 C-3 AveraRe
Uncontrolled Controlled Uncontrolled Controlled Uncontrolled Controlled
34.0 34.3 J4.3
13.8 13.6 13.7
59.2 53.7 58.1
B/C Mix M-Mix
0 (-0-) N/A 0
10,800 244 6950 104 9040 173
19,400 186 12,800 76.0 16,500 179
1151 1.05 75.5 0.435 95.5 0.726
1.94 0.0177 1.41 0.00810 1.64 0.0125
99.1 99.4 99.2
553 417 370. 405 392 329
995 319 681 296 715 245
5.50 1.79 4.01 1-69 4.03 1.39
0.0931 0.0302 0.0746 0.0315 0.0694 0.0239
67.5 57.8 65.6
11,400 661 7320 509 9430 502
20.400 505 13,500 372 17,200 374
120 2.84 79.5 2.12 99.5 2.12
2.03 0.0479 1.48 0.0396 1.7! 0.0364
97.6 97.3 97.9
fAverage emi.flei.on rate of concentration and area-ratio methods (Table 2-10)
N/A = not available
*gS controlled emIBS ion rate based on gas flow rate using saturation volume for the moisture content of the gas
**Collection efficiency percent determined using g/s values
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TABLE 2-3. SUMMARY OF PARTICULATE AND TOTAL ORGANIC CARBON EMISSIONS
DURING RECYCLE OPERATION (ENGLISH UNITS)
N>
I
Date H/ll
Run Number R-l
Type Emissions Uncontrolled Controlled
Scrubber Pressure Drop (in. H-0) 13.8
Scrubber Water Flow Rate (GPM7 223
Production Rate (ton/hr) 229
Process Mix Type Recycle-A
Average Opacity (Percent) Mean,
Range 1.4 (0-5.8)
Particulate and Total Oreanic Carbon (TOC) Results
Front Half Catch - Particulate
(probe, cyclone, and filter)
rag-mass • 4380 84.0
gr/DSCF 3.24 0.0227
Ibs/hr 411 2.72
Ibs/ton production 1.79 0.0119
Back Half Catch - TOC
(impinger solutions and rinses)
rag-mass 605 219
gr/DSCF 0.448 0.0592
Ibs/hr 56.8 7.09
Ibs/ton production 0.248 0.0310
Collection Efficiency Percent** 87.5
Total Catch
ing-mass 4980 303
gr/DSCF 3.69 0.0819
Ibs/hr 468 9.81
Ibs/ton production 2.04 0.0430
Collection Efficiency Percent** 97.9
11/11 11/12
R-2 R-3 Averaee
Uncontrolled Controlled* Uncontrolled Controlled Uncontrolled Controlled
13.8 13.9 13.8
220 219 221
250 236 238
Recycle-A Recycle-A —
0.3 (0-1.7) N/A 0.85
5,260 88.2 5570 111 5070 94.5
4.37 0.0229 3.75 0.0286 3.79 0.0247
499t 2.761 474t 3.42 461 2.97
2.00 0.0110 2.01 0.0145 1.94 0.0125
99.4 99.3 99.4
788 375 748 618 714 404
0.655 0.0975 0.504 0.159 0.536 0.105
69.1 11.1 60.5 19.0 62.1 12.4
0.276 0.0445 0.256 0.0805 0.261 0.0520
83.9 68.6 80.4
6050 463 6320 729 5780 498
5.02 0.120 4.25 0.188 4.33 0.130
568 13.8 534 22.4 523 15.3
2.28 0.0555 2.27 0.095 2.20 0.0645
97.6 95.8 97.1
(•Average emission rate of concentration and area-ratio methods (Table 2-10)
N/A - not available
*lbs/hr controlled emission rate based on gas flow rate using saturation volume for the moisture content of the gas
**Collect ion efficiency percent determined us ing Ibs/hr values
-------
TABLE 2-4. SUMMARY OF PARTICULATE AND TOTAL ORGANIC CARBON
EMISSION DURING RECYCLE OPERATION (METRIC UNITS)
K)
I
Date 11/11
Run Number R-l
Type Emissions Uncontrolled Controlled
Scrubber Pressure Drop (in. H,0) 5.43
Scrubber Water Flow Rate (CPH) 14.1
Production Rate (ton/hr) 57.8
Process Mix Type Recycle-A
Average Opacity (Percent) Mean,
Range 1 .4 (0-5. B)
Particulate and Total Organic Carbon (TOC) Results
front Half Catch - Particulate
(probe, cyclone, and filter)
mg-mase 4380 84.0
mg/DSCM 7420 51.9
g/» 51.8 0.343
g/kg production 0.896 0.00593
Collection Efficiency Percent** 99.3
Back Half Catch - TOC
(impinger solutions and rinses)
mg-mass 605 219
mg/DSCM 1030 136
g/s . 7.16 0.894
g/kg production 0.124 0.0155
Collection Efficiency Percent** 87.5
Total Catch
mg-mass 4980 303
mg/DSCM 8450 188
g/s 59.0 1.24
g/kg production 1.02 0.0215
Collection Efficiency Percent** 97.9
11/11 11/12
R-2 K-3
Uncontrolled Controlled* Uncontrolled Controlled
5.43 5.47
13.9 13.8
63.1 59.6
Recycle-A Recycle-A
0.3 (0-1.7) N/A
5260 88.2 5570 111
10,000 52.5 8590 65.4
62. 9t 0.348t 59.81 0.431
0.919 0.00550 1.01 0.00726
99.4 99.3
788 375 748 618
1500 224 1160 365
8.71 1.40 7.63 2.40
0.138 0.0222 0.128 0.0402
83.9 68.6
6050 463 6320 729
11,500 276 9750 430
71.6 1.74 67.4 2.83
1.06 0.0276 1.14 0.0475
97.6 95.8
(Table 2-10)
Averaee
Uncontrolled Controlled
5.44
13.9
60.2
0.85
5070 94.5
8670 56.6
58.2 0.374
0.942 0.00622
99.4
714 401
1230 242
7.83 1.54
0.130 0.0254
80.4
5780 498
9900 299
66.0 1.93
1.07 0.0320
97.1
N/A • not available
*gS controlled emission rate baaed on gas flow rate using saturation volume for the moisture content of the gas
**Collection efficiency percent determined using g/s values
-------
RADIAN
CORPORWrtOM
Uncontrolled particulate loadings were 3.24, 4.37, and 3.75 gr/DSCF for
Runs R-l, R-2, and R-3, respectively. The corresponding controlled particu-
late emissions were 0.0227, 0.0229, and 0.0286 gr/DSCF for Runs R-l, R-2,
and R-3, respectively. The average controlled particulate mass loading was
0.0247 gr/DSCF which is below the present NSPS standard of 0.04 gr/DSCF.
The particulate (front-half catch) collection efficiency of the wet venturi
scrubber was 99.3, 99.4, and 993, for Tests R-l, R-2, and R-3, respectively.
2.1.3 Discussion of Particulate Emission Test Results
Three topics are discussed in this section. They include:
o difficulties encountered in collecting particulate mass
samples,
o anisokinetic effect on particulate mass emission calcu-
lations, and
o conventional versus recycle particulate mass emissions.
2.1.3.1 Particulate Mass Sampling Difficulties—
Problems encountered during particulate mass sampling included:
o source sampling equipment malfunctions, and
o fluctuations in the moisture content of the process
gas streams.
Glassware broke twice during controlled emission sampling Run C-l.
When this occurred, sampling was stopped, the broken glassware was replaced,
a new leak check was performed, and sampling was resumed. The probe liner
heater also shorted out during the same run (C-l). After the liner heater
shorted out, the probe was disconnected from the sampling train, the liner
end and the nozzle were capped, and the probe was taken to the mobile lab
2-7
-------
RADIAN
COBOCMUmOM
for cleanup using the procedures outlined in Section 5. The shorted-out liner
was then removed and a clean glass liner inserted in the probe. The samp-
ling train was reassembled and after a leak check, sampling was resumed. It
is felt that the equipment malfunctions encountered during Run C-l did not
adversely affect or bias the data obtained during the sampling run.
It is believed that fluctuations in the moisture content of the virgin
aggregate and recycle asphalt pavement feed caused the moisture content of
the uncontrolled emissions gas stream to fluctuate. Two uncontrolled sam-
pling runs conducted on November 11, 1983 using the same mix (Recycle A),
had flue gas moisture values that varied by over 7%. To help alleviate this
problem, a wet bulb/dry bulb reading was taken prior to and during uncon-
trolled sampling runs conducted in the latter stages of the testing effort.
This procedure provided more accurate data, but the uncontrolled gas mois-
ture content was still observed -to fluctuate. In the case of Run C-2, the
measured moisture content was 8% higher than the wet bulb/dry bulb value
measured immediately prior to the run.
During four of the six controlled particulate emission runs, the mois-
ture values determined from the impinger weight gains exceeded the tempera-
ture dependent saturation volume as determined by a psychrometric chart.
Sampling runs with impinger moisture values exceeding the saturation volume
indicate the presence of water mist. The saturation volume for those four
runs was used as the moisture value for all further calculations.
2.1.3.2 Discussion of Anisokinetic Test Results—
Fluctuations in the moisture content of the uncontrolled emissions gas
stream and the presence of water mist in the controlled emissions gas stream
resulted in anisokinetic sampling rates during four particulate mass runs.
These included:
o Controlled Particulate Emissions Run R-2.
o Uncontrolled Particulate Emissions Run C-2.
2-8
-------
RADIAN
COBPCMUmOM
o Uncontrolled Particulate Emissions Run R-2.
o Uncontrolled Particulate Emissions Run R-3.
In order to allow a review of possible effects introduced by anisokine-
tic sampling into the normal mass emission rate calculations, two methods
were used to calculate mass emission rates for the particulate mass emission
runs. The method normally used to calculate particulate mass emission rates
is the concentration method. This method involves multiplying the particu-
late loading (sample mass divided by gas sample volume) by the volumetric
gas flow rate. The second particulate mass emission rate calculation method
is the area-ratio method. Based on the area-ratio method, the sample mass
is divided by the sampling time and then multiplied by the ratio of the
stack area to nozzle area to obtain the particulate mass flow rate.
The difference between the emission rates calculated by these two
methods is an estimate of the maximum bias in the measured emission rate due
to anisokinetic sampling. Table 2-5 includes particulate emission rates
calculated using the concentration method and the area-ratio method. The
average particulate emission rate listed in Table 2-5 was used as the true
value for the particulate emission runs that were outside of the isokinetic
sampling limit of 100 +10 percent
2.1.3.3 Discussion of Particulate Emissions During Conventional and
Recycle Operation—
A major objective of this program is to evaluate how the particulate
emissions change during conventional asphalt concrete production and produc-
tion using recycle asphalt pavement. Based on the particulate emissions
data presented in Tables 2-1 through 2-4, four general observations were
made. These include:
• o The NSPS particulate emission standard (0.04 grains/DSCF)
was met during all particulate emission runs except for Runs-
C-l and C-2.
2-9
-------
TABLE 2-5. COMPARISON OF PARTICULATE EMISSIONS CALCULATED BY THE CONCENTRATION
METHOD VS. AREA-RAT10 METHOD
N>
Emission Rate Ibs/hr
Date
Time
Sample Description
Percent
Isokinetic
Concentration
Method
Area-Ratio
Method
Average
Uncontrolled Emissions
11/12
11/13
11/14
11/12
11/13
11/14
1151-1243
0956-1050
0827-0936
1129-1319
0853-1112
0813-1003
Run
Run
Run
Controlled
Run
Run
Run
C-l
C-2
C-3
Emissions
C-l
C-2
C-3
110
113
104
102
96
99
762
853
599
5.53
8.29
3.45
837
967
622
5.65
8.01
3.43
800
910
610
5.59
8.15
3.44
Uncontrolled Emissions
11/11
11/11
11/12
11/11
11/11
11/12
0843-0937
1645-1730
0748-0846
0839-1433
1515-1704
0713-0900
Run
Run
Run
Controlled
Run
Run
Run
R-l
R-2
R-3
Emissions
R-l
R-2
R-3
95
117
111
104
111
107
411
460
451
2.72
2.61
3.42
391
538
498
2.85
2.90
3.66
415
499
474
2.78
2.76
3.54
Uncontrolled Emissions3
11/11
11/12
11/14
11/15
1253-1330
1418-1520
1014-1143
1225-1440
PSD
PSD
PSD
PSD
R-l
C-l
C-2
C-3
108
103
103
112
486
1080
685
1040
528
1117
710
1170
507
1098
698
1105
Calculated particlate size distribution sampling mass emission rate results may not be representa-
tive of actual stack mass emission rate.
-------
RADIAN
connogjrrtOM
o The particulate collection efficiency of the venturi scrubber
varied from only 99.1 to 99.4 percent.
o The data indicate that the type of mix material fed to the
drum dur.ing each run has a direct effect on the uncontrolled and
control led particulate mass rates, and
o Over the range tested, the production rate of either
conventional mix or recycle mix does not appear to
significantly affect the uncontrolled or controlled
particulate mass loading.
The controlled particulate mass loadings rates were 0.0550 and
0.0814 gr/DSCF for Runs C-l and C-2, respectively, which is above the pre-
sent NSPS standard. Achievement of the NSPS limit during Runs C-3, R-l, R-
2, and R-3 was not due to improved performance of the venturi scrubber, but
instead due to a decrease in the level of uncontrolled emissions. A major
difference between Runs C-l and C-2 and the rest of the runs is the type of
raw materials feed to the drum during each run.
Table 2-6 includes a summary of the asphalt concrete mixes typically
produced by the T. J, Campbell Construction Company. During Run C-l, Type B
mix was being produced. Type B mix was also produced during most of Run
C-2, with some production of Type C mix near the end of Run C-2. Type M mix
was produced during Run C-3 and Type A recycled asphalt mix was produced
during Runs R-l, R-2, and R-3.
Type B, C, and M mixes are top mixes that contain about 20 to 24 per-
cent sand. The Type M mix uses washed sand while Type B and C mixes use
unwashed sand. The washed sand is believed to contain less fines and ad-
hered dissolved salts. Type A recycled asphalt mix is a base mix and con-
tains about 9.8 percent sand. Run results indicate that the type (washed/
2-11
-------
RAOiAN
COOPOBjmOM
TABLE 2-6. AGGREGATE ADDITIONS FOR TYPICAL MIXES AT T. J. CAMPBELL
CONSTRUCTION COMPANY, OKLAHOMA CITY, OKLAHOMA
Type Asphalt
Mix Cement Added
(Percent)
Type B 4.9
(virgin)
Type C 5.0
Type M 5.0
Type A 3.9
(recycle) (4.6)a
Hot Sand 4.5
(recycle) (4.6)a
Bin No.
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
RAP
1
2
3
4
RAP
Percent
of Aggregate
45
22
8
25
43
24
33
0
53
20
0
27
18
9.8
0
47.2
25
15
60
—
—
25
Bin Contents
Screenings
Sand
3/4 in. rock
5/8 in. rock
Screenings
Sand
3/8 in. rock
—
Screenings
Sand (washed)
—
5/8 in. rock
Screenings
Sand
—
1.5 in. rock
RAP
Screenings
Sand
—
__
RAP
Moisture
Content
Estimated
By Plant
Personnel
(Percent)
2.5
12.0
1.5
2.0
1.5
12.0
1.5
— —
2.0
11.0
2.0
2.5
12.0
— _
2.0
2.0
2.0
11.0
2.0
aAsphalt cement in the RAP.
2-12
-------
RADIAN
CORPORATION
unwashed) and quantity (9.8%/20-24%) of sand in the mix feed materials
affect the concentration of particulate matter entrained in the emission
gases .
2.2 TOTAL ORGANIC CARBON RESULTS
Controlled and uncontrolled total organic carbon (TOC) mass
samples were collected simultaneously with particulate mass samples
using the modified EPA Method 5E sampling train. The TOC content of the
0.1 N NaOH impinger and rinse solutions were analyzed directly using an
instrumental technique. TOC results, identified in the data
tables as the "back-half catch," are presented and discussed in this
section.
2.2.1 Conventional Operation TOC Emission Results
Uncontrolled and controlled TOC results for conventional operation are
presented in Table 2-1 (English units) and Table 2-2 (metric units). Uncon-
trolled TOC loadings were 0.205, 0.434, and 0.297 gr/DSCF for Runs C-l, C-2,
and C-3, respectively. The controlled TOC loadings were 0.0532, 0.139, and
0.129 gr/DSCF for Runs C-l, C-2, and C-3, respectively. The TOC (back-half
catch) collection efficiency of the wet venturi scrubber was 73.9, 67.5, and
57.8 percent for Runs C-l, C-2, and C-3, respectively.
2.2.2 Recycle Operation TOC Emission Results
Table 2-3 (English units) and Table 2-4 (metric units) present results
of the uncontrolled and controlled TOC measurements performed during recycle
operation. Uncontrolled TOC loadings were 0.448, 0.655, and 0.504 gr/DSCF
for Runs R-l, R-2, and R-3, respectively. The controlled TOC loadings were
0.0592, 0.0975, and 0.159 gr/DSCF for Runs R-l, R-2, and R-3, respectively.
The TOC collection efficiency of the wet venturi scrubber was 87.5, 83.9,
and 68.6 percent for Runs R-l, R-2, and R-3, respectively.
2-13
-------
RADIAN
2.2.3 Discussion of TOC Test Results
The uncontrolled TOC loadings varied from 0.205 to 0.434 gr/DSCF during
conventional operation and from 0.448 to 0.655 gr/DSCF during recycle opera-
tion. The controlled TOC loadings varied from 0.0532 to 0.139 gr/DSCF
during conventional operation and from 0.0592 to 0.159 gr/DSCF during re-
cycle operation. Based on the limited data available, it is difficult to
develop any correlations between process operation and the degree of varia-
bility in the uncontrolled and controlled TOC emissions during conventional
and recycle operation.
The average uncontrolled TOC loading was approximately 72 percent
greater during recycle operation (0.0536 gr/DSCF) as compared to conven-
tional operation (0.0312 gr/DSCF). But the average controlled TOC loading
during recycle operation (0.105 gr/DSCF) approximated the average controlled
TOC loading during conventional operation (0.107 gr/DSCF). These data
indicate that although the average uncontrolled TOC emissions increased
during recycle operation, they did not result in an increase in controlled
TOC emissions when compared to conventional TOC data. The average removal
efficiency of the venturi scrubber increased from 65.7 percent during con-
ventional operation to 80.4 percent during recycle operation.
2.3 EXTRACTABLE ORGANICS EMISSION RESULTS
Extractable organics analysis was performed on the same 0.1 N NaOH
impinger solutions and rinses that TOC analysis was performed on (modified
EPA Method 5E samples) with the addition of the inclusion of results of a
trichloroethane rinse. An aliquot of the 0.1N NaOH samples were extracted
with chloroform and diethyl ether. After evaporation at room temperature,
the mass of extractable organics was determined gravimetrical ly. The tri-
chloroethane rinses were also evaporated at room temperature to determine
the mass of extractable organics gravimetrical ly. Tables 2-7 and 2-8 con-
tain a summary of uncontrolled and controlled extractable organics and
particulate emission results. Extractable organics are identified as the
2-14
-------
TABLE 2-7. SUMMARY OF UNCONTROLLED PARTICULATE AND EXTRACTABLE ORGANICS EMISSIONS
NJ
I
DATE
RUN NO.
11/12
C-l
PROCESS OPERATION CONVENTIONAL
VOLUME GAS SAMPLED (DSCF)
STACK GAS FLOW RATE (DSCFM)
STACK TEMPERATURE (°F)
PERCENT MOISTURE BY VOLUME
PERCENT ISOKINETIC
PRODUCTION RATE (tons/hr)
PARTICULATE - EXTRACTABLE
ORGANICS RESULTS
19.0
11,700
298
38.0
110
244
11/11
R-l
RECYCLE
20.8
14,800
296
24.4
95
229
11/13
C-2
CONVENTIONAL
19.6
11,700
289
39.6
113
235
11/11
R-2
RECYCLE
18.6
12,300
314
31.5
117
250
11/14
C-3
CONVENTIONAL
19.2
12,500
304
36.7
104
213
11/12
R-3
RECYCLE
22.9
14,000
317
27.7
111
236
CONVENTIONAL
19.3
12,000
297
38.1
109
231
RECYCLE
20.8
13,700
309
27.9
108
238
FRONT HALF CATCH - PARTICULATE
(probe, cyclone, and filter)
mg-mass
gr/DSCF
Ibs/hr
Ibs/ton production
BACK HALF CATCH - EXTRACT-
ABLE ORGANICS
(implnger solutions & rinses]
mg-mass
gr/DSCF
Ibs/hr
Ibs/ton production
PERCENT EXTRACTABLE ORGANICS*
9360
7.60
762
3.12
217
0.176
17.6
0.0721
2.26
4380
3.24
411
1.79
208
0.154
19.5
0.0852
4.54
10,800
8.49
910t
3.87
72.3
0.0568
5.70
0.0243
0.62
5260
4.37
499f
2.00
169
0.140
14.7
0.0588
2.86
6950
5.58
599
2.81
163
0.131
14.0
0.0657
2.28
5570
3.75
474f
2.01
113
0.076
9.12
0.0386
1.88
9040
7.22
757
3.28
151
0.121
12.4
0.0537
1.61
5070
3.79
461
1.94
163
0.123
14.4
0.0605
3.02
t,
Average emission rate of concentration and area-ratio methods (Table 2-10).
Percent Extractable Organics determined using Ibs/hr values and le the percentage of extractable organics of the total catch.
0
5
-------
TABLE 2-8. SUMMARY OF CONTROLLED PARTICULATE AND EXTRACTABLE ORGANICS EMISSIONS
I
M
CT>
DATE
RUN NO.
11/12
C-l
PROCESS OPERATION CONVENTIONAL
VOLUME GAS SAMPLED (DSCF)
STACK GAS FLOW RATE (DSCFM)
STACK TEMPERATURE (°F)
PERCENT MOISTURE BY VOLUME
PERCENT ISOKINETIC
PRODUCTION RATE (tons/hr)
PARTICULATE - EXTRACTABLE
ORGANICS RESULTS
18.2
11,700*
(11.400)
159
32.0
(32.3)
102
(105)
244
11/11
R-l
RECYCLE
57.1
14,000
147
21.3
104
229
11/13
02
CONVENTIONAL
46.2
11.900
(11,400)
155
29.0
(32.3)
96
(100)
235
11/11
R-2
RECYCLE
,59.3
13,300
(12,700)
152
26.6
(30.6)
111
(116)
250
11/14
C-3
CONVENTIONAL
48.5
12,100
(11,800)
153
27.5
(29.7)
99
(102)
213
11/12
R-3
RECYCLE
60.1
14,000
143
20.7
107
236
CONVENTIONAL
47.6
11,900
(11.500)
156
29.5
(32.1)
99
(102)
231
RECYCLE
58.8
13.800
(13,600)
147
22.9
(24.2)
107
(109)
238
FRONT HALF CATCH - PARTICULATE
(probet, cycloneB and filter)
tug-mass
gr/DSCF
Ibs/hr
Ibs/ton production
BACK HALF CATCH - EXTRACT-
ABLE ORGANICS
172
0.0550
5.53
(5.36)
0.0227
(0.0220)
84.0
0.0227
2.72
0.0119
244
0.0814
8.29
(7.95)
0.0353
(0.0338)
88.2
0.0229
2.76f
(2.49)
0.0110
(0.0100)
104
0.0332
3.45
(3.36)
0.0162
(0.0158)
111
0.0286
3.42
0.0145
173
0.0565
5.76
(5.56)
0.0247
(0.0239)
94.5
0.0247
2.97
(2.88)
0.0125
(0.0123)
(Implnger solutions & rinses)
tug-mass
gr/DSCF
Ibs/hr
Ibs/ton production
PERCENT EXTRACTABLE ORCANICSt
245
0.0786
7.88
(7.65)
0.0323
(0.0314)
58.8
(58.8)
86.8
0.0235
2.81
0.0123
50.8
81.1
0.0271
2.71
(2.65)
0.0115
(0.0113)
24.6
(25.0)
229
0.0596
6.79
(6.46)
0.0272
(0.0258)
71.1
(72.2)
87.7
0.0279
2.89
(2.82)
0.0136
(0.0132)
45.6
(45.6)
130
0.0334
4.00
0.0169
53.9
138
0.0445
4.49
(4.37)
0.0191
(0.0186)
43.8
(44.0)
149
0.0388
4.53
(4.42)
0.0188
(0.0183)
60.4
(60.5)
NOTE: Top number based on saturation volume for moisture content of gas: (bottom number) Is moisture content calculated using Implnger
catch indicating the presence of water mist.
Average emission rate of concentration and area-ratio methods (Table 2-10).
^Percent Extractable Organlca determined using Ibs/hr values and is the percentage of extractable organlcs of the total catch.
m
i&
-------
RADIAN
"back-half catch" in Tables 2-7 and 2-8. The extractable organics results
are presented and discussed in this section.
2.3.1 Conventional Operation Extractable Organics Emission Results
Uncontrolled extractable organics loadings were 0.176, 0.0568, and
0.131 gr/DSCF for Runs C-l, C-2, and C-3, respectively. The controlled
extractable organics loadings were 0.0786, 0.0271, and 0.0279 gr/DSCF for
Runs C-l, C-2, and C-3, respectively.
2.3.2 Recycle Operation Extractable Organics Emission Results
Uncontrolled extractable organics loadings were 0.154, 0.140, and
0.076 gr/DSCF for Runs R-l, R-2, and R-3, respectively. Controlled
extractable organics loadings were 0.0235, 0.0596, and 0.0334 gr/DSCF for
Runs R-l, R-2, and R-3, respectively.
2.3.3 Discussion of Extractable Organics Emission Test Results
The uncontrolled extractable organics loadings varied from 0.0568 to
0.176 gr/DSCF during conventional operation and from 0.076 to 0.154
gr/DSCF during recycle operation. The controlled extractable organics
loadings varied from 0.0271 to 0.0786 gr/DSCF during conventional
operation and from 0.0235 to 0.0596 gr/DSCF during recycle operation.
Based on the limited data available, it is difficult to develop any
correlations between process operation and the degree of variability in
the uncontrolled and controlled extractable organics emissions during
conventional and recycle operation.
The average uncontrolled extractable organics loading during
conventional operation (0.121 gr/DSCF) approximated the average
uncontrolled extractable organics loading during recycle operation (0.123
gr/DSCF). The average controlled extractable organics loading was
approximately 15 percent greater during conventional operation (0.0445
2-17
-------
gr/DSCF) as compared to recycle operation (0.0388 gr/DSCF), It is
believed that the variability between the controlled extractable organics
loadings is within the variability of the sampling and analytical techniques.
2.4 COMPARISON OF TOC AND EXTRACTABLE ORGANICS EMISSION RESULTS
Two analytical procedures were used during this program to quantify the
concentration of uncontrolled and controlled organic emissions generated
during conventional and recycle operation. An instrumental technique was
used to determine the concentration of TOC present in the 0.1N NaOH impinger
and rinse solutions generated during EPA Method 5E testing. The same
samples were also analyzed using a gravimetric technique to determine
the concentration of extractable organics. The main objective of performing
both analyses on the same samples was to provide data that could be used to
help assess the utility of both procedures in characterizing organic
emissions from asphalt concrete plants.
2.4.1 Comparison of Uncontrolled TOC and Extractable Organic
Emissions Results
Table 2-9 presents a comparison of uncontrolled TOC and extractable
organics emissions during conventional and recycle operation. The average
uncontrolled TOC loadings indicate that the uncontrolled organic emissions
were about 72 percent greater during recycle operation (0.536 gr/DSCF) as
compared to conventional operation (0.312 gr/DSCF). On the other hand the
average uncontrolled extractable organics loadings indicate that the
uncontrolled organic emissions were essentially the same during both recycle
(0.123 gr/DSCF) and conventional (0.121 gr/DSCF) operations.
2-18
-------
TABLE 2-9. COMPARISON OF UNCONTROLLED TOC AND EXTRACTABLE ORGANICS EMISSIONS
RUN NUMBER
PROCESS OPERATION
DATE
VOLUME GAS SAMPLES (DSCF)
STACK CAS FLOW RATE
(DSCFM)
STACK TEMPERATURE (°F)
PERCENT MOISTURE BY VOLUME
PERCENT ISOKINETIC
PRODUCTION RATE (TONS/HR)
BACK HALF CATCH -
ORGAN ICS RESULTS
(Impinger solutions & rinses)
mg-masfl
gr/DSCF
Ibs/hr
C-l
CONVENTIONAL
11/12
19.0
11,700
298
38.0
110
244
EXT**
TOC* ORG .
253 217
0.205 0.176
20.5 17.6
Ibs/ton production 0.0840 0.0721
C-2
CONVENTIONAL
11/13
19.6
11,700
289
39-6
113
235
EXT.
TOC ORC .
553 72.3
0.434 0.0568
41.6 5.70
0.186 0.0243
C-3
CONVENTIONAL
11/14
19.2
1 2 , 500
304
36.7
104
213
EXT.
TOC ORG.
370 163
0.297 0.131
31.8 14.0
0.149 0.0657
R-l
RECYCLE
11/11
20.8
14,800
296
24.4
95
229
EXT.
TOC ORC .
605 208
0.448 0.154
56.8 19.5
0.248 0.0852
R~2
RECYCLE
11/11
18.6
1 2 , 300
314
31.5
117
250
EXT.
TOC ORG.
788 169
0.655 0.140
59.1 14.7
0.276 0.0588
R-3
RECYCLE
11/12
22.9
14,000
317
27.7
111
236
EXT.
TOC ORG,
748 113
0.504 0.076
60.5 9.12
0.256 0.0386
AVERAGE
CONVENTIONAL
19.3
12,000
297
38.1
109
231
EXT.
TOC ORC.
392 151
0.312 0.121
32.0 12.4
0.139 0.0537
RECYCLE
20.8
13,700
309
27.9
108
238
EXT.
_TQG__ ORQ,.
714 163
0.536 0.12J
62.1 14.4
0.261 0.0605
1"
it>
12
»
*TOC - Total Organic Carbon
**EXT. ORG. - Extractable Organics
-------
&ADIAN
2.4.2 Comparison of Controlled TOC and Extractable Orsanics
Emissions Results
Table 2-10 presents a comparison of controlled TOC and extractable
organics emissions during conventional and recycle operation. The average
controlled TOC loadings indicate that the controlled organic emissions were
essentially the same during conventional (0.107 gr/DSCF) and recycle (0.105
gr/DSCF) operations. The average controlled extractable organics loadings
indicated that the controlled organic emissions were about 15 percent
greater during conventional operation (0.0445 gr/DSCF) as compared to
recycle operations (0.0388 gr/DSCF).
2.4.3 Discussion of TOC and Extractable Organics Emissions Results
Because of the limited quantity-of available data, it is difficult to
develop an accurate'comparison between the TOC and extractable organics
analytical procedures. In formulating an opinion about the two procedures,
it is important that several factors be kept in mind. First, the TOC
analysis results are indicative of the mass of carbon present in all of the
organic species in a sample. The extractable organics analyis results are
indicative of the mass of organic compounds (not just carbon) having a
boiling point greater than 300°C. Also, the TOC analysis procedure is a
direct instrumental technique requiring a minimal amount of sample
preparation (refer to Section 5.2). On the other hand, the extractable
organics analysis procedure does require sample preparation (refer to
Section 5.2) by means of extraction with chloroform and diethyl ether. The
remaining extract is then evaporated to dryness at room temperature before
weighing.
It is believed that the TOC analysis procedure is more suitable than
the extractable organics procedure for characterizing organic emissions from
asphalt concrete plants.
2-20
-------
TABLE 2-10. COMPARISON OF CONTROLLED TOC AND EXTRACTABLE ORGANICS EMISSIONS
NJ
I
r-o
RUN NUMBER
PROCESS OPERATION
DATE
VOLUME GAS SAMPLES (DSCF)
STACK GAS FLOW RATE
(DSCFM)
STACK TEMPERATURE '(°F)
PERCENT MOISTURE BY VOLUME
PERCENT 1 SDK I NET 1C
PRODUCTION RATE (TONS/IIR)
BACK HALF CATCH -
ORGANICS RESULTS
C-l
CONVENTIONAL
11/12
48.2
11,700*
(11,400)
159
32.0
(34.3)
102
(105)
244
C-2
CONVENTIONAL
11/13
46.2
11,900
(11,400)
155
29.0
(32.3)
96
(100)
235
EXT.*** EXT.
TOC** ORG. TOC ORG.
C-3
CONVENTIONAL
11/14
48.5
12,100
(11,800)
153
•27.5
(29.7)
99
(102)
213
EXT.
TOC ORG.
R-l
RECYCLE
11/11
57.1
14,000
147
21.3
104
229
EXT.
TOC ORG .
R-2
RECYCLE
11/11
59.3
13,300
(12,700)
152
26.6
(30.6)
111
(116)
250
EXT.
TOC ORG .
R-3
RECYCLE
11/12
60.1
14,000
143
20.7
107
236
EXT.
TOC ORG .
AVERAGE
CONVENTIONAL
47.6
11,900
(11,500)
156
29.5
(32.1)
99
(102)
231
EXT.
TOC ORG.
RECYCLE
58.8
1 3 , 800
(13,600)
147
22.9
(24.2)
107
(109)
238
EXT .
TOC ORG .
(jmpfnger solutions & rinses)
mg-mass
gr/DSCF
Ibs/lir
Ibs/ton production
166 245
0.0532 0.0786
5.34 7.88
0.0219 0.0323
417 81.1
0.139 0.0271
14.2 2.71
0.0604 O.OH5
405 87.7
0. 129 0.0279
13.4 2.89
0.0629 0.0136
219 86.8
0.0592 0.0235
7.09 2.81
0.0310 0.0123
375 229
0.0975 0.0596
tl.l 6.79
0.0445 0.0272
618 130
0,159 0.0334
19.0 4 . 00
0.0805 0.0169
329 138
0.107 0.0445
11.0 4.49
0.0476 0.0191
404 |/,9
0.105 0.0388
12.4 4.53
0.052 0.0188
*NOTE: Top number based on saturat ion volume for moisture content of gas: (bottom number) Is moisture content calculated using impinger
catch results indicating the presence of water mist.
** TOC - Total Organic Carbon
*** EXT. ORG. - Extractable Organics
-------
RADBAN
2.5 TRACE METAL EMISSION RESULTS
During this program the concentration of uncontrolled and controlled
trace metals were derived from the analysis of "front-half" and "back-half"
catches of the trace metal sampling train described in Section 5.1. The
front-half catch is the sum of the analytical results of the acetone and
trichloroethane probe and glassware washes, the cyclone solids (if
applicable), and the filter solids. The back-half catch is the sum of the
analytical results of the NaOH impingers and HNO.J impingers. One set of
trace metal samples (uncontrolled/controlled) was collected during
conventional and recycle operation.
2.5.1 Conventional Operation Trace Metals Emission Results
Table 2-11 includes a summary of uncontrolled and controlled trace
metals emissions during conventional operation. The collection efficiency
of the wet venturi scrubber for each element during conventional operation,
is presented in Table 2-11.
2.5.2 Recycle Operation Trace Metals JSmission Results
Table 2-12 includes a summary of uncontrolled and controlled trace
metals emissions during recycle operation. The collection efficiency of the
wet venturi scrubber for each elementduring recycle operation is also
presented in Table 2-12.
2,5.3 Discussion of Trace Metals Emission Results
During both conventional and recycle operations, the uncontrolled and
controlled concentrations of calcium, iron, magnesium and aluminum comprised
greater than 99 percent of the trace metals analyzed in the samples. Each
of these elements are non-volatile, according to their elemental boiling
point, and are predominantly associated with the particulate ("Front-half
Catch"). The wet venturi scrubber removed greater than 99 percent of the
2-22
-------
TABLE 2-11. SUMMARY OF TRACE METAL EMISSIONS DURING CONVENTIONAL OPERATION
to
1
to
Date
Sampled Emissions
Production Rate (Ton/llr)
Trace Metal Results
Element
Aluminum
Beryllium
Calcium
Cadmium
Chromium
Iron
Mercury
Magnesium
Manganese
Nickel
Lead
Vanadium
Zinc
H/12
Uncontrol led
Mass
Front Half
(HE)
29,500
2.33
2,654,000
14.7
138
57,700
<273
42,900
911
104
118
<540
194
Mass
Back Half
(HE)
66
0.90
1260
5.4
<1.47
53
<20
50
1.8
<4.4
<118
<88
13
Maes
Total
(HE)
29,600
3.23
2,660,000
20.1
138
57,800
<293
43,000
913
104
118
<628
207
Concentration
( ug/DSCM )
55,000
6.0
4,930,000
37
255
107,000
<544
79,600
1700
193
219
<1170
385
Mass
Front llalf
n>gi
453
0.187
41,000
28
7.2
650
<90
1234
42.7
16.4
4.7
-------
TABLE 2-12. SUMMARY OF TRACE METAL EMISSIONS DURING RECYCLE OPERATION
Date
Sampled Emissions
Production Rate (Ton/Hr)
Mass
Trace Metal Results Front Half
(Me)
Element
Aluminum
Beryllium
Calcium
Cadmium
Chromium
NJ
1 Iron
ho
4^ Mercury
Magnesium
Manganese
Nickel
Lead
Vanadium
Zinc
13,300
0.91
1,154,000
13.7
111
24,600
22,600
362.3
63.6
89
<141
230
11/11
Uncont rol 1 ed
Mass Mass
Back Half Total
(PR) (Kg)
69
1.37
751
6.6
6.25
64
<40
121
3.2
2.8
<113
'82
14
13,300
2.28
1,150,000
20.3
117
24,600
<176
22,700
366
66
89
<223
244
Concentrat Ion
(ug/DSCM)
22,500
3.9
1,960,000
34
199
41,800
<298
38,500
620
112
150
<378
414
11/11
Control led
250
Masa Mass Mass
Front Half Bark Half Total
lV&)
-------
RADIAN
calcium, iron, and aluminum during both conventional and recycle operation.
Magnesium was removed at an efficiency of about 98.7.
Several "more volatile" elements were also detected in the trace metal
samples. These elements included beryllium, cadmium, and zinc. Because of
the greater volatility of these elements, a greater percentage of the
volatile elements were found in the "back-half" portion of the trace metal
sample than the above mentioned nonvolatile elements.
2.6 POLYNUCLEAR AROMATIC HYDROCARBONS EMISSION TEST RESULTS
Polynuclear aromatic hydrocarbon (PAH) samples were collected in the
uncontrolled and controlled air emissions, during this program, using an
adaption of EPA Method 5E. The technique, described in Section 5, includes
the use of Method 5E front-half (filter) and back-half (XAD-2 resin) for
adsorption of organic compounds. One set of PAH samples
(uncontrolled/controlled) was collected during conventional and recycle
operation. The PAH emission results are presented and discussed in the
following section.
2.6.1 Conventional Operation PAH Emission Results
A summary of the uncontrolled and controlled PAH emissions during
conventional operation are presented in Table 2-13. Included in Table 2-13
are the front- and back-half concentrations of both active and nonactive
carcinogenic PAH species. The activity of the PAH species was determined
using a reference book entitled "Polycyclic Aromatic Hydrocarbons in Water
Systems." The removal efficiency of the wet venturi scrubber for each of
the PAH compounds is included in Table 2-13. The removal efficiency of the
venturi scrubber ranged from 1 percent for benzo(b)f luoranthene to 100
percent for benzo(a)pyrene during conventional operation.
2-25
-------
TABLE 2-13. SUMMARY OF POLYNUCLEAR AROMATIC HYDROCARBON EMISSIONS
DURING CONVENTIONAL OPERATION
Sampled Emissions Uncontrolled '
Date 11/14
Volume Gas Sampled- USCF (DSCM) 12.3 (0.3472)
Stack Gas Flow Rate - DSCFM (M'/MIn) 10,200 (289)
Stack Temperature (°F) 313
Scrubber Pressure Drop ( in. H20) 13.4
Scrubber Water Flow Rate (GPM) 221)
Percent Moisture by Volume 42.2
Percent Isokinetic "I
Production Rate (tons/hr) '96
Polynuclear Aromatic
Hydrocarbon Results
Active Carcinogenic a
Species
Benz( a) anthracene
Chrysene
Benzo(b) f luoranthcne
Benzo(J)fluoranthene
Benzo(e)pyrene
Benzo(a)pyrene
lndeno(l,2,3-c,d)-
py rene
Nonactive Carcino-
genic Species
Pbenanthrene
Anthracene
Fluoranthene
Pyrene
Benzo(k) f luoranthene
Perylene
Benzo(g,h,i)perylene
ND = not detected.
'Futoma, David, et al.
Front Half
(ug/DSCHlfrng/hr)
I.I
6.2
0.58
ND
2.6
1.4
1.4
20
2.1,
5.4
16
0.58
0.29
ND
Pojjrc
19
110
10
45
24
24
350
45
94
280
10
5.0
Controlled
11/14
42.2 (1.1963)
11,700 ( )3I)
158
13.4
220
32.2
103
196
CONCENTRATIONS AND MASS EMISSION RATES
Back Half Total Kronl Half Back
(UB/DSCH) (mp,/hr) (
0.28 4.9
I.I 19
<0.10 <1.7
ND
0.86 15
ND
0.29 5.0
120 2100
17 290
7.4 1 30
20 350
ND
0.29 5.0
ND
ycllc Aromatic Hydrocarbons 1
If PNA spe
'nK/DSCM
1 .4
7.3
0.58
Nl)
3.5
1 .4
1.7
140
20
13
16
0.58
0.58
111)
\ i '
24
130
10
61
24
29
2400
350
230
620
10
10
11 Water Systems.
1 (ug/nscM) i
-------
RADIAN
2.6.2 Recycle Operation PAH Emission Test Results
Table 2-14 includes a summary of uncontrolled and controlled PAH
emissions during recycle operations. The controlled concentrations of
benzo(b)f luoranthene, indeno(l,2,3-c,d)-pyrene, anthracene, and
benzo(K)f luoranthene was greater than the uncontrolled concentrations for
these compounds. The removal efficiency of the wet venturi scrubber for the
remaining PAH compounds ranged from 31 percent for pyrene to 73 percent for
benzo(e)pyrene and 41 percent for benzo(a)pyrene.
2.6.3 Discussion of PAH Emission Test Results
Based on the limited amount of available data, it is difficult to
develop correlations between PAH concentrations and conventional or recycle
operations. For most of the PAH compounds analyzed, the concentrations of
the controlled emissions were less than the concentrations of the
uncontrolled emissions. However, during recycle operation, there were
several PAH compounds for which the controlled emissions were greater than
the uncontrolled emissions. It is believed that these results are most
probably caused by sampling and analytical error.
2.7 PARTICLE SIZE DISTRIBUTION RESULTS
An Andersen High Capacity Stack Sampler (AHCSS) was used during this
program to determine the particle size distribution (PSD) of uncontrolled
emissions. The AHCSS sizes particles aerodynamical ly and is designed to
determine the PSD of gas streams with high grain loadings without over-
loading or using short sampling periods.
^Futoma, David, et al. Polvcyclic Aromatic Hydrocarbons in Water Systems.
Roca Raton, FL, CRC Press, Inc., 1981.
2-27
-------
TABLE 2-14. SUMMARY OF POLYNUCLEAR AROMATIC HYDROCARBON EMISSIONS
DURING RECYCLE OPERATION
ho
M
Sampled Emissions
Date
Volume Gas Sampled - DSCF (OSCM)
Stack Cas Flow Rate - DSCFM (M3/Mln)
Stack Temperature ( °F)
Scrubber Pressure Drop (in,H20)
Scrubber Water Flow Rate (GPM)
Percent Moisture by Volume
Percent Isokinetlc
Production Rate (tona/hr)
Polynuclear Aromatic
Hydrocarbon Results
Active Carcinogenic n
Spec les
Benz (a) anthracene
Chryaene
Benzo(b) f luoranthene
Benzo(J) [luoranthene
Benzo(e)pyrene
Benzo(a)pyrene
Indeno(l,2,3-c,d)-
pyrene
Nonactlve Carcino-
genic Species
Phenanthrene
Anthracene
Fluoranthene
Pyrene
Benzo(k) f luoranthene
Perylene
Benzo(g,h, i)perylene
ND - not detected
Futoma, David, et al
Front Half
(ug/DSCM) (ITR.
0.64 11
3.6 64
ND
ND
1.3 23
0.41 7.2
ND
8.3 150
1.5 26
1.9 34
3.4 60
ND
Nl)
ND
Polycycllc
Uncon t ro 1 led
11/15
16.2 (0.4590)
10,400 (294)
299
12.7
214
48.0
105
166
Control led
11/15
45.2 (1.2789)
9.900 (280)
171
12. 7
214
43.4
113
166
CONCKNTRATIONS AND MASS EMISSION RA1F.S
Back Hall Total Front Hall Back
/hrj (HJS/DSCM)
1. 1
4.8
0.087
ND
0.57
0.087
0.15
(mp/tir )
19
85
1.5
10
1.5
2.6
210 3700
15
18
33
0.11
0.33
ND
Aromatic Hydro
260
320
580
1.9
5.8
carbons
(ug/DSCM
1 .8
8.4
0.087
Nl)
1.9
0.50
0. 15
220
16
20
36
0. II
0. 13
ND
In Water
) .(mR/hr)
32
150
1.5
34
8.8
2.6
3900
280
350
640
1.9
5.8
,.„..,.,,
Systems 0
0.75 13
0.15 2.5
ND
ND
0.078 1.3
ND
ND
1.0 17
ND
0.30 5.0
0.83 14
ND
0.078 1. )
ND
Boca Rnton, Fl,.
'hr)( UK/DSCM
0.0010
2.4
0.24
ND
0.47
0.31
0.31
86
18
13
25
0.24
0.078
Nl)
CRC PreRS,
Half
)imK/hr)(
0.02
40
4.0
7.9
5.2
5.2
1400
300
220
420
4.0
1.3
- - ---,.,
Inc., 1981
Total
.PB/DSCI
0.75
2.6
0.24
ND
0.55
0.31
0.31
87
18
13
26
0.24
0.16
Nl)
Remova 1
Ef f Idem y
H) (mj>/hr ) (Percent!
13
44
4.0
9.2
5.2
5.2
1500
300
220
440
4.0
2.7
59
71
-170
73
41
-100
62
-7
37
31
-no
53
„, - ^, - -
l> ww
ft
Reference used to determine if PNA species were active or nonactlve carcinogens.
-------
RADIAN
CORPOCUmOM
Attempts were made at determining the PSD of the controlled emissins
using an Andersen Mark III cascade impactor. The attempts were unsuccessful
because of the presence of water mist in the controlled emissions stream.
As a result, no controlled PSD data are present.
2.7.1 Conventional Operation Uncontrolled Emissions PSD Results
Three uncontrolled PSD sampling runs were performed during conventional
operation. The results of these runs are presented graphically in Figure 2-
1 and tabularly in Table 2-15. During Run G-l aggregate mix B was produced.
During Run C-2 aggregate mix B and C were produced while aggregate mix M was
produced during Run C-3. It should be noted that mix M contains washed
sand.
2.7.2 Recycle Operation Uncontrolled Emissions PSD Results
A total of three PSD samples were scheduled for collection during
recycle operation, but only one uncontrolled PSD sampling run was performed
during recycle operation. The results of the single PSD recycle run (R-l)
are presented graphically in Figure 2-1 and tabularly in Table 2-15. RAP
mix A was produced during the sampling period.
2.7.3 Discussion of Uncontrolled Emissions PSD Results
The three PSD curves of uncontrolled emissions during conventional opera-
tion (Figure 2-1) are similar in shape. The mass mean diameter for Runs C-
1, C-2, and C-3 are 10.5 ym, 6.0 ym, and 8.0 ym respectively.
The mass mean diameter for the single PSD test performed during recycle
operation is approximately 16 ym.
2-29
-------
K)
I
999
998
995
99
98
95
90
iij
fci 80-
Q
"J 70
<
t-
Ifi
50
40-
30
w on
w 20-
10
5
2-
1
05
0.2-
0.1
0
a RUNG i
A. RUNG 2
• RUNG 3
a RUN R 1
100
PARTICLE SIZE MICRONS
Figure 2-1. Particle size distribution curves of uncontrolled emissions
collected during recycle and conventional operation.
-------
TABLE 2-15. SUMMARY OF UNCONTROLLED PARTICLE SIZE
DISTRIBUTION TESTS
NJ
I
Date Time
1H1 .1253-1330
1112 1418-1520
1114 1014-1143
1115 1225-1440
Flow
Run Rate
In (ACFM1)
RECYCLE
1 0.
0.
0.
0.
CONVENTIONAL
C-l 0.
0.
0.
0.
C-2 0.
0.
0.
0.
C-3 0.
0.
0.
0.
439
439
439
439
430
430
430
430
442
442
442
442
456
456
456
456
Stage
1
2
Cyclone
Filter
1
2
Cyclone
Filter
1
2
Cyclone
Filter
1
2
Cyclone
Filter
Mass
Collected
(8)
1.
0.
0.
0.
2.
1.
1.
2.
1.
1.
0.
2.
3.
2.
1.
3.
.1838
2831
4340
1581
9926
.2359
.0506
0152
5725
.0991
.8769
.2131
.2178
3035
3990
0625
% in Size
Range
57.5
13.8
21.1
7.7
41.0
16.9
14.4
27.6
27.3
19.1
15.2
38.4
32.2
23.1
14.0
30.7
Cumulacive
% less than
Size Range
42.
28.
7.
0
58.
42.
27.
0
72.
53.
38.
0
67.
44.
30.
0
6
8
7
9
0
6
7
6
4
8
7
7
Size
Range
(pni)
>13.3
7.2-13.3
2.1-7.2
>0-2.1
>13.3
7.2-13.3
2.2-7.2
>0-2.2
'13.3
7.2-13.3
2.1-7.2
>0-2.1
>13.0
6.9-13.0
1.9-6.9
>0-1.9
1H>50 *
(|im) Isokinetic
13.
7.
2.
-
13.
7.
2.
0
13.
7.
2.
-
13.
6.
1.
-
3 108
2
1
3 103
2
2
3 103
2
1
0 1122
9
9
J)
u
o
ACFM = actual cubic feet per minute
Wet bulb/dry bulb indicated 35% moisture; 42.5% moisture measured which caused super isoklnetic run
-------
RADIAN
2.8 VISIBLE EMISSIONS RESULTS
Visible emissions were measured by a certified reader during most
testing periods when a clear, blue sky was available. The blue sky back-
ground was required for detection of emissions caused by condensed hydro-
carbons in the plume. Opacity readings taken during emission tests are
presented and discussed in this section. Additional measurements were
performed and are included in Appendix G.
2.8.1 Conventional Operation Visible Emissions Results
Opacity readings performed during conventional operation are presented
in Table 2-16. The opacity readings are graphically represented in Figure
2-2. The average measured opacity reading during conventional operation test periods
was 0 percent.
2.8.2 Recycle Operation Visible Emissions Results
Table 2-17 presents opacity measurements performed during recycle
tests. These results are graphically represented in Figures 2-3 and 2-4.
The average opacity measurement was 1.4 and 0.3 percent during Runs R-l and
R-2. The maximum six minute opacity measurement was 5.8 and 1.7 percent
during Runs R-l and R-2 respectively. During the recycle PAH sample collec-
tion period the average opacity measurement was zero percent.
2.8.3 Discussion of Visible Emission Results
One objective of this program was to investigate the "blue haze" plume
caused by condensible hydrocarbons. On the afternoon of November 10, 1983
the water flow to the presprays was turned off for over an hour in an effort
to generate "blue haze" by eliminating the prespray cooling. No "blue haze"
was observed during this period. With concurrence of the EPA Industrial
Studies Branch (ISB) and Emission Measurements Branch (EMB) representatives,
testing under reduced water flow conditions was cancelled.
2-32
-------
TABLE 2-16. SUMMARY OF VISIBLE EMISSION OBSERVATIONS DURING CONVENTIONAL OPERATION
KJ
U)
Average
Opacity for
Date Run No. Time 6 Minutes Date Run No.
11/12/83 T.M.Part/ 1130-1135
Cond.Hyd. 1136-1141
(C-l) 1142-1147
1148-1153
1154-1159
1200-1205
1206-1211
1212-1217
1218-1223
1224-1229
1230-1235
1236-1241
1242-1247
1248-1253
1254-1259
1300-1305
1306-1311
1312-1317
1318-1323
1318-1323
11/12/83 N/A* 1324-1329
1330-1335
1336-1341
1342-1347
1348-1353
1354-1359
1400-1405
1406-1411
1412-1417
1418-1423
1424-1429
0 11/13/83 Part/
0 Cond./
0 llyd .
0 (C-2)
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0 (ave.)
0
0
0
0
0
0
0
0.6
1.5
0.2
0
0.21 (ave.)
Average
Opacity for
Time 6 Minutes
0848-0853
0854-0859
0900-0905
0906-0911
0912-0917
0918-0923
0924-0929
0930-0935
0936-0941
0942-0947
0948-0953
0954-0959
1000-1005
1006-1011
1012-1017
1018-1023
1024-1029
1030-1035
1036-1041
1042-1047
1048-1053
1103-1108
1109-1114
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0 (ave.)
*No source sampling performed during this visible emissions measurement period.
-------
4-
P
ui
O
DC
til
a
3-
1
LO
•JN
O
<
a.
O
iij
O
<
DC
UJ
2-
1-
1100
I
1200
1300
I
1400
1500
Figure 2-2. Six-minute averages of November 12, 1983. Opacity
readings on the venturi scrubber stack during
conventional operation.
-------
RADIAN
TABLE 2-17- SUMMARY OF VISIBLE EMISSION OBSERVATIONS
DURING RECYCLE OPERATION
Average
Opacity for
Dace Run No. Time 6 Minutes Date Run No.
11/11/83 T.M.Part/ 0837-0842
Cond.Hyd. 0843-0848
(R-l) 0849-0854
0855-0900
0901-0906
0907-0912
0913-0918
0919-0924
0925-0930
0931-0936
0937-0942
0943-0948
0949-0954
0955-1000
1009-1014
1104-1109
1110-1115
1116-1121
1122-1127
1128-1133
1308-1313
1314-1319
1320-1325
1326-1331
1332-1337
1400-1405
1406-1411
1412-1417
1418-1423
1424-1429
1430-1435
1436-1441
Average
11/11/83 Part/Cond. 1530-1535
Hyd.(R-2) 1536-1541
1545-1550
1551-1556
1557-1602
1603-1608
1609-1614
1615-1620
1621-1626
1627-1632
1633-1638
1639-1644
1645-1650
1651-1656
1657-1702
1703-1708
1709-1714
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
5 .
2.
2^
4.
4.
1.
2.
5.
3.
2.
2.
5.
0
0
1.
0
1.
1.
0
0
0
0
0
0
0
0
0
0
11/15/83 PAH R-l
2
8
8
4
6
3
3
3
6
0
5
3
0
5
3
1
2
1.4
7
4
3
0
Average
Opacity for
Time 6 Minutes
0855-0900
0901-0906
0907-0912
0913-0918
0919-0924
0925-0930
0931-0936
0937-0942
0943-0948
0949-0954
0955-1000
1001-1006
1007-1012
1013-1018
1019-1024
1025-1030
1031-1036
1037-1042
1043-1048
1049-1054
Average
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Average
0.3
2-35
-------
KJ
P
LU
O
OC
LU
a
O
<
a.
O
UJ
O
<
OC
UJ
3-
(I
2-
TJ1
(I
r
1000
1100
I
1200
I
1300
1400
1500
1600
Figure 2-3. Six-minute averages of November 10, 1983. Opacity readings
on venturi scrubber stack during recycle operation.
-------
KJ
I
5-
P
UJ 4-
0
DC
UJ
(L
i 3~
a
O
UJ
O
< i
-------
2.9 SCRUBBER WATER GRAB SAMPLE MEASUREMENTS
Periodically during each sampling run, grab samples were taken of the
venturi scrubber water influent (pond water) and venturi scrubber water
effluent. The pE and temperature were measured for all grab samples (see
Section 2.11 for analytical results). This section presents results of pH
and temperature measurements performed on scrubber water samples.
2.9.1 Conventional Operation Scrubber Water pH and Temperature Results
Scrubber water pH and temperature results during conventional operation
are presented in Table 2-18. Average pH results for the venturi scrubber
influent were 7.30, 7.30, and 7.36 for Runs C-l, C-2, and C-3, respectively.
Average venturi scrubber effluent pH's were 7.17, 7.18 and 7.17 for Runs C-
1, C-2, and C-3, respectively.
The average venturi scrubber water influent temperatures for Runs C-l,
C-2, and C-3 were 132°F, 126°F and 118°F, respectively. Two main factors
affect pond temperature, ambient temperature and length of scrubber opera-
tion for each day.
The average venturi effluent temperature is a direct function of the
flue gas temperature. Since water has a much higher capacity for heat
transfer than air the flue gas can be cooled substantially with a relatively
small increase in the scrubber water temperature. The average scrubber
water effluent temperatures for Runs C-l, C-2, and C-3 were 156°F, 151°F,
and 152°F, respectively. The average venturi inlet flue gas temperatures
corresponding to the above sampling runs were 298°F, 289°F, and 304°F,
respectively.
2.9.2 Recycle Operation Scrubber Water pH and Temperature Results
Results of pH and temperature measurements during recycle operation are
presented in Table 2-19. The average pH measurements for the venturi scrub-
2-38
-------
KJ
I
Lo
VD
TABLE 2-18. SUMMARY OF SCRUBBER WATER pH AND TEMPERATURE MEASUREMENTS FOR
CONVENTIONAL OPERATION
Run No.
Part/Cl
Part/C2
Part/C3
PAH/C1
Date Time
11/12 1140
1240
1340
Average
11/13 0920
1020
Average
11/14 0850
0945
1230
1400
Average
11/14 0850
0945
1230
1400
Average
Water to
Venturi
pH Temperature, °F
7.28
7.30
7.31
7.30
7.31
7.29
7.30
7.43
7.36
7.31
7.34
7.36
7.43
7.36
7.31
7.34
7.36
127
133
136
132
124
129
126
99
115
127
129
118
99
115
127
129
118
Venturi Exit Water
pH Temperature, °F
7.18
7.15
7.18
7.17
7.24
7.12
7.18
7.12
7.18
7.15
7.22
7.17
7.12
7.18
7.15
7.22
7.17
153
154
160
156
149
153
151
145
147
156
160
152
145
147
156
160
152
Time
1130
1230
1430
0929
1030
0830
0900
0930
1000
0830
0900
0930
1000
Pond Water1
0
Temperature, °F
134
137
139
130
134
104
114
121
128
104
114
121
128
142
143
145
139
143
110
124
130
136
110
124
130
136
JO
0
5
*Data collected by MRI personnel
2Temperatures expressed as inlet temperature - outlet temperature
-------
TABLE 2-19. SUMMARY OF SCRUBBER WATER pH AND TEMPERATURE
MEASUREMENTS DURING RECYCLE OPERATION
Run No. Date Time
Part/Rl 11/11 0900
0945
1440
Average
Part/R2 11/11 1605
1650
Average
KJ
g Part/R3 11/12 0830
0900
Average
PAH/R1 11/15 0915
1000
1050
Average
Water to
Venturi
pH Temperature, °F
7.46
7.32
7.25
7.34
7.28
7.28
7.28
7.46
7.40
7.43
7.44
7.46
7.49
7.46
91
108
129
109
131
131
131
109
111
110
118
129
135
127
Venturi Exit Water
pH Temperature, °F
7.18
7.10
7.22
7.17
7.20
7.22
7.21
7.22
7.11
7.16
7.11
7.10
7.15
7.12
131
131
149
137
153
154
154
142
145
144
176
171
174
174
Time
0901
0930
1430
1602
1700
0830
0900
0903
0957
1055
Pond Water1
o
Temperature, °F
99
107
132
136
137
114
118
124
136
143
110
114
138
140
142
121
128
132
145
151
collected by MRI personnel
2Values expressed as inlet temperature - outlet temperature
z
-------
RADIAN
ber water influent were 7.34, 7.28, 7.43, and 7.46 for particulate sampling
Runs R-l, R-2, R-3, and PAH sampling Run R-l, respectively. The average
venturi scrubber water effluent pH readings corresponding to the above
sampling runs were 7.17, 7.21, 7.16, and 7.12, respectively.
The average venturi scrubber water influent temperatures were 109°F,
131°F, 110°F, and 127°F for Method 5E Runs R-l, R-2, R-3, and PAH Run R-l,
respectively. The average corresponding water effluent temperatures were
137°F, 154°F, 144°F, and 174°F. The average venturi scrubber inlet gas
temperatures for those sampling runs were 296°F, 314°F, 317°F, and 299°F.
2.9.3 Discussion of Scrubber Water Grab Sample Measurement Results
The scrubber water influent and effluent temperature and pH values did
not vary significantly during conventional and recycle operations.
2.10 SCRUBBER WATER ANALYTICAL RESULTS
During each sampling run at least two venturi scrubber water influent
and effluent samples were collected. The grab samples during each run were
composited and then filtered to determine total suspended solids. An ali-
quot of the filtrate was then analyzed for dissolved solids. The remaining
filtrate was analyzed for TOC, trace metals, and/or polynuclear hydrocar-
bons .
2.10.1 Conventional Operation Scrubber Water Analytical Results
Table 2-20 presents the scrubber water analytical results during
conventional operation. Total suspended solids (TSS) concentrations for the
venturi scrubber water influent samples were 161 mg/1, 23.9 mg/1, and 23.5
mg/1 for sampling Runs C-l, C-2, and C-3. The corresponding total dissolved
solids (IDS) concentrations were 1860 mg/1, 1780 mg/1, and 1770 mg/1. TSS
concentrations for the venturi scrubber water effluent samples were 6710
2-41
-------
M
4>
Run No.
Tot^aj^ Or&anj.c Carbon _R_£'sul_ts
H1R/1 ('IS C)
Trace Metals^ JjtejmJ ts
Kl cment (|ig/rol.)
A Iumlnum
Beryl 1 linn
C.-i I r f urn
Cadmlurn
Chromlurn
I ron
Mercury
Manganese
Nickel
Lead -
Vanadi nm
Zinc
Polyaromatlc Hydrocarbon
Kc.suUs ___
Active Carcinogenic
Benz(n) anthracene
Chrysene
llenzci(l)) f luor ant hone
Benzo(J)fluoranthene
Benzo(e)pyrene
Benzo(a)pyrene
IndenofI,2t3-c,d)pyrene
Nonactive CarcinopenJc
._.
Phenanthrene
Anthracene
Fluor.-inlhene
Pyrene
flenzo(k ) f 1 norantliene
Pcry lone
Bcnzo(g, h, i Jpery lene
Total SoJUIs Itesiilts
Sospended So lids
l)i_sso_lyed Sol ids
TABLE 2-20. SUMMARY OF SCRUBBER WATER ANALYTICAL RESULTS
DURING CONVENTIONAL OPERATION
Water t
Venturl
7.10
112
160
0.05
0.001
290
0.007
0.004
0.026
•0.03
54
0.047
<0.003
'0.08
0.069
•0.001
11/12
o Venturl
Ex| t Water
7. 1 7
156
160
0.05
-0.005
)00
• 0.002
' 0 . 00 1
• 0.008
•0.01
54
0.053
0.005
•0.084
'0.001
• 0.001
1 1 / 11 1 1 / 1'. 1
Water lo Ventur) Water to Venturl Water to
Venturl Exit Water Venturl Kxll Water Venturl
7.10 7.18 7.16 7.17 7.16
126 151 118 152 118
180 250 186 210 180
<0. 1
0. 1
Nl)
Nl)
Nil
Nil
Nl)
10
0.4
0.6
1.4
Nl)
Nl)
Nl)
I/I'.
Venturl Water to Venturl
Exit Water Venturl Exit Water
7.17 7.11 7.17
152 124 15)
200 176 210
'0. 1
0. 1
Nl)
Nl)
Nl)
ND
Nl)
6.8
Nl)
0.1
0.6
Nil
Nl)
Nl)
JO
161
I860
6710
IH50
21.9
1780
6510
21.5
1770
5240
69.5
-------
RADIAN
mg/l, 6530 mg/1, and 5180 mg/1 for sampling Runs C-l, C-2, and C-3. The
corresponding IDS concentrations were 1850 mg/1, 1760 mg/1, and 1770 mg/1.
There are no significant differences between the venturi scrubber
influent and effluent trace metals concentrations. Calcium and magnesium
were the only species found in excess of 100 ppb. The concentrations were
290 mg/1 and 54 mg/1 for the influent and 300 mg/1 and 54 mg/1 for the
effluent for calcium and magnesium respectively.
Polynuclear aromatic hydrocarbons were found in trace amounts in the
scrubber water during conventional operation. Phenathrene and pyrene were
found in levels in excess of 1 ppb. Three other species anthracene, fluor-
anthrene, and chrysene were detected in levels of less than 1 ppb. Benz(a)
anthracene was detected, but not at a quantifiable level.
2.10.2 Recycle Operation Scrubber Water Analytical Results
Table 2-21 presents the scrubber water analytical results during recy-
cle operation. TSS concentrations for the venturi scrubber water influent
were 77.8 mg/1, 144 mg/1 and 179 mg/1 for Runs R-l, R-2, and R-3, respec-
tively. The corresponding TDS concentrations were 1960 mg/1, 1970 mg/1, and
1890 mg/1. TSS concentrations for the venturi scrubber water effluent were
3090 mg/1, 4690 mg/1, and 3010 mg/1 for Runs R-l, R-2, and R-3, respective-
ly. The corresponding TDS contents were 1950 mg/1, 1970 mg/1, and 1900
mg/1.
No significant differences were seen between the venturi scrubber
influent and effluent trace metals concentrations. As with conventional
operation calcium and magnesium were the only soluble species found in
excess of 100 ppb. Their concentrations were 300 mg/1 and 54 mg/1 for the
influent and 300 mg/1 and 53 mg/1 for the effluent for calcium and magnesium
respectively.
2-43
-------
TABLE 2-21. SUMMARY OF SCRUBBER WATER ANALYTICAL RESULTS DURING RECYCLE OPERATION
Run No.
llnte
Sample Type
Temperalure , F
Tutn 1 _(^rj5an 1 c Carbqn Ucaul tg
RJ
11/11
K)
if/12
PAH Rl
11/15"
later to
'entiirl
7.34
109
Venturl
Exit Water
7.17
137
W.itrr to
Vcntnrl
7.28
131
VenLur 1
Kx 1 1 WaJ^er
7.21
154
W.itcr to
Venturl
7.43
1 10
Venlurl
Exit Wnter
7. 16
144
Water to
VeuUirl
7.46
127
Ventiirl
Exit Winer
7.12
174
Water to
Venlurl
7.3B
119
Venl ur 1
Exit Water
7.16
152
Results _ __
Active Carcinogenic
-—
Benz(a)anthracene
Chry scne
Ben zo ( b) f liio rant hone
Kcnzo( J) f lunranthcne
Benco(e)py rene
Renzo(a)py rene
Indeno(lp2,3-c,d)|)yrene
NonactLve CarcinoRcnlc
._._.
Phen.mthrene
Antlirnccnc
PI uoranthene
I'y rene
Bcnzo(k) f luorantheno
Pery 1 cnc
Ben 7,0 (K , h, I )pery lene
NJ
-P-
.p-
niR/l (as C)
Trace Metals Renults
Element (iiK/ml.)
A liinil nitm
llery 1 1 him
Calcium
Cadm 1 urn
Clirom 1 urn
1 ron
Mercury
Halites ( Jim
Manganese
Nickel
Lead
Vanad 1 um
7.1nc
Polyaromatic Hydrocarbon
170
•0.05
• 0.005
)00
-0.002
• 0.001
-0.008
•0.03
54
0.060
0.003
•0.084
. 0.003
.0.003
170
0.05
•0.005
300
•0.002
• o.ooi
0.008
• 0.03
53
0.061
•0.003
• 0.084
• 0.003
0.003
190
'0. 1
0. 1
Nl)
Nl)
Nl)
Nl)
Nl)
7.0
Nl)
0.7
I .3
Nl)
Nl)
Nl)
190
•0. I
0. 1
ND
Nl)
Nl)
0.4
Nl)
5.0
Nl)
0.5
0.8
Nl)
0.5
Nl)
I7B
77.8
3090
4690
179
3010
60
Dissolved
1950 1970
1970 1890
I860
1820
1920
-------
RADIAN
Polynuclear aromatic hydrocarbons were found in trace amounts in the
scrubber water during recycle operation. Phenanthrene and f luoranthrene
were the only species found in excess of 1 ppb. Four other species anthra-
cene, perylene, chrysene, and benzo(a)pyrene were detected in levels less
than 1 ppb. The presence of benz(a)anthracene was detected but not quanti-
fied.
2.10.3 Discussion of Scrubber Water Analytical Results
Fluctuations in the TSS concentrations of influent scrubber water
samples occurred during both conventional and recycle operations. The exact
cause for the TSS fluctuations is not known at this time. Floculant was
added to the ponds to help reduce TSS after dredging operations on November
7 and 14, 1984. It is believed that the fluctuations in TSS concentrations
of the influent scrubber water samples were not caused by the addition of
floculant on November 7 and 14, 1983.
The average TSS concentration of scrubber water effluent samples was
approximately 70 percent greater during conventional operation (5920 mg/L)
as compared to recycle operation (2980 mg/L). The higher TSS concentrations
in the scrubber effluent water during conventional operation are due to the
high uncontrolled particulate emissions observed during conventional
operations as compared to recycle operation. The particulate removal
efficiency of the venturi scrubber was basically the same during both modes
of production.
The average TDS concentration of influent scrubber water samples was
1800 mg/1 during conventional operation and 1920 mg/1 during recycle opera-
tion. The average TDS concentration of effluent scrubber water samples was
1800 mg/1 during conventional operation and 1910 mg/1 during recycle opera-
tion. Based on the above data, the average concentration of TDS did not
vary significantly in the scrubber water influent and effluent samples.
2-45
-------
The concentration of trace metals and PAH's present in scrubber water
influent and effluent samples were essentially the same during conventional
and recycle operation.
2.11 PROCESS SAMPLING RESULTS
During each conventional and recycle operation test period, samples of
virgin aggregate and recycled asphalt pavement (during recycle operation) were
collected and analyzed for percent moisture. Care was taken to obtain a
representative sample including collecting very large samples (approximately
10 pounds) and riffling the sample to the 500-700 grams used for analysis.
2.11.1 Conventional Operation Grab Sampling Results
Table 2-22 presents moisture values of the virgin aggregate during
conventional operation. The percent moisture by weight values were 2.68%,
2.32%, and 2.63% for Runs C-l, C-2, and C-3. These moisture values are
slightly lower than the 3-4% estimated by plant personnel.
2.11.2 Recycle Operation Grab Sampling Results
Table 2-23 presents moisture values of the virgin aggregate and recycle
asphalt pavement used during recycle operation. The percent moisture by
weight values were 1.46%, 1.83%, 1.20%, and 6.88% for the virgin aggregate
and 1.48%, 1.40%, 2.12%, and 4.88% for the recycled asphalt pavement, for
particulate Runs R-l, R-2, R-3 and polynuclear aromatic hydrocarbons Run R-
1, respectively. Plant operators estimated 3-4% moisture for the virgin
aggregate and 2% moisture for the recycled asphalt pavement during the
particulate runs. During PAH Run R-l, plant estimates were 8% for the
virgin aggregate and 3.5% for the recycled asphalt pavement.
2-46
-------
RADIAN
CORPORATION
TABLE 2-22. SUMMARY OF PROCESS SAMPLE MEASUREMENTS
FOR CONVENTIONAL OPERATION
Virgin Aggregate
Run No.
Part/Cl
Part/C2
Part/C3
PAH/C1
Date
11/12
11/13
11/14
11/14
Time
1345
0920
0850
1235
0850
1235
Sample amount (g)
666
676
669
717
693 (ave.)
669
717
693 (ave.)
Percent Moisture
2.68
2.32
2.64
2.62
2.63
2.64
2.62
2.63
by Weight
(ave. )
( ave . )
TABLE 2-23. SUMMARY OF PROCESS SAMPLE MEASUREMENTS FOR RECYCLE OPERATION
Virgin Aggregate
Run No.
Part/Rl
Part/R2
Part/R3
PAH/R1
Date
11/11
11/11
11/12
11/15
Time
0900
1400
0835
0915
Sample Amounc (g)
607
924
734
638
Z Moiscure
by Weight
1.46
1.83
1.20
6.88
Recycle Asphalt
Sample Amount (g)
456
846
517
573
Pavement
% Moisture
by Weight
1.48
1.40
2.12
4.88
2-47
-------
RAOIAN
CtM»»M
2.11.3 Discussion of Process Sampling Results
The average moisture content of the virgin aggregate was 2.54% during
conventional operation and 1.50% during recycle Runs R-l, R-2, and R-
3. The moisture content of the virgin aggregate increased to 6.88% during
PAH Run R-l. The average moisture content of the RAP was 1.67% during
recycle Runs R-l, R-2, and R-3. The moisture content of the RAP increased
to 4.88% during Run R-l.
2-48
-------
RADIAN
CORPOfUITIOM
SECTION 3
PROCESS DESCRIPTION AND OPERATION
This section provides a brief description of the asphalt concrete plant
operated by the T. J. Campbell Construction Co. in Oklahoma City, Oklahoma.
The procedures used to monitor the operation of the asphalt concrete plant
during both conventional and recycle testing are also presented in
this section.
3.1 PROCESS DESCRIPTION
A description of the T. J. Campbell asphalt plant (including the emis-
sions control system) is presented in this section.
3.1.1 Process Equipment Description
T. J. Campbell Construction Company operates a CMI drum-mix asphalt
plant in Oklahoma City, Oklahoma (refer to Figure 1-1). Plant operation
began in 1979 and was modified in March 1983 to include a new, larger
capacity drum which was designed to handle recycled asphalt pavement (RAP).
Primary design changes for utilization of RAP were an injection system for
the RAP in the center area of the drum and a heat shield between the RAP
injection point and the burner. The modifications were designed to reduce
the temperature to which the RAP is exposed. Table 3-1 presents a summary
of technical data on the asphalt concrete plant.
The CMI drum at T. J. Campbell is 36 feet long and has expanded front
and back ends. The expanded ends are 8.5 feet in diameter, and the mid-
section is 7 feet in diameter. The expanded front end allows for greater
heat transfer near the burner flame, while the expanded back end causes the
3-1
-------
RADIAN
TABLE 3-1. TECHNICAL DATA ON THE ASPHALT CONCRETE PLANT OPERATED BY THE
T. J. CAMPBELL CONSTRUCTION COMPANY, OKLAHOMA CITY, OKLAHOMA
Type:
Manufacturer:
Model Number:
Dated Installed:
Capacity: rated
typical
Dryer: fuel
capacity
firing rate
Drum Size: diameter
length
Drum Slope:
Product Temperature:
RAP Entry Position:
Asphalt Heater:
Storage Silos (3):
Drum-mix
CMI
UVM-1200RS-162
March 1983
250-350 tons/h
240 tons/h
Natural gas
109 million BTUs
80-90 million BTUs/h
ends—8.5 ft
middle—7 ft
36 ft
0.75 in. per ft
275° to 325°F
Center feed
Fuel—Natural gas
Storage capacity—35,000 gal
Capacity—235 tons each
Heating—Heat transfer oil
3-2
-------
RADIAN
exhaust gas velocity to decrase to allow the larger particles to settle out
in this region. The drum is natural gas-fired. The burner at T. J. Camp-
bell is a Hauck power flame burner with a 109 million BTU rating. Virgin
aggregate is stored in four cold feed bins and RAP is stored in a separate
cold feed bin. The liquid asphalt is stored in a heated 35,000 gallon tank
on site. The asphalt storage container is maintained at 300°F. The
finished asphalt concrete mix is stored in one of three heated storage
silos.
3.1.2 Emission Control System Description
Figure 3-1 illustrates the emission control system (venturi scrubber)
used by T. J. Campbell. Process emissions from the drum-mixer exit the
discharge end of the drum and enter a knockout box to remove some of the
larger particles by reducing the air velocity. After the knockout box, the
emissions are ducted to a wet venturi scrubber. Specifications for the
venturi scrubber are listed in Table 3-2. In the duct work between the
knockout and venturi are water sprays, two nozzle bars with 13 nozzles per
bar, to cool the emission gases. Water is also injected at the venturi
throat through a 12-nozzle spray bar. Additional water is flushed through a
collection box below the venturi.
Scrubber water is contained in two adjacent earthen ponds that are
interconnected by means of a dike. One pond is approximately 55 feet x 24
feet and the other is approximately 65 feet x 24 feet with an effective
depth of 3 to 6 feet. Scrubber effluent flows into the end of one pond
while scrubber supply water is pumped from the other pond. The dike di-
viding the two ponds serves as a weir to reduce the suspended particulate
matter in the scrubber supply pond. Silt is cleaned from the ponds weekly
and is landfilled. Pond make-up water is supplied from a well. The pH of
the ponds is controlled by addition of lime; flocculant is occasionally
added to the ponds to aid settling. The venturi pressure drop is variable
(12.5 to 18 inches of water column).
3-3
-------
STACK
PRODUCT TO
STORAGE
VENTURI
LOCATION
ORING
ON
Rl
IVYS
)HING
3N
( ^
t
),
DRAFT
FAN
VENTURI
RETURN WATER
Figure 3-1. Wet venturi emissions control scrubber operated by the T.J. Campbell
Construction Company, Oklahoma City, Oklahoma
-------
RADIAN
CORPORATION
TABLE 3-2. TECHNICAL DATA ON THE WET VENTURI SCRUBBER AT THE T. J.
CAMPBELL CONSTRUCTION COMPANY, OKLAHOMA CITY, OKLAHOMA
Type:
Manufacturer:
Date Installed:
Total Air Flow:
Water Circulation Rate:
Makeup water:
Pressure Drop:
Scrubber Inlet Temperature:
Scrubber Motor
Pressure in Venturi Nozzle:
Fan Motor:
Ponds - number
sizes (approx)
capacity (approx)
Scrubber Outlet:
Scrubber Sludge: quantity
disposal
Venturi scrubber
CMI
Spring 1979
35,000-36,000 acfm
300 gpm (design)
Well water as needed
12.5 to 14.5 inches w.c.
300°F
60 hp
100 Ibs
150 hp
55 ft x 24 ft and 65 ft x 24
ft; both approx. 3 to 5 ft
deep
70,000 gal and 100,000 gal
Rectangular steel stack with
sampling ports
2 percent of the No. 200 and less
fines run through drum
Fill
3-5
-------
RA01AN
3.2 PROCESS OPERATION
Operation of the T. J. Campbell plant is typical of other drum-mix
plants. The T. J. Campbell plant operates about 10 hours per day. typically
8:00 AM to 6:00 PM, and does not operate on weekends unless requested by a
customer. The rate of asphalt concrete production is dependent upon the
temperature of the product and the moisture content of the raw feed mate-
rial. The maximum rated capacity of the T. J. Campbell plant is 350 tons
per hour at a product temperature of 240°F and 1-2 percent feed moisture.
The T. J. Campbell plant operates at a product temperature higher than
normal for the industry (300°F as opposed to 275 to 285°F) to produce a more
workable mix for smaller paving jobs. With a product temperature of 300°F
and a feed moisture content of 5 to 6 percent, the rated capacity of the
plant is 250 tons per hour. A daily production of 2,000 tons is considered
very good. The T. J. Campbell plant produces a variety of commercial and
recycle mixes. A brief description of the process operating procedures used
during conventional and recycle operation is presented below.
3.2.1 Conventional Process Operation
During conventional operation, virgin aggregate is added to the burner
end of the rotating drum. The virgin aggregate is stored in four cold feed
bins. Aggregate from each bin is metered onto a conveyor according to the
desired commercial mix. Table 3-3 includes a description of the various
commercial mixes produced by T. J. Campbell during the test program.
The liquid asphalt is injected into the dryer about 2 feet downstream
from the center of the drum. The liquid asphalt is stored in a heated
35,000 gallon (gal) tank on site, maintained at a temperature of 300°F.
The grade of asphalt used during the test period is designated AC-20, which
has a 60 to 100 penetration grade. Campbell has two suppliers of liquid
asphalt, Kerr KcGee (Wynnewood, Oklahoma) and Allied Chemical (Stroud,
Oklahoma). No recycling agents are used by Campbell. The finished asphalt
concrete mix drops out the end of the drum and is lifted by bucket conveyor
3-6
-------
RADIAN
TABLE 3-3. AGGREGATE ADDITIONS FOR TYPICAL CONVENTIONAL MIXES PRODUCED AT
THE T.J. CAMPBELL CONSTRUCTION COMPANY, OKLAHOMA CITY, OKLAHOMA
Type
Mix
Type B
(virgin)
Type C
Type M
TABLE
Asphalt
Cement Added
(Percent)
4.9
5.0
5.0
3-4. AGGREGATE
Bin No.
1
2
3
4
1
2
3
4
1
2
3
4
ADDITIONS
Percent
of Aggregate
—
45
22
8
25
43
24
33
0
53
20
0
27
FOR TYPICAL RAP
T. J. CAMPBELL CONSTRUCTION COMPANY
Type
Mix
Type A
(recycle)
Hot Sand
(recycle)
Asphalt
Cement Added
(Percent)
3.9
(4.6)a
4.5
(4.6)a
Bin No.
1
2
3
4
RAP
1
2
3
4
RAP
Percent
of Aggregate
18
9.8
0
47.2
25
15
60
—
—
25
Bin Contents
Screenings
Sand
3/4 in. rock
5/8 in. rock
Screenings
Sand
3/8 in. rock
—
Screenings
Sand (washed)
—
5/8 in. rock
MIXES PRODUCED
, OKLAHOMA CITY
Bin Contents
Screenings
Sand
1.5 in. rock
RAP
Screenings
Sand
—
—
RAP
Moisture
Content
Estimated
By Plant
Personnel
(Percent)
2.5
12.0
1.5
2.0
1.5
12.0
1.5
2.0
11.0
2.0
AT THE
, OKLAHOMA
Moisture
Content
Estimated
By Plant
Personnel
(Percent)
2.5
12.0
2.0
2.0
2.0
11.0
2.0
aAsphalt cement in the RAP
3-7
-------
RADIAN
to one of three storage silos. These silos are heated with heat transfer
oil and are insulated. The asphalt concrete is then loaded onto trucks on a
scale. The truck used by Campbell to haul the product are owned and oper-
ated by independent truckers.
3.2.2 Recycle Progress Operation
RAP is predominantly used in base course mixes. Table 3-4 includes a
description of the various RAP mixes produced by T. J. Campbell during the
test program. During recycle operation, RAP was added to the center of the
rotating drum and the quantity of virgin aggregate added to the rotating
drum was reduced. Typical RAP percentages are 25 to 30 percent. The re-
maining recycle process operating procedures are similar to the conventional
process operating procedures presented in Section 3.2.1.
3.3 PROCESS MONITORING DURING THE EMISSION TEST PROGRAM
The operation of the drum-mix asphalt plant was monitored by MRI per-
sonnel during both the conventional and recycle test periods. Table 3-5
contains a summary of the process data collected during the emissions
testing program. The test period included the company's peak production
week of over 9,000 tons and its peak production day, November 11, 1983,
when 2,354 tons were sold.
3.4 EMISSION CONTROL SYSTEM MONITORING DURING THE EMISSION TEST PROGRAM
The operation of the venturi scrubber emission control system was
monitored by MRI personnel during both the conventional and recycle test
periods. Emission control system parameters that were monitored during
testing included:
o venturi scrubber pressure drop,
o total scrubber water flow to the venturi, and
o scrubber water flow to the venturi throat.
3-8
-------
TABLE 3-5. PROCESS INFORMATION DURING EMISSION TESTING,
T.J. CAMPBELL CONSTRUCTION COMPANY, OKLAHOMA CITY, OKLAHOMA
U)
I
Production Virgin,
Oale Time rate. tpha Iph
11/10/83 9:30
(a.m.) 10:00
10:33
11:00
11:30
11:50
(p.m.) 2:01
2:31
2:57
3:31
3:52
4:12
4:28
11/11/83 8:37
(a.m.) 9:01
9:30
10:01
10:30
11:00
11:30
(p.m.) 12:10
12:30
1:00
1:30
2:00
2:30
3:01
3:31
4:02
4:30
5:00
5:26
201.3
219.2
232.4
228.5
219.2
217.4
209.1
248.3
250.7
262.8
274.3
248. 1
231.2
226.7
208.2
214.6
231.5
245.6
262.2
279.2
213.8
215.4
223 7
212.4
218.3
205.3
238.3
254.2
208.5
265.4
267.8
264.8
191.1
208.3
221.0
217.5
208.7
206.7
150.8
177.3
179.3
192.5
195.5
181.9
167.4
164.1
161 7
157.4
167.1
173.7
191.8
198.3
157.1
153.9
157.6
151.0
157 3
139.9
171.4
180.3
165.3
188.9
189.8
197 0
RAP.
tph4
--
52.5
64.1
64.5
62.9
71.4
59 1
57.6
56.4
40 1
51 2
58.2
65.2
63 3
73.4
50.8
55.3
60.2
55.8
55.0
58.9
60.4
67 9
36. 1
69.8
71 7
60.8
A|)ha.lt
tpli
10.2
10.9
11.4
11.0
10 5
10.7
5.8
6.9
6.8
7.4
7.4
7.1
6.2
6.3
6.2
6.0
6.2
6.7
7. 1
7.5
5.9
6.2
5.9
5.6
6.0
6.5
6.5
6.0
7.1
6.7
6.3
7.0
Mix
, temp. ,
°F
270
290
290
310
310
290
290
290
290
285
285
305
290
295
295
290
295
295
290
260
325
295
305
310
290
300
290
285
255
270
285
280
Burner
setting,
%
30
40
40
40
40
40
30
35
40
40
40
45
35
30
30
30
35
40
40
40
30
30
30
30
30
20
35
40
30
45
45
50
Operator estimate Drum
moisture internal
content pressure, Mix
Virgin
5
5
5
5
5
5
4-5
4-5
4-5
4-5
4-5
4-5
4-5
3-4
3-4
3-4
3-4
3-4
3-4
3-4
34
3-4
3-4
3-4
3-4
3-4
3-4
3-4
3-4
34
3-4
3-4
RAP
;;
3
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
AP
-0.25
-0.09
-0. 10
-0.09
-0.10
-0.01
-0 34
-0.30
-0.33
-0.32
-0.17
-0. 16
-0.25
-0. 19
-0 18
-0.15
-0. 12
-0.05
-0.04
-0.04
-0. 13
-0.09
-0 11
-0. 10
-0. 14
-0 14
-0.06
-0.02
-0.02
-0.01
-0.01
0
des ign
C mix
C mix
C mix
C mix
C mix
C mix
Recycle-A
Recycle-A
Recycle-A
Hecyc)e-A
Recycle-A
Recycle-A
Recycle-A
Recycle-A
Recycle-A
Recycle-A
Recycle-A
Recycle-A
Recycle-A
Recycle-A
Recycle-A
Recycle-A
Recycle-A
Recycle-A
Kecycle-A
Recycle-A
Recycle-A
Recycle-A
Recycle-A
Retycle-A
Recyc le-A
Recycle-A
Comment
Turned off prespray water flow
at 2:41 p.m.
Turned on prespray water flow
at 3:44 p.m.
9:45-9:50 RAP bin clog reduced
production rale
Reduced production rale due lo
loader problems
Stopped operation 3:41 lo 3:44;
drag slat clogged
Stopped process al 5:30 lo
switch to C mix (virgin)
o
5
z
(continued)
-------
TABLE 3-5 (continued)
I
M
O
Date
11/12/83
(a.m.)
1 ine
7: 10
7:30
8:01
Production
rale. tpha
215.6
237 8
238. 1
Virgin. RAP
tph Iph
155.0 55.4
173.5 58.1
174.1 57.4
AphaJt,
Iph
52
62
66
Mix
temp. ,
"F
290
290
295
Burner
selling.
%
40
35
35
Operator estimate
moisture
content
Virgin RAP
3-4 2
3-4 2
3-4 2
Drum
Internal
pressure ,
flP
0 09
0 08
0. 11
Mix
des Ign
Recycle-A
Recycle- A
Recycle-A
Comment
8:05 to B: 10--drum off;
switch-
ing lo load different storage
(p.m.)
8:30
9:00
11:00
11:30
12:00
.12:30
1:01
1:30
2:00
234.1
253.5
256 8
247.6
250.0
248.8
235.0
235.4
222.2
171.6 56 5
183.4 63.6
244.2
235.1
238.5
236.8
223.3
223.6
211 5
60
6.5
12 6
12 5
12.3
12 0
11.7
118
10 7
290
270
275
270
280
290
280
280
285
35
40
60
60
60
55
50
50
50
3-4 2
3-4 2
~3
~3
~3
~3
___ "*
3-4
3-4
Oil
0.03
0
0
0
0
0
0
0
Recycle-A
Recycle-A
B mix
B alx
8 nix
B mix
B mix
B mix
B nix
silo
At 9:20 stopped adding RAP lo
drum; switching to B mix
11:55 look asphalt cement sample-
Source Allied, Stroud, Oklahoma
Reduced producllon rate;
no I
enough trucks to haul the asphalt
11/13/83
(a.m.)
11/14/83
(a.m.)
2:30
3:01
8:01
8:29
8:58
9:29
9:59
10:30
11:05
11:29
8:03
8:30
9:00
9:30
10:00
10:30
11:08
215.7
209.7
212.8
256.9
236.7
238.3
241. 1
243.4
230. 1
222.8
185.1
209.1
219.9
218.9
224.6
219.3
201.5
205 3
199.4
202.9
244 3
225.1
226.7
229.0
231.7
218.1
211.6
176.2
198.4
208.9
207.9
213.3
208.5
191.2
10 4
10 3
99
12 6
116
11 6
12.1
11.7
114
11 2
89
10.7
11.0
11 0
113
10 8
10 3
290
285
295
275
275
285
285
280
280
255
305
305
290
290
285
275
280
35
35
35
50
60
50
45
45
60
60
40
45
45
50
50
50
50
3-4
3-4
3-4
3-4
3-4
3-4
3-4
3-4
34
3-4
3-4
3-4
3-4
3-4
3-4
34
3-4
0 01
0 02
0 13
0
0
0
0 02
0
0
0
0 01
0
0
0
0
0
0
B mix
B mix
B nix
B nix
B nix
B mix
B mix
B 01 ix
C nix
C mix
H mix
H mix
M mix
H mix
H mix
H mix
C IRIX
concrete
10:54 slopped operation
switch lo C mix
11:52 slopped operalion
switch to H mix
10:55 stopped operation
switch to C Hix
to
to
lo
; r~7 ,
Z
-------
TABLE 3-5 (continued)
Production Virgin,
Date Time rate. tpha tph
11:30
(p.m.) 12:00
12:30
1:00
2:06
2:25
11/15/83 7:38
(a.m.) 8:00
8:30
9:03
9:30
9:57
10:30
10:55
(p.m.) 12:07
12:30
1:00
206.8
182.6
199.7
202.5
204.5
190.1
222. 1
215.6
241.5
178.6
157.7
170.7
156.1
166.6
245.6
241.1
237.4
196.5
173.4
189.8
192.4
194.5
180.5
211.0
204.8
229.4
134.2
116.0
126.5
119.8
117.1
233.3
229. 1
225.3
RAP AphaU.
tpha tph
10.3
9.2
9.9
10.1
10 1
9.6
11.1
10.8
12.1
37.9 6.5
36.4 5.3
38.1 6.1
30 8 5.5
43 9 5.6
12.3
12 0
12.1
Mix
temp. ,
°F
295
300
285
300
270
290
255
205
290
285
310
255
255
265
280
285
265
Burner
setting,
%
35
40
40
35
55
50
50
45
50
55
65
60
65
65
60
60
60
Operator estimate Drum
moisture Internal
content pressure. Mix
Virgin
3-4
3-4
3-4
3-4
3-4
3-4
3-4
3-4
3-4
8
8
a
8
a
3-4
3-4
3-4
RAP AP
0
0
0
0.03
0
0
0
0
0
3.5 0
3.5 0
3.5 0
3.5 0
3.5 0
0
0
0
design
C mix
H mix
H mix
H mix
C mix
C mix
H mix
H mix
H mix
Recycle-IISd
Recycle- US
Recycle-HS
Recycle-HS
Recycle-HS
H nix
H nix
M mix
Comment
11:43 plant shut off to switch
to H mix
1:18 plant shut down; silo
filled; slow lay down operation
Stopped operation at 6:44 to
switch to hot sand RAP mix
8:56 started recycle mix; hot
hot sand mix typically runs at
lower production rale
11:00 shut off operation to
switch to M mix
1:21 stopped to switch to C
mix
1:35 226.7
1:55 223.8
215.5
212.8
11.2
11 0
270
295
60
65
3-4
3-4
C mix
C mix
1:38 to 1:41 shut off water to
prespray and venturi throat
.Measured by weigh bridge on feed conveyors.
Measured by flow meter at asphalt storage tank.
'fiecycle-A = recylce A mix.
Hecylce-IIS = recycle hot sand nix.
-------
RADBAN
Tables 3-6 and 3-7 contain a summary of the venturi scrubber operating
data collected during the test program.
3.5. SUMMARY OF PERTINENT PLANT OPERATION INFORMATION DURING THE EMISSION
TEST PROGRAM
This section includes a summary of pertinent information concerning the
operation and monitoring of the asphalt concrete plant and venturi scrubber.
3.5.1 Asphalt Concrete Production Summary
Table 3-8 presents a summary of the average asphalt concrete production
and mix type produced during each test period.
3.5.2 Blue Haze Production
The water flow to the presprays was turned off for over an hour on the
afternoon of November 10, 1983 in an effort to generate blue haze by elimi-
nating the prespray cooling. No blue haze was observed during this period.
With the concurrence of the EPA Industrial Studies Branch (ISB) and Emission
Measurements Branch (EMB) representatives, testing under reduced water flow
conditions was cancelled.
3-12
-------
RADIAN
CORPORATION
TABLE 3-6. SUMMARY OF VENTURI SCRUBBER OPERATING DATA COLLECTED
DURING CONVENTIONAL OPERATION AT T. J. CAMPBELL
CONSTRUCTION COMPANY, OKLAHOMA CITY, OKLAHOMA
Pressure Drop Scrubber Water Flow Rates (GPM)
Run No. Date Time (In.
Part Cl 11/12 1100
1200
1230
1301
1330
Part C2 11/13 0801
0829
0858
0929
0959
1030
1105
1129
Part C3 11/14 0803
0830
0900
0930
1000
1030
PAH Cl 11/14 1200
1230
1300
1406
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
H20) Total to System Venturi Throat
.5
.5
.5
.5
.5
. 5 ( avg )
.5
.5
.5
.5
.5
.5
.5
.0
.4 (avg)
.5
.5
.5
.5
.5
.5
. 5 ( avg )
.5
.5
.5
.0
.4 (avg)
215
220
220
220
220
219 (avg)
215
220
215
220
220
220
220
220
219 (avg)
215
215
215
215
215
215
215 (avg)
220
220
220
220
220 (avg)
41
41
41
42
42
41 (avg)
41
42
42
42
42
42
42
42
42 (avg)
42
42
41
41
42
42
42 (avg)
43
42
42
42
42 (avg)
3-13
-------
RADIAN
TABLE 3-7.
SUMMARY OF VENTURI SCRUBBER OPERATING DATA COLLECTED
DURING RECYCLE OPERATION AT T. J. CAMPBELL CONSTRUC-
TION COMPANY, OKLAHOMA CITY, OKLAHOMA
Pressure Drop Scrubber Water Flow Rates (GPM)
Run No. Date Time
Part Rl 11/11 0837
0901
0930
1001
1030
1100
1130
1210
1230
1300
1332
1400
1430
Part R2 11/11 1501
1531
1602
1630
1700
1726
Part R3 11/12 0700
0730
0801
0830
0900
PAH Rl 11/15 0903
0930
0957
1030
1055
(In. H20) Total to System Venturi Throat
12.5
12.5
12.5
14.5
14.5
14.5
14.5
14.0
14.0
14.0
14.0
14.0
14.0
13.8 (avg)
14.0
13.5
13.5
14.0
14.0
14.0
13.8 (avg)
14.0
14.0
14.0
14.0
13.5
13.9 (avg)
13.0
13.0
12.5
12.5
12.5
12.7 (avg)
235
235
225
220
220
220
220
220
220
220
220
220
220
223 (avg)
220
220
220
220
220
220
220 (avg)
215
220
220
220
220
219 (avg)
225
210
215
210
210
214 (avg)
40
40
40
38
41
41
41
41
42
41
42
42
41
41 (avg)
41
41
41
42
41
41
41 (avg)
42
42
41
42
41
42 (avg)
30
30
30
30
30
30 (avg)
3-14
-------
RADIAN
CORPORJCT1OM
TABLE 3-8. AVERAGE PRODUCTION AND MIX TYPE DURING TESTING PERIOD—
T.J-. CAMPBELL CONSTRUCTION COMPANY, OKLAHOMA CITY, OKLAHOMA
Date
11/13/83
11/14/83
11/14/83
11/15/83
Test period
time
(beginning-end)
08:53-ll:12a
08:13-10:03a
10:14-11:43b
12:25-14:00b
Average production
rate, tph
235.4
212.8
209.2
232.3
Product type
11/11/83
11/11/83
11/12/83
11/12/83
11/12/83
08:39-14:33a
15:15-17:04a
07: 13-09 :00a
11: 39-13: 19a
14: 18-15 :20b
229.3
249.8
235.8
243.5
215.9
Recycle A mix
Recycle A mix
Recycle A mix
Virgin B mix
Virgin B mix
Virgin B&C mix
Virgin M mix
Virgin M&C mix
Virgin M&C mix
Controlled emission test periods - uncontrolled emission tests
conducted sometime during the indicated time periods.
Uncontrolled particle size test periods.
3-15
-------
RADIAN
SECTION 4
SAMPLING LOCATIONS
A schematic diagram of the asphalt concrete process is presented
in Figure 4-1. The general location of each sampling point and the parame-
ters measured at each sampling location are also presented in Figure 4-1.
Section 4 contains a brief description of each of the sampling locations
used at T. J. Campbell during the emissions testing program.
4.1 VENTURI SCRUBBER INLET SAMPLING LOCATIONS
Uncontrolled emissions samples were collected in the duct work between
the drum mixer and the wet venturi scrubber. A side view and top view of
the duct work immediately upstream and downstream of the uncontrolled emis-
sions sampling location is illustrated in Figure 4-2. Flue gas exiting the
rotating drum enters the knockout duct that carries the flue gas upward
about 10 to 12 feet where the flue gas then flows horizontally in a triangu-
lar duct. The triangular duct funnels the gas to a 90° downward bend into
the wet venturi scrubber. Uncontrolled emissions samples were collected in
the triangular duct.
Figure 4-3 presents the location of the four 3-inch ports that were
used to measure the gas flow rate and collect particulate mass, TOG, extrac-
table organics, trace metals, and polynuclear aromatic hydrocarbon sam-
ples at the venturi inlet. The four sampling ports were located about two
feet upstream from the water sprays in the triangular duct. These co-
current sprays, used to cool flue gases prior to venturi entry, did not
interfere with the sampling activities. Figure 4-3 includes a description
of the 16 sampling points used to characterize the inlet duct.
4-1
-------
I
K)
Recycled
Asphalt
Pavement
Aspbalt
Virgin '
Aggregate
Flow Rate
Partlrulate (front half)
TOC, CondensI hie Hydrocarbons
(back half)
Particle Size Distribution
PAH
Gas Composition (C0? , Oj,
TOC - total organic carbon
2T.M. - trace metals
JTSS - total suspended solids
"TDS - total dissolved solids
BaP - benzo(a)pyrene
6PAH - polynoclear aromatic hydrocarbons
Srrubber Pond
Flow Rate
Participate (front half)
TOC, Condenstble llydr*o<;arlions
(back half)
T.H.
Particle Size Distribution
PAH6
Gas Composition (CO?, 0?,
N2, 11,0)
Opacity
Figure 4-1. Schematic of asphalt concrete process including
sampling point locations and sampling matrix.
-------
TOP OF KNOCKOUT
/
43-INCH PORTS
t
GAS
FLOW I
PORT
I TO I
VENTURI
Figure 4-2A. Side View of Inlet Duct Sampling Ports
THERMOCOUPLE
WATER
'SPRAY
43-INCH PORTS
-18 INCHES ON CENTER
•FIRST AND LAST PORT
9 INCHES FROM WALL
6-INCH PORT
Figure 4-2B. Top View of Inlet Duct Sampling Ports.
4-3
-------
VERTICAL SAMPLING PORTS
(TOP OF DUCT)
1
PORT 1 r
-1 2
~| PORT 2 P
-1 3-
""(PORT 3 (~
-1 4-
«« — 9' — B»
~~| PORT 4
-1
1-9 9-9 1-9 A-9
1-1 9-1 1-1 A-1
1
-4 2
-4 3
-4 4-
^* NJ U A
H H -H -(
I I X I
a 3 33 33
C C C C
— rb u i.
^r
o
1'
\
• t
)
n
r
j
CO
1
,
bi
.
i
70A3540
Figure 4-3. Venturi scrubber inlet sampling location for gas flow
rate, particulate mass, condensible hydrocarbons, trace
metals, and polyaromatic hydrocarbons emissions sampling.
4-4
-------
RADIAN
Uncontrolled flue gas samples for 02 and CC^ analysis were collected at
sampling point 2-2 as illustrated in Figure 4-3.
Particle size distribution (PSD) samples were collected through the
single 6-inch port (Port 5 illustrated in Figure 4-4) mounted on the east
side of the triangular duct. The center of Port 5 is situated 13.25 inches
from the top of the duct. PSD samples were collected 27 inches from the
east duct wall (Point 5-1).
4.2 VENTURI SCRUBBER OUTLET SAMPLING LOCATIONS
Controlled emissions samples were collected at the outlet of the ven-
turi scrubber. Flue gas exiting the venturi scrubber entered the exhaust
fan and then passed through a flow control damper. The flue gas then exited
through a rectangular stack. Controlled emissions samples were collected
from two sets of sampling ports on the stack.
The first set of ports consisted of three 3-inch ports located about
eight feet downstream of the control damper. The second set of ports con-
sisted of six 3-inch ports located about six feet further downstream from
the first set of ports.
Particle size distribution tests were unsuccessfully attempted through
the three ports located immediately downstream of the control damper. Fig-
ure 4-5 illustrates the location of the port and point used for the particle
size distribution tests on controlled emissions.
Gas flow rate measurements and particulate mass, TOC, extractable
organics, trace metals, and polynuclear aromatic hydrocarbon samples
were collected using the set of six 3-inch ports. Figure 4-6 illustrates
the location of the six ports and the locations of the twenty-four sampling
points used to collect controlled emissions samples.
4-5
-------
SAMPLING PORTS
•72'-
.9-.
•r 6"-
• r 6'-
| [PORT 3
| |PORT 4
& i
6-INCH PORT USED
FOR PARTICLE SIZE
SAMPLING
PORTS
5-1
S
CD
Figure 4-4. Venturi scrubber inlet sampling location for the collec-
tion of particle size distribution samples.
4-6
-------
-31.25"
O O O O O O
PARTICULATE SIZE DISTRIBUTION
SAMPLE PORT
O © O
GAS FLOW
DAMPER
~1
• 35.5"
•22.2"
1-1
SAMPLE POINT 1-1
70A3602
cr
O
Q.
O
a
2
Figure 4-5. Venturi scrubber outlet sampling location for particle size
distribution sampling.
-------
-P-
oo
31.25'
PARTICULATE
SAMPLING PORTS
Q00000
O O O
GAS FLOW
DAMPER
6
5
4
3-
2
1
4t\
0 0
^
•n *>" , . M
^ 133" ' t*
F4.5"»
1 4 THRU 6 4
1-3 THRU 6 3
1 2 THRU 6 2
1-1THRU6 1
6
5
4
3
2
1
SAMPLING POINTS
70A3601
Figure 4-6. Venturi scrubber outlet sampling location for gas flow,
particulate mass, condensible hydrocarbons, trace metals,
and polyaromatic hydrocarbons emission sampling.
-------
RADIAN
4.3 VISIBLE EMISSION OBSERVATION LOCATIONS
Visible opacity observations were made of the plume exiting the stack.
A total of six locations were used to make the opacity observations during
this program. Figure 4-7 presents the layout of the T. J. Campbell asphalt
plant and the approximate location of the observer with respect to the stack
at each position during visible emissions measurements.
4.4 VENTURI SCRUBBER WATER SAMPLING LOCATIONS
Samples of water supplied to the venturi scrubber and samples of ven-
turi scrubber effluent water were collected during emissions testing. Sam-
ples of pond water being supplied to the venturi scrubber spray nozzles were
collected at the floating pump intake (refer to Figure 4-8). The intake
line floats out in the pond and access to the intake is by means of a wooden
plank. Water samples were collected near the pump intake by dipping a
sample container into the pond at the intake position.
Venturi scrubber water drains into a collection box below the venturi.
The scrubber water then drains back to the settling pond by means of an 8-
inch diameter plastic pipe. Samples of the scrubber effluent water were
collected from the collection box below the venturi scrubber.
4.5 VENTURI SCRUBBER PROCESS MONITORING LOCATIONS
The venturi scrubber pressure drop and venturi scrubber water flow
rates were monitored during the emissions test program.
4.5.1 Venturi Scrubber Pressure Drop Monitorine
Figure 4-9 illustrates the locations used to monitor the venturi pres-
sure drop. Swagelok® connectors were installed in the duct work immediately
upstream and downstream of the venturi scrubber. Tygon® tubing was used to
4-9
-------
©
MAINltNAMCt
COKVtNllOHAi. ANO fttCTClt MIX
E &U.DS
©
0
Position
No. Date
1
2
3
4
5
6
11-10-83
11-11-83
11-11-83
11-12-83
11-13-83
11-15-83
Approximate
Distance
Time from Stack (ft)
1000-1625
0819-1126
1308-1718
0722-1429
0800-1150
0815-1054
1000
125
100
200
80-100
250
Direction of Observer Plant
from Discharge Point Mode
SE
NE
SW
E
S-SE
E-SE
R
R
R
C&R
C
R
C - conventional operation
R - recycle operation
Figure 4-7. Locations of visible emission observations at the
T.J. Campbell asphalt plant, Oklahoma City,
Oklahoma.
4-10
-------
INFLUENT
POND
TO
SCRUBBER"
PUMP
24 FT.-
RETURN PIPE
FLOATING
INTAKE LINE
DENOTES
SAMPLING
LOCATIONS
WEIR
EFFLUENT
POND
:TTCD
E I tn
"1
©
Qr.PI IRRPR
__— ~~^^* r-r-i-i iir-M-r
m
in
co
I
n
<
o
Figure 4-8.
Layout of effluent and influent scrubber
ponds including sampling locations.
4-11
-------
FLOW
I
M
to
PRESPRAY
NOZZLES
VENTURI THROAT
SPRAY NOZZLES
MAGNEHELIC
GAUGE
,®
Figure 4-9. Venturi scrubber pressure drop monitoring location.
-------
RADIAN
connect the sample taps to a Magnehelic®dif ferential pressure gauge for use
in monitoring the scrubber differential pressure.
4.5.2 Venturi Scrubber Water Flow Rate Monitoring
The total water flow rate to the venturi scrubber system and the flow
rate of water to the venturi spray nozzles were monitored using paddle wheel
type sensors. Flosensors® were used to monitor the water flow rate at the
two locations. Figure 4-10 depicts the locations of the two Flosensors®in
the scrubber system. One Flosensoi®was installed in the 4-inch main line to
monitor the total flow of water to the scrubber system. A second Flosensor®
was installed in the 2-inch line that supplies water to the venturi spray
nozzles. Both Flosensors®were installed in vertical sections of pipe to
ensure full-pipe flow of water during monitoring.
4.6 ASPHALT CONCRETE PROCESS SAMPLING LOCATIONS
During emissions testing samples of the virgin aggregate and recycled
asphalt pavement were collected from the conveyor belts that transport the
raw materials to the drum mixer from the storage bins.
Samples of the liquid asphalt cement were obtained from a vendor truck
that transported the asphalt cement to the plant.
4-13
-------
EFFLUENT
POND
I-1
4>
WEIR
INFLUENT
POND
FLOSENSOR WATER FLOW
TO VENTURI SPRAY NOZZLES
FLOSENSOR-TOTAL WATER
FLOW TO VENTURI
TO DRAIN
TRAY
VALVE
Figure 4-10.
Location of flosensors used to monitor the flow rate
of water to the T.J. Campbell wet venturi scrubber.
-------
RADIAN
COBPOfumOM
SECTION 5
SAMPLING AND ANALYSIS
This section contains general descriptions of sampling equipment, sam-
ple collection techniques, and sample recovery techniques used during the
emissions testing program at the T.J. Campbell asphalt concrete plant. Also
included are analytical preparation techniques and analytical methodology
used to analyze the samples collected during sampling. Additional information
is provided in Appendix J.
5.1 SAMPLING PROCEDURES
This section provides a description of the sampling procedures that
were used to collect samples of the flue gas, scrubber waters, and process
solids for analysis.
5.1.1 Source Sampling Procedures
Included in Table 5-1 is a list of the various parameters that were
measured at the inlet and outlet of the venturi scrubber and the sampling
methodology that was used during source sampling. Each of the sampling
methods listed in Table 5-1 are described in this section. Whenever possi-
ble, EPA referenced source sampling methods were used. The EPA reference
methods were taken from the Environmental Reporter, Volume I - Federal
Regulations, Section 121, "Air," Appendix A. If an EPA reference method did
not exist, a detailed description of the methodology is provided.
5.1.1.1 Gas Phase Composition—
Following are discussions of the methods which were used to measure gas
phase composition.
5-1
-------
TABLE 5-1. SUMMARY OF SOURCE SAMPLING PARAMETERS AND METHODOLOGY
Parameter Measured
Number and location of sampling points,
gas velocity and volumetric gas flow
(ia.s phase romposl t lon/dow point
'i
3 3
3 3
1 1
1 1
1
2?
z
'Number of valid sampling runs performed
^Number of attempted sampling runs
-------
RADIAN
Moisture Determination—The moisture content of the outlet gas stream
was determined using a modified version of the methodology described in EPA
Method 4. This method requires that a known volume of particle free gas be
pulled through a chilled impinger train. The quantity of condensed water is
determined gravimetrical ly and then related to the volume of gas sampled to
determine the moisture content.
The moisture content of the gas stream was determined simultaneously
during each EPA Method 5E test and each particle size distribution determi-
nation. The absolute filter in the EPA Method 5E and particle sizing trains
removed the particulate matter from the gas stream, allowing condensed water
to collect in the impinger train.
The moisture content of the gas stream is required to calculate the
molecular weight of the gas (wet) and the isokinetic gas sampling rate.
Relative Humidity—A wet bulb/dry bulb apparatus was used in conjunc-
tion with a psychrometric chart to determine the relative humidity of the
scrubber gas streams. The wet bulb/dry bulb apparatus consists of two
thermocouples strapped together. The front end of the first thermocouple
extended out about three inches further than the second thermocouple. A
cloth sock was placed tightly over the front two inches of the first thermo-
couple (wet bulb). Prior to sampling, the cloth sock was saturated with
water. The thermocouples were then inserted into the center of the duct and
the temperature of the wet bulb thermocouple monitored. After the tempera-
ture of the wet bulb thermocouple stabilized (reached equilibrium), the
temperature of the dry thermocouple was"measured. The wet bulb and dry bulb
temperatures were used with a psychrometric chart to determine the relative
humidity and moisture content of the gas stream. A high temperature psych-
rometric chart (dry bulb temperature -500°F) was used during this program
because of the high temperature (—300°F) of the uncontrolled emissions gas
stream. The wet bulb/dry bulb temperatures were determined at least once
during each test run to verify the moisture content of the gas streams.
5-3
-------
IZADEAN
Molecular Weight Determination—The dry molecular weight of the gas
stream was determined using the grab sampling technique described in EPA
Method 3. The dry molecular weight of the gas was calculated based upon the
02> C02» and N£ concentration. CC^ and 02 concentrations were determined
using an Orsat apparatus. N~ was determined by difference.
A small diaphragm pump with a stainless steel probe were used to ex-
tract a small volume (—10 liters) of the gas sample which was collected in a
Tedlar®bag. Collection of the gas sample in the Tedlar® bag required 15 to
20 minutes and was performed immediately following a source sampling run
(ex. EPA Method 5E). A specific volume of gas is then transferred to the
Orsat. During analysis, the gas sample is passed through two absorbing
solutions designed to selectively remove C02 and then ©2- The decrease in
the gas volume in the Orsat container is proportional to the dry concentra-
tion of the absorbed species. The balance of the gas mixture was assumed to
be 1$2' *f more than six passes were required to obtain a constant (0.3%
difference, absolute) reading for either ©2 or C02» the appropriate absorb-
ing solution was replaced.
5.1.1.2 Volumetric Gas Flow Rate Determinations—
Total gas flow rates at the scrubber inlet and outlet were determined
using procedures described in EPA Method 2. The volumetric gas flow
rate was determined by measuring the cross sectional area of the inlet duct
and the stack and the average velocity of the gas stream. The area of the
inlet duct and the stack was determined by direct measurement.
The number of sampling points required to statistically measure the
average gas velocity in the stack was determined using the procedures out-
lined in EPA Method 1. The number of sampling points and their distance from
the duct wall is a function of the proximity of the sampling location to its
nearest upstream and downstream flow disturbance. A total of 24 sampling
points (4x6 matrix) were used at the stack sampling location.
5-4
-------
RADIAN
The inlet sampling location (refer to Section 4) did not meet EPA
Method 1 criteria but represented the best possible location available for
collecting uncontrolled emission samples. The number of inlet sampling
points were limited to 16 (4x4 matrix) because of the high particulate
loading and limited sample collection time.
The gas stream velocity was calculated from the average gas velocity
pressure (AP), the average flue gas temperature, wet molecular weight, and
absolute pressure. AP and temperature profile data were measured at each of
the sampling points using an S-type pitot tube and type-K thermocouple. A
Magnehelie® gauge was used to measure the pressure drop (AP) across the S-
type pitot.
Barometric pressure readings were obtained daily by phoning Tinker Air
Force Base. The static pressure was measured by inserting a stainless steel
probe into the duct. A Magnehelic® gauge attached to the probe was used to
measure the static pressure within the duct.
5.1.1.3 Particulate Loading Determination—
A modified version of the sampling procedure specified in EPA Method
5E was used to measure the particulate and condensible hydrocarbon load-
ings. The primary modifications to the standard procedure include:
o impinger train configuration and impinger contents depending
upon the chemical specie(s) of interest,
o the sample recovery procedure(s),
o performing an acetone probe rinse prior to the trichloroethane
probe rinse, and
o maintaining the filter temperature at 250°F + 10°F.
5-5
-------
RAOBAN
Figure 5-1 illustrates the EPA Method 5E sampling train. A sample of
particulate-laden flue gas was collected isokinetica 1 ly through a stainless
steel gooseneck nozzle. A stainless steel or glass-lined heat traced probe
transported the flue gas from the duct to the hot box. Problems were
encountered with glass liners breaking during the runs. To eliminate this
problem a stainless steel probe was used during later runs. The trace metal
samples were collected using a glass liner. The probe temperature was closely moni-
tored and controlled at 250°F ;+10°F. After entering the hot box, the
particulate matter was removed from the gas stream by means of a glass
filter housed in a glass holder. The temperature of the sampled gas was
monitored and controlled at the filter using a time proportioning tempera-
ture controller to a temperature of 250°F + 10°F.
The filtered gas stream then entered a series of impingers immersed in
an ice bath. The configuration and contents of the impingers depended on
the type of chemical specie(s) of interest. The impinger train used during
condensible hydrocarbons and particulate determinations consisted of four
impingers situated in an ice bath. The first two impingers were of the
Greenburg-Smith design and contained 250 ml of 0.1 N sodium hydroxide (NaOH)
for hydrocarbon collection. The third and fourth impingers were of the
modified Greenburg-Smith design. The third impinger was dry and the fourth
impinger contained about 250 grams of silica gel for final moisture removal.
Section 5.1.1.4 provides a description of the trace metals impinger train
configuration that was used simultaneously with the particulate loading
determination. All impingers were weighed before and after sampling using a
top loader balance. The impinger weight gain data was used to calculate the
moisture content of the flue gas.
During sampling, the flue gas velocity was monitored by an S-type pitot
tube attached to a Magnehelic® gauge. The isokinetic sampling rate was
maintained through a system of valves and a leak less pump. The sampling
rate was monitored using a calibrated orifice with a Magnehelic® gauge and
5-6
-------
HEATED
GLASS LINER
PHOBE LINER
TEMPERATURE
SENSOR
DRY
IMPINGER
TEMPERATURE
SENSOR
TEMPERATURE
SENSOR
GOOSENECK
NOZZLE
GAS FLOW
TEMPERATURE CONTROLLER
FOR MAINTAINING FILTER
HOLDER TEMPERATURE |250'F|
ORIFICE
MAGNAHELIC
PUMP
IS
I
70B3477
Figure 5-1. Modified EPA Method 5E sampling train designed to
collect particulate and condensible hydrocarbon
samples at the venturi scrubber inlet and outlet.
-------
RADIAN
the total sample volume was measured using a calibrated dry gas meter. The
gas stream temperature was monitored using a type-K thermocouple and a
pyrometer.
When sampling was completed, the nozzle, probe, and interconnecting
glass pieces prior to the filter were brushed and washed, first with three
volumes of acetone and then with a volume of 1,1,1-trichloroethane. The
dual solvent rinse was requested by EPA to relate results to comparative
Method 5 data and collect samples within the protocol of Method 5E. The
acetone and trichloroethane "front-half" rinses were stored separately in
individual 500 ml glass bottles with teflon lid inserts. The filter was
transferred to the filter's original petri dish along with any particles or
loose filter material in the holder.
After weighing, the impinger contents were quantitatively transferred
to individual 500 ml glass bottles with teflon lid inserts. All of the
glassware from the filter to the silica gel impinger was rinsed, first with
two aliquots of 0.1 N NaOH and then with a volume of trichloroethane. The
trichloroethane "back-half" rinses were stored separately in individual 500
ml glass bottles with teflon lid inserts.
The filters, impinger solutions, and acetone, trichloroethane, and NaOH
rinses were carefully packaged for shipment back to Radian for weighing and
other analyses.
5.1.1.4 Trace Metals Sample Collection—
Samples of the gas streams were collected during this program for trace
metals analysis. Collection of the volatile trace metals samples was achieved
by incorporating an acid impinger into the impinger train described in
Section 5.1.1.3. The impinger, containing 250 ml of 10% ultrex nitric acid
(HNOo), was placed immediately downstream of the two 0.1 N NaOH impingers
used for hydrocarbons collection. Sample collection was similar
to the procedure described in Section 5.1.1.3. Figure 5-2 graphically
illustrates the trace metals sampling train.
5-8
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Ol
I
HEATED
GLASS LINER
TEMPERATURE
SENSOR
TEMPERATURE
SENSOR
GOOSENECK
NOZZLE
GAS FLOW
TEMPERATURE CONTROLLER
FOR MAINTAINING FILTER
HOLDER TEMPERATURE (250'F)
ORIFICE
MAGNAHELIC
70A3604
Figure 5-2. Sampling train designed to collect trace metals samples at the
venturi scrubber inlet and outlet.
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RADIAN
Upon completion of sampling, the particulate and TOC/extractable hydro-
carbon sample recovery procedure described in Section 5.1.1.3 was used. The
HNOj impinger solution was stored in a 500 ml Nalgene bottle. The HNO-j
impinger was rinsed with an aliquot of 10% HN03 and the rinse added to the
sample bottle.
The filter, acid and base impinger solutions, and the acetone and
trichloroethane rinse solutions were shipped back to Radian for trace metals
analysis using procedures described in Section 5.2.
5.1.1.5 Polynuclear Aromatic Hydrocarbons Sample Collection—
Figure 5-3 illustrates the sampling train that was used to collect
samples of the gas stream for PAH analysis. The PAH sample collection
procedure is similar to the particulate loading procedure described in
Section 5.1.1.3. The major differences between the two systems include
impinger configuration, contents, and sample recovery procedures.
The PAH impinger train consisted of a dry impinger for cooling down the
gas before entering the glass canister containing ZAD-2 resin for PAH ad-
sorption. The temperature of the gas entering the resin canister was moni-
tored using a thermocouple. Following the XAD-2 resin canister was a second
dry impinger for collection of any condensate occurring downstream of the
XAD-2 resin. The third impinger contained silica gel for final moisture
removal. The glassware in the hot box, the two dry impingers, and the XAD-2
resin canister were wrapped with aluminum foil to reduce sample exposure to
ultraviolet radiation, which can cause possible photodegradation of the
PAH'S.
Upon completion of sampling, the sampling train was returned to the
mobile laboratory for sample recovery. Incandescent lights were used in the
mobile laboratory during sample recovery to minimize PAH photodegradation.
The nozzle and glass probe liner were brushed and rinsed with methylene
chloride. All interconnecting glassware in the hot box and impinger train
5-10
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HEATED
GLASS LINER
TEMPERATURE
SENSOR
GOOSENECK
NOZZLE
Ui
I
TEMPERATURE CONTROLLER
FOR MAINTAINING FILTER
HOLDER TEMPERATURE (250°F)
ORIFICE
MAGNAHELIC
PUMP
70B347B
Figure 5-3. Sampling train designed to collect polynuclear aromatic hydrocarbon
samples at venturi scrubber inlet and outlet.
-------
RAOBAN
(except the silica gel impinger) were also rinsed with methylene chloride.
The methylene chloride rinses were stored in amber glass bottles with teflon
lid inserts. The filter was transferred to a glass petri dish and wrapped
with aluminum foil to protect it from direct light during storage and ship-
ment. The XAD-2 resin was transferred from the canister to a pint Ball jar
and wrapped with aluminum foil for storage. Methylene chloride was used to
rinse the resin into the jar. A lid with a teflon insert was used to seal
the jar. The PAH sample was analyzed at Radian using the procedure des-
cribed in Section 5.2.
5.1.1.6 Particle Size Distribution Determination—
During this project the particle size distribution at the inlet and
outlet of the scrubber was determined using the sampling trains illustrated
in Figures 5-4 and 5-5, respectively. Both sampling trains were similar in
design and used equipment designed to classify particles present in the gas
stream with respect to their aerodynamic size.
Because of the high particulate loading encountered at the scrubber inlet, an
Andersen High Capacity Stack Sampler (AHCSS) was used to determine the inlet
particle size distribution. A cut-away view of the AHCSS is illustrated in
Figure 5-6. The AHCSS contains two impaction chambers followed by a cyclone
and a backup absolute thimble. Particles were automatically fractionated
into four size ranges and the results were then plotted to represent the
size distribution (see Figure 2-3).
A right angle probe was used at the scrubber inlet to allow the AHCSS
to be pointed into the gas stream. A straight-neck sampling nozzle was
attached to the AHCSS to minimize the impaction of larger particles that
might otherwise occur using a gooseneck nozzle at the inlet.
PSD sampling at the scrubber outlet was attempted using an Andersen
Mark III cascade impactor. The impactor classifies aerosols aerodynamical ly
into nine size fractions. Glass fiber impactor substrates were used to
collect the particles from the gas stream. The substrates decrease the
5-12
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-TEST DUCT
ABSOLUTE |
FILTER
H2O
IMPINGERS
DRY
IMPINGER
TEMPERATURE
V) SENSOR
Ul
I
ANDERSEN
HIGH CAPACITY
STACK SAMPLER
STRAIGHT
NOZZLE
1/2" DIA STEEL
PIPE PROBE
SILICA GEL
DESSICCANT
ICE BATH
BYPASS VACUUM
TEMPERATURE SENSORS f VALVE GAUGE
VACCUM
LINE
PUMP ORIFICE
GAS FLOW
-i/-
70A3476
ORIFICE
GAUGE
Figure 5--4. In-stack Andersen high capacity stack sampler sampling train
used to determine the particle size distribution at the venturi
scrubber inlet.
-------
I
H
*-
TAPERED
STRAIGHT!
NOZZLE
1
GAS FLOW
TEMPERATURE
\_
1/2" STEEL
PIPE PROBE
ANDERSEN
MARK III
SILICA GEL
DESSICANT
PUMP ORIFICE
TEMPERATURE
SENSORS
(%
BY PASS
VALVE
MAIN
VALVE
MAGNEHELIC
GAUGE
ICE BATH
VACUUM
GAUGE
VACUUM
LINE
Figure 5-5. In-stack Andersen Mark III Cascade impactor sampling train used to
determine the particle size distribution at the venturi scrubber outlet,
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^
FLOW
ACCELERATION
JET
rO
VENT
TUBE
LKDcm
SCALE
ISOKINETIC PROBE
FIRST IMPACTION STAGE
SECOND IMPACTION STAGE
CYCUONE STAGE
GLASS FIBER
THIMBLE FILTER
Figure 5-6. Schematic of the Andersen Model HCSS High
Grain-Loading Impactor
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errors that are encountered in weighing the large metal plates. The sub-
strates were pretreated before use by baking the filters at 500°F for two
hours. The substrates were then desiccated and weighed using a Mettler
AE163 analytical balance. Preweighed sets of substrates were stored in
polyethylene petri dishes until use in the field.
The Andersen impactor was oriented horizontally and a straight-neck
nozzle used. Because of the high moisture content of the outlet flue gas,
an auxiliary heating system (heating tape and insulation) was required to
elevate the operating temperature of the Andersen. An elevated temperature
was used to try to evaporate water droplets present in the gas stream. A
discussion of the problems encountered during this sampling is presented in
Section 2. To assist in this evaporation process, a ten- to twelve-inch
heated extension (0.5-inch ID stainless steel tube) was used between the
nozzle and impactor. A thermocouple mounted in the gas stream directly
behind the Andersen was used to monitor the Andersen operation. A variac
was used to control the heating tape, and thereby the exit gas temperature
of the impactor.
Impactor sampling at the inlet and outlet was performed at a point of
average velocity in the gas stream. The isokinetic flow rate through the
nozzle was precalculated based on velocity data obtained during earlier
sampling (modified Method 5E). Operation of both the AHCSS and Andersen
Mark III required that the flow rate through the impactor be kept constant.
This requirement eliminated the possibility of adjusting the flow rate if
variations in gas velocity occurred.
Prior to sampling at the inlet the AHCSS was allowed to preheat in the
duct for at least 45 minutes to allow ample time for the unit to reach the
flue gas temperature. After sampling, the AHCSS and the Andersen Mark III
were carefully unloaded and the solids and/or substrates desiccated and
weighed. The majority of the Andersen Mark III substrates lost weight due
to the moisture droplets wetting the substrates and making sample recovery
impossible. The individual weight gains of the stages and filters were used
5-16
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»^*^
along with the impactor operating conditions to calculate the particle size
distribution of the scrubber inlet. The impingers were weighed before and
after sampling to determine the moisture content of the gas stream.
5.1.1.7 Visible Determination of Opacity—
The visible opacity of the outlet stack plume was determined by visual
observation using the procedure described in EPA Method 9. When meteoro-
logical conditions permitted, observations were performed during stack gas
sampling runs for particulate and TOC/extractable hydrocarbons loading,
trace metals, and polynuclear aromatic hydrocarbons. Readings were per-
formed when there was a clear blue sky background. The clear blue sky
background was required for detectin of emissions caused by condensed hydro-
carbons in the plume.
5.1.2 Process Water Sampling
Scrubber water influent and effluent samples were collected during the
field testing program. Scrubber water was contained in two ponds located
near the venturi scrubber. Water supplied to the scrubber was pumped from
the end of one pond through a floating intake line. Water from the scrubber
flows by gravity to the opposite end of the second pond. A dike across the
two ponds served as a weir to facilitate settling of solids. Following are
descriptions of sampling methods for the scrubber water streams.
Scrubber Water Sample Collection—Samples of the process water pumped
to the venturi scrubber were collected at the floating intake pump. The
venturi scrubber return water samples were collected at the bottom of the
venturi as the water was gravity fed to the settling pond. Samples were
collected in 500 ml amber glass bottles with Teflon® liners. An attempt was
made to collect at least three samples during each particulate and IOC/- •
extractable hydrocarbons loading, trace metals, and polynuclear aromatic
hydrocarbons run.
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RADIAN
Scrubber Water Flow Rate—The total flow rate of water to the venturi
and to the venturi throat was monitored using Signet Scientific paddle-wheel
Flosensors® The Flosensors© were installed in vertical sections of pipe on
the discharge side of the pump. Installation of the sensors in this manner
was necessary to ensure that flow of water covers the entire cross-sectional
area of the pipes for an accurate measure of flow rate which is based upon
stream velocity. The Flosensors® were coupled with analog read-out devices
which include flow accumulators. Flow rate data was recorded several times
during each particulate and TOC/extractable hydrocarbons loading, trace metals,
and PAH run. The data was recorded by MRI personnel.
Scrubber Water Temperature and pH—At the times of collection of ven-
turi scrubber water samples, the temperature and pH of the stream were
measured. Temperature was measured by direct insertion of a mercury thermo-
meter into the water stream at the collection point. pH measurements were
performed using an Orion digital hand-held pH meter. The pH meter was
standardized with pH 7 and pH 10 buffers just prior to each set of measure-
ments. The pH of the venturi influent water was measured by direct inser-
tion of the pH probe into the pond at the collection point. Effluent
scrubber water pH was measured at the sampling location in a collected
beaker of the water.
MRI measured the temperature of the pond water at the location of the
scrubber water intake pump and at the scrubber water return location. These
measurements were taken using a mercury thermometer.
5.1.3 Process Solids Sampline
Three process solids streams were sampled;
o virgin aggregate,
5-18
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RADIAN
o recycled asphalt pavement, and
o asphalt.
The sampling .and analytical requirements for virgin aggregate and
recycled asphalt pavement were the same. The two streams are belt-conveyed
individually from storage hoppers to the drum mixer. Samples were collected
from the belt conveyors in a large collection tray. The samples were rif-
fled to obtain a representative sample and taken directly to the mobile
laboratory for moisture analysis. At least one sample was collected and
analyzed for moisture during each particulate and TOC/extractable hydrocarbons
loading, trace metals, and polynuclear aromatic hydrocarbons run. Addi-
tional samples of the virgin aggregate and recycled asphalt pavement were
collected for storage.
Samples of the asphalt were collected during the testing program in
one-gallon metal cans. No analyses have -as yet been performed.
5.1.4 Process Parameters
MRI was responsible for monitoring the venturi pressure drop across the
venturi scrubber. Radian installed connections in the ductwork just before
and after the venturi. Tubes were fitted to the two locations and connected
to a Magnehelie® differential pressure gauge. MRI was also responsible for
monitoring the water flow rate to the venturi throat and total flow to the
venturi scrubber.
5.2 ANALYTICAL METHODOLOGY
The previous section described sampling procedures. This section des-
cribes the analytical procedures and points out where samples for analysis
were retrieved from the various sample streams.
5-19
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RADIAN
The majority of analyses for this project were performed at Radian's
Austin laboratories. Samples for analysis resulted from the following:
o particulate, TOC/extractable hydrocarbons sampling train
for controlled and uncontrolled air emissions;
o particulate, TOC/extractable hydrocarbons, and trace metals
sampling train for controlled and uncontrolled air emissions;
o polynuclear aromatic hydrocarbons sampling train for controlled and
uncontrolled air emissions;
o scrubber water to and from the venturi; and
o virgin aggregate and recycled asphalt pavement.
Figures 5-7 through 5-10 present analytical schemes for the three samp-
ling trains and scrubber waters. These figures indicate where samples were
retrieved from the various systems and the analyses performed. The follow-
ing analyses were performed:
o gravimetric analysis of solvent rinses,
o gravimetric analysis of ether chloroform extract of impingers,
o total organic carbon,
o major organics and benzo(a)pyrene,
o trace metals,
o total solids,
5-20
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Ui
NJ
I'.n t leulal u Semitic Tula
Krunl Hail Probe
Ho. 1
Accloltu
Nu. '2
Uiy;
Dry;
Back lljlf lioplngur Solution/Rinses
lm|tJngur SolutloiiH
(0.1N HaOII) and
O.IN HdOII Ulnae
A) IqilUt
Al I(|UOC
AJjust pll to
7 with MCI
CoudLMtslblu Extract
wllll ttlle./
Cli loro form
Dry; UulKh
Dry;
9
Figure 5-7. Partlculate and condensible hydrocarbons sample recovery analytical matrix.
-------
Ul
I
N)
K.anllv, (,„,;)
(n.S)
PJI I I. iiljl.-, IIH:. Extractable
llytjr ut ai buny , diij 1idi:c
Hotjlu Sample Tijln
•
it (lull
(•lulu.- K Iliac
ll.>
A...-
1
.Ml.-
J
lly; M.-lulil
llu 2
TCt
I'nil.u KI,ibua/HI
J
...
flllur
II,,. Ucl.1,
II. y; Mo lt;li 1
(mj)
III till. It. ,1.1,1,
will, MCI
Illlll,, .iiul 11.11,
HI IllIU IU-Hl.1,,.
win, 111:1
Illlll,, .,11.1 11,0..
Hnl I Jtl wl III
111:1 . mini ,
and 11,0,
Tf d<
v Mi-l.il
And 1 yd 1 a
Al li
B.i,V II jH lai|>lngi-r Sulm luns/Hliisi^ 1
l™,,l"f-'
(0. Ill 1
U. Ill II.
.101
Ail J 1 yt» I si
fli.-si.lib
Cat bun)
1
bolulliin:, li,,|iliiy.-l S,, 1 ill 1 oils
,I)M) anJ Scco,,J«^RlH«c; j|||T ^ mj
A II,, ,ul I Dry
1 1
Ad|,,bl ),ll lo Hny.ill
7 ullh IICI
txl rut 1 will.
HI,, I /1. 1,1, ,!,,!(, im
ultli
IIIIO), i
1 lit y; Wi-tgli
"
I
1 III II 1 1
a (nig)
H, i.1,1, M-
111:1
IM.I 11,11,
1 liii,,- M.lals
1 An.ilysl:.
OlB.llll, i (my)
luce H^l.lli. 1
And 1 y a 1 H 1
IJ3
( WIIM
J3
Figure 5-8 Particulate, extractable hydrocarbons, and trace metals sample
recovery analytical matrix.
-------
Kruut 11,111 Probe H Iniiu/H ) ler
Back Half XAD-2 Resin and Inplnger
Solution
Ul
I
N>
Suxlilet txtracclon
ullh He thy Itnn
Chloride
Implnger Solut lull
(11,0) with
Mfthylene ChlorlJi.-
Rinse
Figure 5-9. Polynuclear aromatic hydrocarbons sample recovery analytical matrix.
-------
t_n
I
Soxlilet Rxlract
with Methylcnu
Chturlde
l-'.xlriict wlih
II^Ss, IIIHI,,
anil H,l>,,
__
Figure 5-10. Scrubber water samples analytical matrix.
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RADIAN
COgfOitATKMi
o pK and temperature, and
o moisture.
Gravimetric Analysis of Solvent Rinses—The sampling train for particu-
late and TOC/extractable organics and the train which combined trace metals with
particulate and TOC/extractable organics produced several solvent rinses requiring
gravimetric analysis. The solvent rinses included:
o acetone probe rinse,
o trichloroethane probe rinse, and
o trichloroethane rinse of impingers and associated glassware.
The rinse samples were placed in glass bottles and transported to
Radian's Austin laboratories for analysis. The volume of solvent in each
sample was determined gravimetrical ly and then the entire sample was evap-
orated at room temperature. The sample could not be dried at elevated
temperatures because of the potential loss of hydrocarbons. When dry,
the sample was desiccated and weighed to a constant weight.
The residue in the solvent rinses collected during the trace metals
runs was dissolved in HC1, HNOo, and IL^ and was analyzed by Inductively
Coupled Argon Plasma Emissions Spectroscopy (ICAPES).
Gravimetric Analysis of Extractable Organics—The extractable organics
sample consisted of the EPA Method 5E "back-half" trichloroethane rinse and
0.1N NaOH impinger solution and rinse described in Section 5.1.1.
Analysis of the trichloroethane "back-half" rinse consisted of several
steps. First, the volume of each rinse sample was determined gravimetric-
ally. Each rinse sample was then transferred to a clean and preweighed
beaker. The rinse samples were then allowed to evaporate to dryness at room
5-25
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RADIAN
temperature. The beakers were dessicated for 24 hours and then weighed
to a constant weight. A constant weight is defined as two weighings that
agree within 0.5 mg or 1 percent of the residue mass.
Each trichloroethane rinse sample was corrected for the solvent blank.
The actual magnitude of the solvent blank correction was dependent upon the
volume of trichloroethane present in each sample. To determine the magni-
tude of the trichloroethane blank, a known volume of unused trichloroethane
solvent was evaporated using the above procedure. The mass of residue remain-
ing after evaporation was then correlated to the volume of trichloroethane
to generate a blank correction factor (mg of blank residue/volume of tri-
chloroethane in the sample).
The extractable organics content of the NaOH impinger samples was
determined using the following procedure. First, a 400 ml sample aliquot
was adjusted to pH 7 using HC1 to improve extraction efficiency. The
sample was then extracted with three portions of a 3:1 mixture of chloroform
and diethyl ether for a total of 200 mis. The solvent was then filtered.
The filtrate was evaporated to dryness at room temperature (70-75°) and
weighed to a constant weight following desiccation. The trichloroethane
rinse of the impingers and associated glassware was also evaporated to
dryness and weighed and the mass of residue added to the ether/chloroform
extraction mass. The summed results were related to the gas sample volume
to determine the gas phase concentration of extractable organics.
The TOC content of the EPA Method 5E sodium hydroxide impinger solution
was determined instrumental ly during this program. A 20 ml aliquot of the
NaOH impinger solution was acidified with HnSO* and then sparged with nitro-
gen gas to remove any inorganic carbon.
The sample was then analyzed using a Beckman 915B Total Carbon Analy-
zer. The TOC concentration of the sample was determined by comparing the
5-26
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sample results with the results of standards prepared with potassium hydro-
gen phthalate. Blank TOC corrections were not required because of insig-
nificant TOC blank values.
This procedure differed from that proposed in EPA Reference Method 5E
in that Method 5E specifies analyzing for inorganic carbon total carbon and
subtracting inorganic carbon from total carbon to give total organic carbon.
Maior Organics and Benzo(a)Pvrene—Major organics and benzo(a)pyrene
were analyzed by gas chromatography-tnass spectrometry (GO-MS) in samples
retrieved from the polynuclear aromatic hydrocarbons sampling train and
scrubber water samples. The analytical scheme quantifies benzo(a)pyrene
(BaP) and a group of isomers of BaP, several major polynuclear aromatic
hydrocarbons (PAH), and several major organic compounds. The PAHs and major
organic compounds which were analyzed were selected based upon relative peak
heights of the GC-MS scan.
The samples produced in the PAH sampling train were the methylene
chloride (MeCI^) probe rinse, the filter, the condensate, the XAD-2 resin,
and resin trap MeCLo rinse. The filter and XAD-2 resin were extracted
individually in soxhlet extractors for 24 hours each with MeCI^. The MeCI^
rinses of the probe and resin were incorporated in the soxhlet extractions.
Scrubber water samples were collected and filtered on-site and the
filtrate stored in amber glass bottles with Teflon® liners, and kept cold
prior to analysis.
Organic analyses were performed by GC-MS for both benzo(a)pyrene (BaP)
and related polynuclear aromatic hydrocarbons (PAH). Table 5-2 lists the PAH com-
pounds which were quantified.
Isotopically labeled benzo(a)pyrene-d^2 was added to all samples prior
to extraction as a check on extraction efficiency. Table 5-3 summarizes the
analytical conditions which were employed for the GC-MS analyses.
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TABLE 5-2. POLYCYCLIC AROMATIC HYDROCARBONS DETERMINED BY GC-MS
Phenanthrenes (178) Benzopyrenes (252)
Phenanthrene Benzo(a)pyrene
Anthracenes Benzo(e)pyrene
Perylene
Pyrenes (202 Benzo(b)fluoranthrene
Benzo(j)fluoranthrene
Pyrene Benzo(k)fluoranthene
Fluoranthene
Benzoperylenes (276)
Chrysenes (278)
Benzo(g,h,i)perylene
Chrysene Indeno(l,2,3-c,d)pyrene
Benz(a)anthracene
Triphenylene
Note: The molecular weight of each group is shown in parentheses.
TABLE 5-3. GC-MS CONDITIONS
Operating Parameter Experimental Conditon
Instrument Hewlett Packard 5985A
lonization voltage 70eV
Scan rate 1 scan/second
Scan range 40 •*• 450 amu
Column SE54 fused silica capillary
H2 flow rate 30 cm/sec
Initial temp 25°
Initial hold 2.0 min
Program rate 8°/min
Final temp 300°C
Final hold 20 min
Injector temp 25°C
Injection Cool on-column
Sample size 1 pL
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Trace Metals—The concentrations of the following trace metals were
determined in the controlled and uncontrolled air emissions and influent and
effluent scrubber waters.
nickel lead vanadium
calcium manganese iron
chromium magnesium zinc
cadmium beryllium aluminum
mercury
The analysis for trace metals was performed using Inductively Coupled
Argon Plasma Emission Spectroscopy (ICAPES). The technique combines the
multielemental capabilities of emission spectroscopy with a radio-frequency
generated argon plasma source.
The sample is aspirated into the argon plasma which may reach tempera-
tures of 10,000°K. The emission is focused onto a grating which diffracts
the light according to the Paschen Runge theory. The diffracted light
bands are passed through slits selected for each element of interest and
measured by photomu Itip lier tubes. The system is computer-controlled which
allows for simultaneous multielement determinations by comparing the elec-
trical charge of each photomu Itip lier tube to the current measured during
standardization. ICAPES also provides automatic background correction
to adjust for matrix interferences.
The Radian system is an ARL Model 34000B which is capable of analyzing
up to 40 elements simultaneously with detection limit of 1 to 5 ppmv.
Solid samples were dissolved into an acidic solution of HC1, HNO-j, and
H-Ort for analysis.
Scrubber Water TOG Analysis—The TOC content of scrubber water filtrate
samples was determined instrumental ly during this program. A 20 ml sample
5-29
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aliquot was acidified with l^SO^ and then sparged with nitrogen gas to
remove any inorganic carbon. The sample was then analyzed using a Beckman
915B Total Carbon Analyzer. The TOC concentration of the sample was deter-
mined by comparing the sample results with the results of standards prepared
using potassium hydrogen phthalate.
Total Solids—Total solids in the scrubber waters were determined by
the analysis of total suspended solids (TSS) and total dissolved solids(TDS)
on-site. During each test run, samples of the influent and effluent venturi
scrubber waters were collected. Samples were filtered through one filter to
determine a composite TSS concentration by measuring the residue collected
on the filter and relating the mass to the volume of scrubber water deter-
mined gravimetrically. The TDS concentration in the resulting composite
sample was determined by measuring a 50 milliliter aliquot of the sample
into a tared 100 milliliter beaker and evaporating to dryness at 105°C,
desiccating the sample, and weighing. The concentration of TDS is the mass
of residue remaining related to the volume of the aliquot.
pH and Temperature—Samples of the influent and effluent venturi scrub-
ber waters were collected during each particulate and TOC/extractable hydro-
carbons loading and PAH runs. pH measurements were performed at the samp-
ling location during sample collection with a hand-held pH meter.
Scrubber water temperatures were monitored at the sampling location
during sample collection using a mercury thermometer.
Moisture—During each particulate and TOC/extractable hydrocarbons
loading, trace metals, and/or polynuclear aromatic hydrocarbon run, at least
one sample of the virgin aggregate and recycled asphalt pavement were col-
lected for moisture analysis. The samples were collected in a large tray,
riffled to obtain a representative sample and taken directly to the on-site
mobile laboratory for moisture analysis. In the mobile lab, approximately
600 grams of the material was weighed into an aluminum pan and dried over-
night at 105°C. The sample was then weighed to within +0.1 gram.
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5.3 DATA REDUCTION
This section provides a discussion of the data reduction procedures
used to process the raw data generated during this sampling program. EPA
referenced data reduction procedures were used whenever possible. When an
EPA referenced data reduction procedure was not available, a detailed des-
cription of the data reduction procedure is provided. Further information
is given in Appendix B.
5.3.1 Gas Stream Sampling Data Reduction
Data reduction procedures and equations used for gas stream sampling
data reduction were taken from applicable parts of 40 CFR 60, Appendix A.
Raw field data were reduced to engineering units using Radian's Source
Sampling Data Reduction Computer Program. Copies of the data reduction
printouts are presented in Appendix A. As a verification check of the
computer reduction, several runs were hand calculated using the equations
outlined in Appendix B. No significant differences were found.
Farticulate Mass Emission Rate Data Reduction
In order to allow a review of possible effects introduced by anisoki-
netic sampling into the normal mass emission rate calculations, two methods
were used to calculate mass emission rates for the particulate mass emission
runs. The method normally used to calculate particulate mass emission rates
is the concentration method. This method involves multiplying the particu-
late loading (sample mass divided by gas sample volume) by the volumetric
gas flow rate. The second particulate mass emission rate calculation method
is the area-ratio method. Based on the area-ratio method, the sample mass
is divided by the sampling time and then multiplied by the ratio of the
stack area to nozzle area to obtain the particulate mass flow rate.
5-31
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RADIAN
Equation:
(m/t) x (A/A) = HER
where: m = mass of particulate matter collected during sampling (pounds)
t = elapsed sampling time (hours)
Ag = area of stack (square feet)
An = area of nozzle (square feet)
HER = mass emission rate (pounds per hour)
The difference between the emission rates calculated by these two
methods is an estimate of the maximum bias in the measured emission rate due
to anisokinetic sampling. Table 2-5 includes particulate emission rates
calculated using the concentration method and the area-ratio method. The
average particulate emission rate listed in Table 2-5 was used as the true
value for the particulate emission runs that were outside of the isokinetic
sampling limit of 100 i 10 percent.
Total Organic Carbon (TOG) Emissins Data Reduction
Equation:
(TOC(L) xVt) - (TOC(B) xVT)
T
'(g) DGV
Nomenclature:
TOC, . = Total organic carbon in gas phase, mg/dscm
\ QS
TOC, . = Total organic carbon in impinger catch, mg/1
TOC, . = Total organic carbon in the impinger blank,
mg/1
V = Total volume of impinger catch, 1
DGV = Volume of gas sampled, standard conditions
dry standard cubic meters, dscm
5-32
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RADIAN
Trace Metals Emission Data Reduction
Equation:
(E)
Nomenclature:
A + T + (CxCT) + F + (S x ST) + N x N )
TM,
~ Total trace metal specie mass concentration, pg/dscm
A - Total concentration of trace metal specie in acetone
probe wash, ug
T = Total concentration of trace metal specie in trichloro-
ethane probe wash, yg
C = Concentration of trace metal in the cyclone catch, yg/g
CT = Total weight of cyclone solids, g
F = Total concentration of trace metal specie in the filter,
Ug
S = Concentration of trace metal in the NaOH impinger, ug/ml
S = Total volume of NaOH impinger catch, ml
N = Concentration of trace metal in the nitric acid impinger,
yg/ml
N = Total volume of the nitric acid impinger, ml
DGV = Dry gas volume, standard conditions, dry standard
cubic meters (dscm)
Particle Size Distribution Data Reduction (AHCSSl
The procedure for calculating the particle size distribution of the
particulate caught by the AHCSS was taken directly from the operating manual
for the AHCSS.
Add up the weight gains for the four stages to obtain the total parti-
culate collected.
Divide the amount collected in an individual stage by the total amount
collected to determine the percentage of the total collected in each stage.
5-33
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RADBAN
Starting with stage 4 (backup filter) compute the cumulative percent
less than the staged size range. The cumulative percent less than stage 3
(the cyclone) is equal to the percent caught in stage 4. The cumulative
percent less than stage 2 is the sum of the percent caught on stage 3 and
the percent caught on stage 4. The cumulative percent less than stage 1 is
the sum of the percents caught on stages 4, 3, and 2.
o
Particle density is considered to be 1.0 gm/cnr and the particles are
considered to be spherical. Particle sizes are reported as equivalent
aerodynamic diameters.
Using Figure 5-11 with gas flow rate at stack conditions and stack
temperature, determine the d^Q (50% Effective Cut Off Diameter) for each
stage.
Plot the results on log probability graph paper with the particle
diameter (den) as the ordinate and the cumulative percent less than the
stated size range by weight as the abscissa.
Polynuclear Aromatic Hydrocarbon (PAH) Emissions Data Reduction
Equation:
P
PAH
(G) = Concentrac:i-on °f pAH specie in flue gas, yg/dscm
(G) DGV
Nomenclature:
PAH
P_ = Total concentration of PAH specie, yg
B = Specie blank, pg
DGV =• dry gas volume, standard conditions, dscm
5-34
-------
9
8
7
6
5
A
3.0
2.0
1. 0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
! .: •
;
T £
T
'
IBIC FEET/MII
•
- —
_l
u
V
' '• - -I"-',.
FLOWRATE
- -
—
-•
_..
....
...
-
—
-
—
i
—
—
! I :
— —
1
—
ii--i
ill;
.: .
i ;
j'
*
i
— — i
—
• i
! i
t .
••
•I-
-
—
TTT
r •
!'l
!|
;!i
:;:
|1
*:
i'!;
!.
;'.
—
.._
:|.
•,!;
!i:
I
. ,
-
: . : i
i ' - i
'. . i
. , . •
' . ; !
' • i
I
>
— -
:
: ;
. i • •
r
i :
\
\
_._>
: . . i
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: j:
— -'--
\T"
\
•i!\
ii:
• i •
i .;
.!••
:'•
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.....
\':--
\
;:..
' .;,
1
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. •
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i
I :;
v
1
1
---
— -
--
:i'
i
~j
-!
i —
i — ' r~'~ —
•:•
HCSS IMPACTOR 50% CUTPOINT,
MICROMETERS (wm)
AIR TEMP = 300»F
PARTICLE DENSITY =1.0 GM/CC
SPHERICAL PARTICLES
2
V
\
v
\
V
\
V:
\
—
i
\
\
- -L
—
-
• —
...
;;
;•"
----
:
•i
1 1 • i
!.'.'
r~
r-
--
':
II : :
t*t1 '
;i|!
l~ _(
0.1
0.2 0.3 0 . 4 0.5 j 0.7 j 0.9}
0 !6 0'.8
3 A 5 6 7 8 9 10
20 30 40 50 60 70 80 90 iOO
Figure 5-11. Gas flow rate at stack conditions and stack temperature.
-------
RAOBAN
5.3.2 Process Sampling Data Reduction
PAH in Scrubber Water Data Reduction
Equation:
PAH
^(W) 0.4
Nomenclature:
PAH. . = Concentration of PAH in the scrubber water, yg/liter
\w i
P/Tx = Total concentration of PAH specie, ug
0.4 = Volume of scrubber water extracted, liter
PAH in Scrubber Solids Data Reduction
Equation:
PAH = !ill
PAH(s) s
Nomenclature:
PAH = Concentration of PAH specie in scrubber solids, ug/gram
PJ.-S = Total concentration of PAH specie, yg
S = Weight of scrubber solids extracted, g
Weight Percent Solids Data Reduction
Equation:
Nomenclature:
S(WT)= Wei§ht 7' solids
F(p) = Final filter weight, g
F(T-) = Filter tare weight, g
W(T) = WeiSht of scrubber water filtered, g
100 = conversion from fraction to percent
5-36
-------
l--'tal Dissolved Solids Data Reduction
Equation:
— H^
Nomenclature:
IDS = Total dissolved solids, mg/1
W, = Weight of beaker and residue after evaporation,
W, . = Beaker tare weight, mg
0.05 = Volume of solution evaporated, liter
5-37
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RADIAN
SECTION 6
QUALITY ASSURANCE
Quality assurance/quality control guidelines outline pertinent steps
during the production of analytical and emission data to ensure the accept-
ability and reliability of the data generated. The measures outlined in
this segment were followed to ensure the production of quality data from the
sampling and analytical efforts.
6.1 STANDARD QUALITY ASSURANCE PROCEDURES
QA/QC procedures are followed during sampling and analysis to
ensure that the data generated are of acceptable quality. These quality
control and quality assurance procedures are used during EPA reference
method sampling and/or routine analysis. Additional QA/QC procedures may be
called for on a site—specific basis. This section describes QA/QC proce-
dures applicable to the methods used, as well as specific procedures used
during this test program.
6.1.1 Sampling Equipment Preparation
The checkout and calibration of source sampling equipment is vital to
maintaining data quality. Referenced calibration procedures were strictly
adhered to when available, and all results were documented and retained. If
a referenced calibration technique for a particular piece of apparatus is
not available, then a state-of-the-art technique was documented and fol-
lowed. Table 6-1 summarizes the parameters of interest and the types of
sampling equipment that were used to measure each parameter. The techniques
«
used to calibrate the equipment are as follows:
6-1
-------
TABLE 6-1 SUMMARY OF CALIBRATED EQUIPMENT USED IN PERFORMING SOURCE SAMPLING
Paramett
Volumetric Gas
Flow Rate
Gas Phase
Composition
Moisture
Molecular
Weight
Particulate
Mass & TOG/
Extractable
Hydrocarbons
Trace Metals
Polynuclear
Aromatic
Hydrocarbons
Particle Size
Distribution
Calibrated Equipment Used in Measuring Parameters
Type-S Differential Temperature Gas
Pitot Pressure Measuring Metering Isokinetic
er Tube Gauge Device System Orsat Nozzles
EPA-1, * * *
EPA- 2
EPA-4 * * *
EPA- 3 *
Modified * * * * * *
EPA-5E
Modified * * * * * *
EPA- 5
Modified * * * * * *
EPA- 5
* * * * A *
p
5
z
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RADIAN
o Prior to sampling all equipment was cleaned and checked
to ensure operability.
o Equipment requiring pretest calibration (Table 6-1) was
calibraed in accordance with "Quality Assurance Handbook
for Air Pollution Measurements Systems, Volume III,
Stationary Source Specific Methods," (EPA 600 4-77-027b).
o Equipment calibration forms were reviewed for completeness
to ensure acceptability of the equipment required for each
specific application.
o The Andersen Mark III Impactor and AHCSS were cleaned and
visually inspected.
o Each component of the various sampling systems was carefully
packaged for shipment.
o Upon arrival on site—the equipment was unloaded, inspected
for possible damage, assembled for use, and checked for
operability.
6.1.2 Collection of Samples
The most important aspect of sample collection is obtaining a valid
sample. This section focuses on measures taken to obtain valid samples.
Those measures were:
o Pretest and posttest leak checks of the sampling trains
were made.
o The sampling systems were visually inspected prior to
sampling to ensure proper assembly and operability.
6-3
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RADIAN
o The S-type pitot tubes were leak checked before and after
sampling and inspected for damage.
o The Magnehelic® gauges were leveled and zeroed prior to
s amp 1 ing .
o Temperature measurement systems were visually checked for
damage and operability by measuring the ambient temperature
prior to each sampling run.
o The nozzles were visually inspected for damage before and
after each sampling run.
o The Andersen Mark III Impactor and AHCSS were preheated
to minimize condensation of water in the particle sizing
device.
o Data requirements were reviewed prior to each sampling run.
o Ice was maintained in the icebaths during all sampling runs.
o Number and location of sampling ports were checked prior to
each sampling run.
o Sampling ports were sealed to help prevent possible air
inleakage.
The molecular weight of the flue gas was determined using EPA Reference
Method 3 (4). Quality control for Method 3 focused on the following:
o The sampling train was purged prior to sample collection.
o The Orsat analyzer was leveled and the fluid levels zeroed
prior to use.
6-4
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ADIAN
o The Orsat analyzer was leak-checked prior to use.
o The Orsat analyzer was thoroughly purged with sample prior
to analysis.
o Analyses were repeated until the analysis agreed within
0.3% absolute.
o The Orsat absorbing solutions were changed when more than six
passes were required to obtain a stable reading of any component.
The moisture determinations were made simultaneous with the modified
EPA Reference Method 5E. Quality control procedures for Method 4 focused on
the following:
o Before and after sampl-ing each impinger was carefully weighed
to the nearest 0.02 g. Care was taken to see the impingers
were dry and the stopcock grease was removed from the ball joints
prior to each weighing.
The particulate loading determinations were performed using a modified
EPA Reference Method 5E. Quality control procedures for this method focused
on the following:
o Prior to particulate sampling preliminary velocity, temperature,
and moisture determinations were made. This aided in calculating
isokinetic flow rates.
o Prior to sampling, particulate filters were baked, desiccated
and weighed. They were then placed in clean petri dishes until
used.
o Particulate filters were handled with tweezers.
6-5
-------
RADIAH
The visible opacity of controlled emissions were observed using EPA
Reference Method 9. Quality control procedures for this method focused on
the following;
o The visible emissions observer was certified within six months
of the test program.
o The location of the observer was independently verified„
o A clear blue sky was required to ensure valid visible emission
observations.
6.1.3 Sample Recovery
To ensure data integrity careful sample recovery techniques must be
adhered to. This section outlines quality control procedures followed to
ensure data integrity. These include:
o Particulate filters were handled out of drafts and transferred
with treezers.
o Sample trains were disassembled and the samples recovered in
clean areas to prevent contaminatin.
o The nozzle was capped prior to and following sampling.
o The samples were transferred to appropriate storage containers
and clearly labeled. Liquid levels were noted.
o Field blanks were included for each method. These consisted of
(i.e. unused) sampling trains which were assembled, dis-
assembled, recovered, and analyzed in the same manner as
actual sampling trains and samples.
6-6
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RADIAN
o Samples were carefully labeled, logged into the field logbook
and assigned a unique identification code immediately after
collection.
o The impingers were rinsed three times with aliquots of
fresh impinger solution.
6.1.4 Preparation of Samples for Analysis
Prior to sample analysis each sample must be properly prepared. This
section outlines quality control procedures used to ensure proper sample
preparation. Included are:
o Each sample identification code was crosschecked for
accuracy against the sample logbook.
o The analytical requirements of each sample were reviewed.
o The samples were checked for leakage or damage and any
anomalies were noted.
6.1.5 Sample Analysis,
The exact quality assurance/quality control procedures taken during
analysis were dependent on the specific analysis. One or more of the fol-
lowing steps were taken:
o Duplicate analyses were performed on 5-15% of the samples.
o Internal QC samples were analyzed to verify instrument or
procedural variance.
o Blind QC samples were submitted to the analytical lab along
with the field generated samples.
6-7
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RADIAN
o Blanks were analyzed to correct for background and/or matrix
interferences.
o The samples were spiked with known additions of the species
of interest.
6.1.6 Data Reduction
Several steps were taken to verify the correctness of the data reduc-
tion. Steps routinely used include:
o
Alternate procedures were used to reduce the data. A common
example is reducing source sampling data by using Radian's
Source Sampling Data Reduction Program and comparing selected
results against hand calculations.
o A certain percentage (approximately 10%) of the results were
recalculated from raw data by someone unassociated with the
original data reduction.
o The data was carefully checked for unexplained variance and
internal consistency, i.e. are the results consistent with
expected and/or other results).
6.1.7 Data Documentation and Verification
Several measures were taken to verify the completeness and accuracy of
the data generated. These include:
o All sampling data was recorded on preformated data sheets,
o Analytical results and calculations were recorded in bound
laboratory notebooks.
6-8
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RADIAN
T* TWIT* Oi
o Data tables were made and reviewed for completeness and
accuracy.
o All data that appeared to be outside expected ranges were
carefully scrutinized for process upsets and reanalyzed as
necessary.
o Data generated were compared to process operation and
system upsets .
6.2 TEST PROGRAM SPECIFIC QUALITY CONTROL/QUALITY ASSURANCE PROCEDURES
Each sampling site presents its own individual problems and peculiari-
ties. Because of this any QA/QC program must be custom tailored to each
specific site. This section presents the procedures that were specific to
the T.J. Campbell asphalt concrete sampling program.
6.2.1 Sampling Equipment Preparation
This section outlines equipment modifications that were used during
this program to ensure the sample data produced were valid. These measures
are in addition to the standard equipment calibration and checkout proce-
dures outlined in Section 6.1.1. These include:
o Variacs were used to control the probe heater temperature.
o Inline thermocouples were installed to monitor the gas
stream temperature as it exited the filter holder.
o A time-proportioning temperature controller was used to control
the hot box temperature to within +10°F.
6-9
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RADIAN
cotn»
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RADIAN
o Particulate filters used during polynuclear aromatic
hydrocarbon sampling were methylene chloride extracted
prior to use and stored in glass petri dishes.
o All glassware used during sampling was specially cleaned.
All particulate mass collection filters were baked at 500°F prior to
use. They were then desiccated, weighed, and placed in clean petri dishes.
The particulate filters used during polynuclear aromatic hydrocarbon sampling were
extracted with methylene chloride, baked at 500°F, and stored after weighing
in methylene chloride rinsed glass petri dishes.
All glassware used during sampling was cleaned as follows:
o The glassware was first washed thoroughly with laboratory
soap and water.
o The glassware was kiln-fired at 500°C for 18 hours.
o After the glassware cooled, it was rinsed with methylene
chloride and all the ball joints were capped with aluminum
foil.
6.2.2.2 Preliminary Measurements—
This section outlines QC checks and measurements performed prior to
sampling to assist in the calculation of anisokinetic sampling rate. These
include:
o A check for cyclonic or turbulent flow was performed prior
to sampling at the uncontrolled emissions sampling 'location.
o Preliminary velocity, temperature and moisture determinations
were performed to aid in conducting isokinetic sampling.
6-11
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RADIAN
o Wet bulb/dry bulb moisture determinations were performed
prior to individual sampling runs.
It was discovered early into the sampling program that the moisture
content of the scrubber inlet could vary drastically from run to run. For
this reason preliinary moisture determinations were performed to calculate
accurate isokinetic sampling rates prior to each sampling run.
6.2.2.3 Sampling Procedures—
This section outlines measures taken to ensure that valid and repre-
sentative samples were collected. The measures include:
o Approximately 10 pound aggregate samples were taken. The
samples were riffled to produce the 600 gram sample used to
determine the moisture content.
o Two to four scrubber water samples were taken during each
sampling run. The samples were composited and all subsequent
analyses were performed on the composite sample.
o All glassware except the silica gel impinger was wrapped
with aluminum foil during the polynuclear aromatic hydrocarbon
sampling runs to help prevent photodegradation of the
organic species.
6.2.3 Sample Recovery
This section outlines special QA/QC measures taken during sample re-
covery. These measures are in addition to particulate filter handling,
performance of field blanks, labeling and logging in of samples and other
steps outlined in Section 6.1.3. Measures taken to further ensure the
integrity of the samples during recovery include:
o Incandescent lighting was used during recovery of the
6-12
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RADIAN
polynuclear aromatic hydrocarbon sampling trains. This was to
reduce the chance of photodegradation of the organic
species by ultraviolet light.
o Polynuclear aromatic hydrocarbon samples were stored in amber
glass bottles with teflon lid inserts to prevent photo-
degradation and/or contamination of the sample during
storage and transport.
o Particulate filters used during the polynuclear aromatic
hydrocarbon sampling runs were stored after use in glass
petri dishes. The petri dishes were wrapped in aluminum
foil to prevent possible photodegradation of the sample.
6.2.4 Preparation of Samples for Analysis
Quality control procedures incorporated during the preparation of the
samples for analysis are outlined in this section. These were in addition
to visually checking the samples for damage and ensuring proper labeling and
other procedures outlined in Section 6.1.4. These measures include:
o Sample matrix sheets were developed as an aid in analytical
preparation and as a flow diagram for the actual analysis.
o Each polynuclear aromatic hydrocarbon sample was spiked with
I 9
deuterated benzo(a)pyrene-d prior to sample extrac-
tion as a QC check on extraction efficiency.
o Particulate filters and impactor substrates were desiccated
for at least 24 hours prior to their first weighing.
o The particulate filters were weighed at 24-hour intervals
to a constant weight.
6-13
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RADIAN
6.2.5 Sgrnple Analysis
This section outlines additional QC procedures employed during the
program to evaluate the quality of the analytical data. These procedures
are in addition to such measures as duplicate analysis, blank analysis,
internal QC samples, and other measures outlined in Section 6.1.5. Included
are:
Immediately prior to sample analysis each polynuclear aromatic
hydrocarbon sample wa
internal QC standard.
i *?
hydrocarbon sample was spiked with benzo(a)pyrene-d as an
o Total organic carbon audit samples were submitted to the
analytical laboratory prior to the submission of the field samples
o Field blanks were evaluated to determine species background
and possible contamination problems.
The results of the total organic carbon audit samples are presented in
Table 6-2. A statistical evaluation of the audit samples is presented in
Appendix 1.3.3.3.
The results of the field blanks are presented in Table 6-3. The clean-
up results wre used to correct the anaytical results for background.
6-14
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RADIAN
TABLE 6-2. SUMMARY OF TOTAL ORGANIC CARBON
AUDIT SAMPLE MEASUREMENTS
EPA Prepared Sample Results (9/9/83)
Sample No. Date of Analysis
EPA 1 10-28-83
EPA 2 thru
EPA 3 11-02-83
EPA 5
Radian Prepared Sample Results
Sample No. Date of Analysis
Set 1 - Submitted 11-30-83
Radian #1
Radian #2
Radian #3
Radian #4
Radian #5
Radian #6
Set 2 - Submitted 12-12-83
Radian //I1
Radian #2
Radian #3
Radian #4
Radian #5
Radian #6
(A)
Actual
Values
4.1
61.2
61.2
4.1
(A)
Actual
Values
80
40
80
4
4
40
801
202
20 *
802
801
201
(R)
Radian Analysis
Values (mg/L)
4.5
70
69
3
(R)
Radian Analysis
Values (mg/L)
85
45
81
4
3
41
85
21
19
84
77
21
Percent Error
R-A/A x 100
9.76
14.4
12.7
-26.8
Percent Error
R-A/A x 100
6.25
12.5
1.2
0
-25.0
2.5
6.25
5.0
-5.0
5.0
-3.75
5.0
Sample in 0.1 in NaOH matrix
2Sample in distilled water
6-15
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TABLE 6-3. SUMMARY OF CLEANUP RESULTS
cr>
Participate and Condenslble
Organic Sample Blanks
Front Half (mg)
Probe rinses
Back Half (mg)
Condensible hydrocarbons
Total organic carbon (mg/L)
Trace Metals Sample Blanks
Train 1
Uncontrolled
Element Filter Blank
Al <.5
Be <0.5
Ca <3
Cd <0.2
Cr <0.1
Fe <0.8
llg <3
Mg <3
Mn <0.1
Ni <0.3
Pb <8
V <6
Zn <0.6
Train
1
NaOH Blank
<.05
<0.0005
<0.002
<0.001
<0.008
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