EPA-650/2-74-101
OCTOBER 1974
Environmentol Protection Technology Series
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EPA-650/2-74-101
ATMOSPHERIC EMISSIONS
FROM ASPHALT ROOFING
PROCESSES
by
R. W. Gerstle
PEDCo-Environmental, Inc.
Atkinson Square (Suite 13)
Cincinnati, Ohio 45246
Contract No. 68-02-1321 (Task 15)
ROAP No. 21AXM-011
Program Element No. 1AB015
EPA Project Officer: Belur N . Murthy
Control Systems Laboratory
National Environmental Research Center
Research Triangle Park, North Carolina 27711
Prepared for
OFFICE OF RESEARCH AND DEVELOPMENT
U.S. ENVIRONMENTAL PROTECTION AGENCY
WASHINGTON , D. C. 20460
October 1974
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EPA REVIEW NOTICE
This report has been reviewed by the National Environmental Research
Center - Research Triangle Park, Office of Research and Development,
EPA, and approved for publication. Approval does not signify that the
contents necessarily reflect the views and policies of the Environmental
Protection Agency, nor does mention of trade names or commercial
products constitute endorsement or recommendation for use.
This document is available to the public for sale through the National
Technical Information Service, Springfield, Virginia 22161.
11
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ABSTRACT
Asphalt roofing manufacturing processes and the types of air pollution
control devices applied to them are described. Quantitative data on
controlled and uncontrolled particulate and gaseous emissions, including
polycyclic compounds, from the asphalt blowing and felt saturating
processes are provided. Information on plant locations, production
rates, and Industry growth is included. Total uncontrolled particulate
emissions from felt saturating, consisting largely of organic partic-
ulate compounds, averaged from 3.9 to 8.7 Ib per ton of saturated felt;
CO and gaseous hydrocarbons were also emitted. Control devices reduced
these emissions by about 50%. Seven identified polycyclic organic
compounds accounted for 0.0003% of the particulate matter both before
and after control. Particulate matter was mostly smaller than 1 micron.
For asphalt blowing operations controlled by fume incineration, par-
ticulate emissions amounted to 0.3 to 3.1 Ib per 1000 gal. (0.075 to
0.79 Ib per ton) of asphalt; polycyclic organic matter ranged between
0.0008 and 0.0019% of the total particulate; CO and gaseous hydrocarbons
are also emitted. These data indicate that a well-operated plant
equipped with available control devices does not have a major impact on
ambient air concentrations.
111
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TABLE OF CONTENTS
LIST OF FIGURES
LIST OF TABLES
ACKNOWLEDGMENTS
SUMMARY AND CONCLUSIONS
1.0 INTRODUCTION
1.1 Technical Objectives
1.2 Industrial Classification
1.3 Acquisition of Information
2.0 INDUSTRY TRENDS AND ECONOMIC FACTORS
FACTORS
2.1 Product Shipments
2.2 Industry Trends
2.2.1 Historical Sales Rates
2.2.2 Relationship to Construction
Industry
2.2.3 Relationship to Mining and
Mineral Products Industry
2.3 Geographic and Demographic Data
2.. 4 Economic Factors
2.5 Industry Growth Projections
3.0 RAW MATERIALS AND PRODUCT SPECIFICATIONS
v 3.1 Raw Materials
3.1.1 Bitumens
3..1.2 Fillers
3.1.3 Felts and Woven Fabrics
3.2 Product Description
Page No,
vii
viii
x
1
7
7
8
9
11
11
11
11
15
15
19
21
23
26
26
26
29
29
30
3.2.1 Prepared Roofing 30
3.2.2 Asphalt Shingles 30
3.2.3 Adhesive Compounds for Build-Up
Roofs, Damp Proofing and Waterproofing 31
3.2.4 Bituminous Cements 31
IV
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TABLE OF CONTENTS (Continued)
Page No,
3.3 New Product Development 32
4.0 PROCESS DESCRIPTION AND ATMOSPHERIC
EMISSIONS 33
4.1 General 33
4.2 Saturator 35
4.2.1 Process Description 35
4.2.2 Atmospheric Emissions from Saturators 36
4.3 Asphalt Blowing 47
4.3.1 Process Description 47
4.3.2 Emissions 50
4.4 Mineral Surfacing Application 58
4.5 Hot Asphalt Storage 59
4.6 Sand Dryer 61
5.0 CONTROL TECHNOLOGY AND COSTS 62
5.1 Control of Saturator Emissions 62
5.1.1 Electrostatic Precipitators 63
5.1.2 Scrubbers 64
5.1.3 Afterburners 64
5.1.4 Mesh Filters 66
5.1.5 Saturator Emission Control Costs 69
5.2 Control of Asphalt Blowing Emissions 7^
5.3 Control of Surfacing Agents 72
5.4 Control of Holding Tank Emissions 73
6.0 IMPACT OF ATMOSPHERIC EMISSIONS 74
6.1 Emission Summary 74
6.1.1 Particulate Emissions 74
6.1.2 Gaseous Emissions 76
6.2 Pollutant Effects 76
6.3 Ambient Air Concentrations 82
6.3.1 Method of Calculations 82
6.3.2 Calculated Ambient Air Concentrations 83
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TABLE OF CONTENTS (Continued)
Page No,
6.4 Emission Impact 88
7.0 REFERENCES 90
8.0 APPENDICES 93
VI
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LIST OF FIGURES
No. Page No
2.1 Sale of Asphalt Roofing Products in the
United States 14
2.2 New Housing Starts and Strip Shingle
Production 16
2.3 Production of Petroleum Asphalts in the
United States 18
2.4 Location of Major Asphalt Roofing Manu-
facturing Centers and Number of Plants
Identified in Each State 20
4.1 Asphalt Roofing Mill Process 34
4.2 Particle Size Distribution in Uncontrolled
Saturator Exhaust 42
4.3 Air Blowing of Asphalt 49
4.4 Relation of Particulate Emissions and
Asphalt Melt Point 53
5.1 Flow Diagram for Low-Voltage Electrostatic
Precipitators 64
5.2 Flow Diagram for HEAF 68
6.1 Retention of Particulate Matter in Lung in
Relation to Particle 79
6.2 Estimated Atmospheric Concentration of
Emissions from Asphalt Roofing Plants 84
VII
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LIST OF TABLES
No.
Page No,
1 Average Particulate and PPOM Emissions '
2 Gaseous Emissions
4
1.1 Asphalt Roofing Products 8
2.1 Annual Shipments of Asphalt Products 12
2.2 Production of Asphalt Saturated Products
by Size Class, 1967 13
2.3 Petroleum - Runs to Stills and Refinery
Products 17
2.4 Populations of Asphalt Roofing Plant Areas 21
2.5 Construction Materials-Indices of Wholesale
Prices 22
2.6 Annual Changes in Sales of Asphalt Roofing
Products and Other Parameters 25
3.1 Classification of Bitumens 27
3.2 Elemental Analyses of Asphalt Fractions
and Natural Asphalts 28
4.1 Reported Uncontrolled Particulate Emissions
from Asphalt Saturators 37
4.2 Particulate Emissions from Asphalt
Saturators 38
4.3 PPOM Emissions from Asphalt Saturators
4.4 Relation of PPOM to Total Particulate and
Product Quantities 45
4.5 Gaseous Emissions from Asphalt Saturators 46
4.6 Particulate Emissions from Asphalt Blowing 51
4.7 PPOM Emissions from Asphalt Blowing 54
4.8 Gaseous Emissions from Asphalt Blowing 57
4.9 Analysis of Vapors Displaced During Filling
85/100 Paving-Grade Asphalt into a Fixed-
Roof Tank 60
Vlll
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LIST OF TABLES (Continued)
No. Page No,
5.1 Control Equipment Used on Saturators 63
5.2 Economics Of Various Systems for Controlling
Emissions from Roofing Plant Saturators 70
6.1 Particulate and PPOM Emission Data Summary 75
6.2 Gaseous Emission Summary 77
6.3 Carcinogenic Potential of Selected Asphalt
Roofing Emission Compounds 80
6.4 Atmospheric Concentrations of Particulate
Pollutants from a 10-Ton/Hour Asphalt
Roofing Plant 86
6.5 Atmospheric Concentrations of Gaseous
Pollutants from a 10-Ton/Hour Roofing
Plant 87
IX
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ACKNOWLEDGMENTS
Dr. Belur Murthy of the Control Systems Laboratory,
U.S. Environmental Protection Agency, was EPA Project Officer,
providing technical review and direction. Mr. Richard
Gerstle, Project Manager for PEDCo-Environmental Specialists,
Inc., directed and participated in the preparation of this
report. Mr. William DeWees directed the field sampling and
analytical effort that comprised a major part of this study.
In addition, some of the major asphalt roofing manu-
facturers, especially Celotex Division of Jim Walther Corpor-
ation and Johns-Manville Corporation, cooperated in providing
information for this study.
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SUMMARY AND CONCLUSIONS
The asphalt roofing industry as defined under Standard
Industrial Classification 2952 comprises establishments primarily
engaged in manufacturing asphaltic roofing products in roll
and shingle form. There are approximately 230 establishments
in the country which produced a total of 9.4 million short
tons of product in 1972 valued at $700 million. The industry
is related to the building industry and in recent years has
been growing at a rate of 3 to 4 percent per year. Raw material
supplies and costs are closely tied to the petroleum refining
industry.
The manufacture of asphalt roofing products consists of
impregnating a felt with specially prepared, heated asphalt.
This is accomplished by passing a continuous sheet of the felt
(usually heavy paper) over rollers in a saturator which is a
long narrow trough containing asphalt at 400-450°F. This dipping
causes the asphalt to coat the felt on both sides. The saturated
felt may be coated with granules and cut into shingles, or
shipped in roll form. Product specifications dictate the weight
(thickness) and exact type of felt, and the asphalt melt point.
Asphalt used in the saturator is prepared by blowing air
through it to reduce its volatile content and raise its melting
point. This batch operation is performed in vertical tanks or
stills with asphalt at a temperature of 430-500°F. Many roofing
plants buy asphalt which has already been blown, usually at an
oil refinery.
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Atmospheric emissions of both gaseous and particulate
organic compounds occur from the blowing and saturating pro-
•cesses. These organic compounds include small amounts of
particulate polycyclic organic matter (PPOM). In addition,
gaseous emissions of CO, aldehydes, and sulfur compounds also
occur. The quantity of these emissions depends on the type
of product and on the type of emission control equipment.
Emissions of particulate and polycyclic particulate
matter (PPOM) are summarized in Table 1, and are based on
measured emission data obtained during this study.
Table 1. AVERAGE PARTICULATE AND PPOM EMISSIONS
Operation
Saturating
Blowing
Particulate, Ib/ton of felt
Uncontrolled
6.3
4.5
Controlled
2.7
0.32
PPOMf % of particulate x 10~4
Uncontrolled
3.0
1.65
Controlled
3.2
13
a) Seven identified compounds only. BaP is approximately 10%
of this quantity.
These data show particulate emissions of approximately 6.3
and 2.7 pounds per ton of saturated felt for saturating operations
without controls and with controls. Higher control efficiencies
can be expected when control equipment is operated under optimum
-------
conditions. Approximately 50% by weight of the particulate
emissions are less than one micron in size.
PPOM accounted for 0.0003% of the collected particulate
matter. PPOM was reduced by passage through control devices
used to reduce particulate emissions. This reduction was in
direct proportion to the particulate reduction.
Saturator emissions are controlled by a variety of de-
vices including afterburners, High Energy Air Filters (HEAF),
and low voltage electrostatic precipitators. Operating costs
for saturator control devices vary widely depending on the type
of device and are in the range of $0.26 to $3.1 per ton of
saturated felt. When afterburners are used, the heat generated
is partially used to preheat asphalt.
Particulate emission rates from blowing operations are
highly variable and increase when high-melt-point asphalt is
produced.
These emissions averaged 4.5 and 0.3 pounds per ton of
saturated felt for the uncontrolled and controlled conditions
respectively.
PPOM emissions from blowing amounted to 0.0013% of
the total particulate after a fume incinerator.
Practically all asphalt blowing operations are controlled
by direct-fired fume incinerators. These devices are fre-
quently process heaters used to preheat the asphalt before gas
or light oil are used as fuels.
-------
Emissions of carbon monoxide and gaseous hydrocarbons
are summarized in Table 2.
Table 2. GASEOUS EMISSIONS
(Ib/ton of saturated felt)
Process
Saturating
Blowing
CO
Uncontrolled
2.6
0.16
Controlled
1.8
1.7
HCa
Uncontrolled
0.55
0.43
Controlled
0.49
0.4
a) Total gaseous hydrocarbons expressed as methane.
NOTE: Range values are averages of test data.
These data show that CO averaged 6.3 and 2.7 pounds per
ton of saturated felt before and after control equipment.
Gaseous hydrocarbons averaged approximately 0.5 pound per
ton of felt. Aldehydes were present in small amounts and
average less than 0.05 pound per ton. Fume incinerators
were only partially effective in reducing these pollutants.
Blowing operations yielded emissions similar to those
from felt saturating. In addition, hydrogen sulfide in the
range of 0.3 to 0.7 part per million was present in the un-
controlled gas stream. After passage through a fume incinerator
the H S was reduced to less than 0.02 ppm.
-------
Sulfur dioxide emissions from blowing operations vary
directly with the asphalt's sulfur content, and during one
test amounted to 0.5% of the sulfur present in the asphalt.
Particulate emissions from other processes associated with
roofing include those from sand drying and application of
surfacing agents. These emissions are readily controlled by
available equipment and are not usually a problem.
Ambient air concentrations were calculated utilizing a
single point dispersion model; and emission parameters de-
termined from this study. These calculations show that
asphalt roofing plants with emission controls would not be
expected to cause primary ambient air standards for par-
ticulate, CO and gaseous hydrocarbons to be exceeded under
normal operating conditions. Particulate emissions from un-
controlled plants could however, cause excessive ambient air
concentrations. Odors also occur from poorly controlled
plants.
Ambient air standards for PPOM compounds do not exist.
However, based on available information, it does not appear
that roofing plants with typical particulate controls are
a major contributor of these compounds to the ambient air.
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0 CONVERSION FACTORS °
ENGLISH UNITS TO METRIC UNITS
Multiply
by
Atmosphere 760.0
DTU (British Thermal Units) 252.0
Cubic foot
Foot
Gallons (US)
Grain
Grains/cubic foot
Horsepower
Pound
Tons (long)
Tons (short)
28.32
30.48
3.785
0.065
2288
0.7457
435.6
1016
907.0
To Obtain
millimeters of mercury
gram calories
liters
centimeter
liters
gram
milligrams/cubic meter
kilowatts
grams
kilogram
kilogram
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1.0 INTRODUCTION
This report presents results of a study to characterize
and measure atmospheric emissions from asphalt roofing manu-
facturing processes and related information on control equip-
ment and the impact of emissions on the ambient air in the
vicinity of asphalt roofing plants.
1.1 TECHNICAL OBJECTIVES
The primary objectives of this study were to measure
the atmospheric emissions of particulate polycyclic organic
matter (PPOM) from asphalt roofing manufacturing processes;
to describe the demographic parameters of this industry, such
as size, location, and growth patterns; to determine the
impact of emissions on the ambient air; and to predict the
degree of control required to maintain levels of pollutants
in the ambient air. The characterization of PPOM included
quantitative measurements of effluent gas streams to deter-
mine concentrations of selected polycyclic organic compounds
before and after control devices. Two asphalt blowing and
two saturating operations, representing the major process
segments, were tested to determine emission rates. Emission
rates were related to various process variables to provide a
basis for estimating emissions from other plants within this
industry.
-------
1.2 INDUSTRY CLASSIFICATION
- The asphalt roofing industry, Standard Industrial Clas-
sification 2952, comprises establishments engaged primarily
in manufacturing asphalt and tar roofing products in roll
and shingle form, either smooth or faced with grit, and in
manufacturing roofing cements and coatings. Products within
these categories are listed in Table 1.1.
Table 1.1 ASPHALT ROOFING PRODUCTS CATEGORIES
A) Roll roofing and cap sheets
Smooth-surfaced
Mineral-surfaced
B) Strip shingles
Standard
Self-sealing
C) Individual shingles
D) Asphalt sidings
Roll form
Shingle form
E) Insulated siding
F) Saturated felts
Asphalt
Tar
G) Adhesive compounds
Built-up roofing
Damp proofing and waterproofing
H) Bituminous cement (asphalt putty)
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1.3 ACQUISITION OF INFORMATION
Process descriptions were formulated by consulting the
technical literature, visiting asphalt roofing plants, and
conversing with various industry personnel and control equip-
ment vendors. Statistical data were obtained largely from
the U.S. Government Department of Commerce and the Bureau of
Mines. Plant locations were determined to the extent possible
from listings of the Asphalt Roofing Manufacturer's Association,
Dun & Bradstreet, and EPA's emission data survey listings. It
is believed that all major manufacturing plants as of mid-1973
were identified in these surveys.
Equipment vendors were contacted to obtain information on
efficiencies and costs of controls and related information as
applied to asphalt roofing.
Some emission data were obtained from the literature
and from vendor's information. Since these data usually were
not related to process parameters, their usefulness was limited.
Therefore, emission data for this report were obtained mainly
from field tests conducted as part of this project at two
asphalt blowing and two saturator operations. Standard stack
sampling methods as specified in the Federal Register were used
in the emission tests wherever possible. The particulate
sampling train (EPA Method 5) included impingers contained in
an ice-water bath and a final "cold" filter to trap PPOM com-
pounds. All PPOM analyses were performed with gas chromato-
graphic separation and mass spectrophotometric detection by
-------
Battclle Laboratories in Columbus, Ohio. Emissions were
sampled under two distinct operating conditions at each plant,
and samples were collected before and after the control device.
10
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2.0 INDUSTRY TRENDS AND ECONOMIC FACTORS
2.1 PRODUCT SHIPMENTS
Shipments of asphalt roofing products totaled 9.4 million
short tons* in 1972, as shown in Table 2.1. Asphalt roofing
represented 89.7 percent of the total; saturated felts, 9.6
percent; and asphalt and insulated siding, about 0.7 percent.
These products were valued at over $700 million.
According to the Census of Manufacturers, there were 233
2 2
asphalt roofing establishments in 1972. ' These establish-
ments averaged about 67 employees and had average shipments of
approximately $4.3 million each, for a total of $1.004 billion
in shipments. Table 2.2 shows the size distribution of these
firms in 1967 and the average value of shipments for each size
class. The current size distribution of plants, similar to
the 1967 distribution, indicates a wide and fairly uniform
distribution of plants within each size category.
2.2 INDUSTRY TRENDS
2.2.1 Historical Sales Rates
Shipments by this industry have been rather erratic from
year to year. The overall trend has been upward, with the
shipment tonnage increasing at a rate of about 3 percent per
year, as shown in Figure 2.1.
* Conversion table from English to metric is
on page 6.
11
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Table 2.1 ANNUAL SHIPMENTS OF ASPHALT PRODUCTS
(tons)
2.1
Product _
code Product
29523 11 Asphalt roofing, Total
Asphalt sidings, Total
29523 35 Insulated siding, all
types and finishes
Saturated felts. Total
United States, Total
Year
1963
5,441,313
42,906
96,786
989,557
6,570,562
1964
6,041,022,
38,721
79,777
995,128
7,154,648
1965
6,124,269
32,778
57,121
979,632
7,193,800
1966
5,751,881
29,141
59,311
879,581
6,719,914
1967
6,460,334
24,580
43,327
876,019
7,404,260
1968
6,525,205
21,744
39,874
874,998
7,458,889
1969
7,035,595
20,611
35,432
919,687
8,011,325
1970
6,877,567
13,604
32,149
848,262
7,771,582
1971
7,951,774
9,620
35,531
915,556
8,912,481
1972
8,389,592
6,997
65,517
895,062
9,357,168
Does not include asbestos-based materials.
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Table 2.2 PRODUCTION OF ASPHALT SATURATED
2 3
PRODUCTS BY SIZE CLASS, 1967
Number of employees
1 to 4
5 to 9
10 to 19
20 to 49
50 to 99
100 to 249
250 to 499
500 to 999
Total
Number of
establishments
33
22
33
46
44
42
4
2
226
13
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12
10
c
o
1.
o
.c
«" 8
in
C
o
o
o
s «
o.
1 |
i i T i r i i i iiiiiiir
T
X
PROJECTION
x
X
TOTAL ROOFING PRODUCTS
f ROLL ROOFING AND SHINGLES
STRIP SHINGLES
/ /v
INSULATED SIDINGSv
i i 1 i i t i 1 i I V- 1__| — I—
SATURATED FELTS
i i.-i—l.-i.-t i i I i I I i I
1950 1955
1960
1965
YEAR
1970
1975 1980
Figure 2.1 Sale of asphalt roofing products in the United States
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At this rate of increase, shipments of asphalt and tar
roofing products should reach approximately 10 million short
tons by 1977. This is approximately 600,000 short tons more
than was shipped in 1972.
2.2.2 Relationship to Construction Industry
Roofing and sheet metal work are classified by the Bureau
of Census as part of the construction industry. The Bureau of
Census reports that the value of new construction in 1971 ex-
2 4
ceeded $109 billion. " Roofing and sheet metal contractors
represented about 2.5 percent of the total construction industry
receipts and 3.3 percent of the value of new construction in
1967.2>5
, 'The correlation between new housing starts and the sale of
asphalt roofing products, as shown in Figure 2.2, is not well
defined. A better correlation is obtained by consideration of
a single product such as strip shingles. Even in that case,
however, the variations in new housing starts in the past decade
do not always follow those in shingle production. On the other
hand, trend lines for new housing starts and strip shingle pro-
duction do exhibit similar growth patterns (about 5 percent
per year).
2.2.3 Relationship to Mining and Mineral Products Industry
Several of the raw materials used in the manufacture of
roofing products are classified by the Bureau of Census as Mining
and Mineral Products. These are mainly petroleum asphalt, coal
tar, and mineral fillers.
15
-------
2500
I I i I l r
i r
i r T i i
i I i i i I i l l T r
10
CTi
2000
v>
•O
c
HI
VI
3
O
-c
1500
<
to
CO
z
•—I
in
O
1000
NEW
HOUSING.
STARTS
TREND LIME FOR
NEW HOUSING
STARTS
TREND LINE FOR
STRIP SHINGLE
PRODUCTION
STRIP SHINGLE PRODUCTION
4 => ~*~
H z —
•z. "~
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Figure 2.3 shows the amount of asphalt used in roofing
products in relation to total asphalt production. These data
show that the roofing products industry consumes approximately
16 percent of the asphalt produced. Paving consumes the major
portion. The percent of asphalt used in the roofing industry
has decreased from 25 percent in 1953 to the current 16 percent,
even though total consumption has increased.
Table 2.3 shows the total asphalt produced as a function
of quantities of petroleum and natural gas refined.
PETROLEUM-RUNS TO STILLS
.2.6
Table 2.3
AND REFINERY PRODUCTS, BY CLASS'
(in millions of barrels of 42 gallons)
PRODUCT
("rii'li- pntrolouin .
I'-'iiic-sdc. ... .
K'lM'iKIl. . ....
NfUiiriil-Rns ll'iuld.s
Output
Disf illulo fuel oil
Ursi'luiil fuel oil
jpl diH
Lulu irants
W:n (I Iihl. v'xolh)-
C»kr (Mihl. 1 f\\. ton)
As|.h:ilL (.1 5 M>| I sh tun)
J«lnin*'"nirt Kflsvs . ...
Odin OuUhcd product
OihiT unflnlsliiHl nils (not) ... .
IMO
2.180
2. mi.',
l.l'IU
i:n
05
2.IM
UPS
119
399
425
52
4
17
W
(SO
12
( ;
1955
2.M7
2. ;:«>
2. -147
'."•:t
i "f>
2.857
1 332
117
6113
4.20
M
5
M
44
19
II
It
1960
.1 119
2.053
2 582
371
107
.1.119
1 510
130
607
332
89
59
0
60
RS
78
(N't)
30
ft
6i
1965
3 527
3.301
2. 848
453
226
3.527
1 694
93
765
269
191
63
5
86
t5t-i
107
5S
JS
so
1967
3 S27
3. 5S2
3.174
403
'.MS
3.827
1 S39
99
804
276
273
65
0
91
— &
111
K7
Z
107
1968
4 0.17
3.774
3. 3(b
466
2f,3
4,037
1,934
1111
839
276
315
r.o
6
95
— tfft-
118
95
50
K
in
1969
4 119
3. 880
3.361
516
26\l
4.149
2. 022
102
847
266
322
65
6
103
— -rnr
123
'.IS
55
as
its
1970
4 252
3 '.167
3. 485
4S2
"S5
4.252
2.100
'.'5
S06
2.18
302
66
6
108
147
116
100
63
S8
131
1971
(prcl.)
4 379
4.0!«
3. 4R2
606
"Ml
J.379
2. 1M
K6
!HI
'.'75
305
65
7
10.1
157
121
111
c.n
ii I
I3S 1
Ucprcsonls rrro. NA Not Bvnlbblc.
The quantity of asphalt produced as a percent of crude
(
input increased from 2.6 in 1950 to 3.2 in 1960 and to 3.5
percent in 1972.
If asphalt shortages occur and prices rise, the roofing
industry would probably increase its portion of total asphalt
consumption and the paving industry would switch to other
17
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00
30
Ul
=}
Q
<
- « 20
10
i r
I I I I
i r
1720
1910
mo
YEAR
1950
1960 '61
.
_—•..«•••••
!•••
.-••*•.
TOTAL PRODUCTION
PAVING
ROOFING
MISCELLANEOUS
i i i
i i I i i i i I i i I i
1950 )955
1960 1965
YEAR
1970
1975
Figure 2.3 Production of petroleum asphalts in the United States.
-------
paving materials, such as concrete. This would occur because
there is no known substitute for asphalt roofing.
Although coal tars are a part of the mining and minerals
industry classification, their use is not a major factor in
the roofing industry because of their increased cost.
In 1972 the roofing industry used almost 2.5 million tons
of mineral granules in shingle production. This amount, how-
ever, is less than 1 percent of total sand and gravel shipments
in the U.S.
2.3 GEOGRAPHIC AND DEMOGRAPHIC DATA
Figure 2.4 shows the approximate location of asphalt
producing centers in the U.S. and the number of identified
establishments in each state. This map shows that major producing
areas coincide with population centers and that this industry is
located in 34 states. Table A-l, Appendix A, is a listing of indi-
vidual asphalt roofing plants compiled from available listings.
The table also gives the approximate dollar value of products
produced in each state.
Six large plants account for about 20 percent of the
production of asphalt roofing products in the United States.
The balance of production is in medium-sized plants. Table 2.4
summarizes plant location and population data, which show that
the large majority of plants are located in larger cities and
urban areas.
19
-------
vT/^\\
X/^'Va
/ -2^" ,4 >• 13
^fe-. s--»-^« -
i Ar*'-i*x««
*•••»»•« yj
iZw^*'*'*" \"
Major manufacturing area
• Minor manufacturing site
Figure indicates number of
establishments in that state
Figure 2.4 Location of major asphalt roofing manufacturing centers and
number of plants identified in each state.
-------
Table 2.4 POPULATIONS OF ASPHALT ROOFING PLANT AREAS
Number of
plants
Six largest
plants
Population of city, thousands
Under
10
42
10
to 50
42
50 to
100
22
100
to 500
45
1
500 to
1,000
26
2
Over
1,000
25
3
Asphalt is a major component in roofing product manufac-
ture as well as a by-product from crude oil refining. The
quantity of asphalt present in the crude oil varies consider-
ably from one geographic area to another. This variation would
suggest that certain economies could be achieved by locating
plants near the geographic areas where large quantities of crude
oil are refined. This occurs to some extent, since a large
portion of roofing product sales comes from plants located in
Texas, California, Illinois, and Ohio, which also have large
refining facilities. Location of plants in 30 other states,
however, indicates that shipping economics favor manufacturing
of roofing products in the geographical area in which they are
to be used. To serve these regional plants, asphalt must be
transported from the refinery to the plant.
2.4 ECONOMIC FACTORS
Table 2.5 shows the indices of wholesale prices on various
commodities in selected years from 1950 to 1971.
21
-------
Table 2.5 CONSTRUCTION MATERIALS INDICES OF
WHOLESALE PRICES2'5
(1967 = 100)
i-oMMnniTV
A II material*
Softwood Ilinilu-r:
1 fl-.v. llr .
Snill lirrn pine
nilii-r
llniduood lumber.
Mlllu-orh
nywn.nl
Softwood
Hardwood
Muildinc paper and
Uianl
I'rrpiirrd paint
I'lnlshi-il sliM'l prod.:
Stiurliiral slin|M's..
Hrliiliirrinc liars .
Illarli pipi-, rnrlNiii
Win* trills
Nnnfi-rrnns mrlal
products
Copiirr water
1 nlilnc
llulI'lltiK wire..
IMI
90.4
'.17. S
100. 0
kS. 7
S7. 7
120. 4
1 13. 4
1(10.2
!KI. 1
82.1
71.0
S7.8
79.4
'l3 4
88.3
S3. 2
fi4. 7
IMO
95.6
**'| 3
•13
rc.MHOI'lTV II
I'lumliiML: fljturr> S%
Kii.inu-lfd irnn.. . 11
Vilrniii.-. rliina .. IIV
llrnv. litnnci ' fi'
1 Icatini: f'li.ipiunu ,hi'
Stc.in: iirl ho!
w:iii'r : S
Metal il.inrs.sasli. '•
mid trim 10i
I'lato >;l n- lus
i
ColHTt'ti .
Inpri'difiils S!
I'orilaiidiTiiieiit. S!
I'rndticls ' St
I'ipi- ' S-
Structiirnl clay
proilinl[.<: !v
flvp<;uiM pru'hicts PI
Asphalt mifiiiK 96
Floor e'lverings: !
Asphalt tile 8(
Vinyl nivcrlng . ' <
i
KS . I960 I96J 1970
J i 1
|
.7 '.13.3 93.3 in.'.S
.7 IU\-I !is. 1 1114
. 1 1(V,_ 3 %. 5 'IIXS '.i
. 1 7.". 1 ' 50 4 ,115.S
.5 HIS « US. :i Mil. 0
i p
.3 i 99. S M. 4 110.7
i
.!> , '.iS. 9 ! '.IS. 4 'll.'.il
.0 11.'. -.' 91. S (NA)
. 2 '.17.0 97. S 114 i'i
.0 1(»). 3 US. 1 1115.7
.0 I U7. 2 , %. 3 112.2
.6 Illl. 9 (II. 0 '103.5
.8 '.13.7 %. 6 'liHg
,'J '.''1. 1 101.2 ,100 0
.3 ' 1)7.4 '.IS. 7 ,|0j| 0
t
1 J
.8 '11.3 96.5 1112. !l
X) 107. 1 lOfi. 3 1 '.'7.5
1
1971
tlfi. 4
114.4
111.8
120 0
11.V5
llfi. 4
11$. 1
(X.O
121. 'i
124. f.
120.fi
112.0
114.2
H*. S
tt'f-3
131. i
113.3
NA = Not available. X = Not applicable.
The indices for asphalt roofing generally appear very
stable, showing a slight price increase over a long period of
time. A large increase occurs, however, from 1970 to 1971;
over 3 times the total rise for the last 15 years. Softwood
lumber is the only other commodity that even approximates to
such a pattern of sharp increase. With such a price jump not
occurring throughout the industry, a drop in sales of asphalt
products might be expected. The sales, however, increased.
The following conclusions are drawn from these data on the
relationship between the roofing industry and the total con-
struction industry:
1) Although the roofing industry represents a major seg-
ment of the construction industry, the sale of roofing products
22
-------
is not as dependent upon new construction starts as is the rest
of the construction industry. This is true partly because of
the large replacement market for roofing products.
2) After a tradition of few large price changes, the
price of asphalt roofing increased 23.4 percent in 1 year with
no apparent loss in sales, an indication that there are few
economically feasible substitutes. This finding suggests that
the industry could pass along price increases that might result
from the installation of pollution control devices without sub-
stantial loss of product sales.
Currently, residential property holders spend about $320
per year per residence for improvements, maintenance, and
2 6
repairs. " This amount has remained relatively constant since
1965 (when adjusted for inflation). Roofing represents about
7 percent of this maintenance bill, which includes roofing pro-
ducts, labor, and profits. Revenues of this segment of the
construction industry exceeded $1 billion in 1971.
2.5 INDUSTRY GROWTH PROJECTIONS
The asphalt roofing industry appears economically healthy,
having been able to date to pass on increased costs of raw
materials and labor to the consumer. The industry has shown
steady overall increases in sales, with fluctuations occurring
at various intervals. Possible shortages of crude oil and
therefore of asphalt, probably will not affect the roofing
industry greatly, since it represents only a small portion of
total asphalt consumption. Because the refining of crude always
23
-------
results in the production of asphaltic compounds or residua,
changes in refining product mix will have little effect on
asphalt production.
Records show that the production of saturated felts and
insulated siding has been fairly level. Production of roofing
products (especially shingles), however, has grown at an
average rate of about 4.6 percent during the last 10 years.
Table 2.6 shows the percentage changes in various parame-
ters and changes in roofing product sales. No direct correla-
tions between these parameters are evident.
Projections of the growth trends of the asphalt roofing
industry are thus best based on past performance, as shown
earlier in Figure 2.1; the industry will probably continue for
the near future to grow at an average rate of 3 to 4 percent per
year. This trend will continue until some other product
finally replaces asphalt as an economical roofing constituent.
No such product is currently evident.
24
-------
NJ
U1
Table 2.6 ANNUAL CHANGES IN SALES OF ASPHALT ROOFING
PRODUCTS AND OTHER PARAMETERS
(percent)
Years
53-54
54-55
55-56
56-57
57-58
58-59
59-60
60-61
61-62
62-63
63-64
64-65
65-66
66-67
67-68
68-69
69-70
70-71
Change in
roofing prod-
uct sales
8.9
0.5
-6.0
10.2
0.7
7.4
-3.0
14.7
Change in
population a
+ 1.8
•+1.8
+1.8
+1.8
+1.7
+ 1.7
+ 1.6
+ 1.6
+1.5
+1.5
+ 1.4
+1.2
+ 1.1
+1.1
+ 1.0
+ 1.0
+ 1.0
+1.0
Change in sales of
petroleum asphalts for
roofing products .
-6.0
+7.8
-2.6
-17.3
+ 10.0
+6.4
+6.9
+ 3.1
+5.7
-0.5
+ 10.4
-4.4
-1.0
-0.6
+20.0
-14.4
+4.1
+4.1
Change in value
of new construc-
tion c .
+5.7
+12.4
+2.3
+ 3.2
+2.1
+ 10.3
-1.2
+ 3.0
+6.5
+7.7
+ 4.4
+ 8.9
+ 3.5
+2.0
+ 11.7
+ 7.8
-0.7
+ 16.3
Change in new .
housing starts
+ 7.9
+6.1
-18.0
-9.2
+ 12.9
+ 12.4
+ 19.8
+ 5.3
+ 9.3
+ 10.1
-4.9
-3.3
-20.8
+ 10.5
+ 16.9
-2.9
-2.0
+ 4.2
U.S. Bureau of Census, Current Population Report Series, P-25, Nos. 465 and 482.
American Petroleum Institute, Petroleum Pacts and Figures, 1971 Edition.
Economic Statistics Bureau of Washington, D.C. Handbook of Basic Economic Statistics (1973)
Vol. XXVII »1
Ibid
-------
3.0 RAW MATERIALS AND PRODUCT SPECIFICATIONS
This section describes the raw materials used in the
asphalt industry and the resulting asphalt products as a basis
for understanding of the major process steps and potential
pollutant emissions. Additional detailed information is
given in the references for this section.
3.1 RAW MATERIALS
Three major types of raw materials are required to pro-
duce asphalt roofing materials: (1) bitumens, consisting
mainly of asphalt and tar, (2) solid filler and coating mate-
rials, and (3) felts and woven fabrics.
3.1.1 Bitumens
Within the United States the term "bitumen" refers to
either asphalt or coal tar products. The two major sources
of bituminous material are petroleum, which yields petroleum
* 31
asphalt, and coal, which yields coal tar and roofing pitch. *
Table 3.1 classifies bituminous materials.
3.1.1.1 Asphalt - Asphalt is defined by the American Society
for Testing and Materials as "a dark brown to black cementi-
tious material, solid or semisolid in consistency, in which
the predominant constituents are bitumens which occur in nature
as such or are obtained as residua in refining petroleum."
26
-------
Table 3.1 CLASSIFICATION3 OF BITUMENS3'2
Asphalts
1. Petroleum asphalts
A. Straight-reduced asphalts
1. Atmospheric or vacuum reduction
2. Solvent precipitated
B. Thermal asphalts, as residues from cracking
operations on petroleum stocks
C. Air-blown asphalts
1. Straight-blown
2. "Catalytic"-blown
2. Native asphalts
A. With mineral content below 5 percent
1. Asphalitites such as gilsonite,
grahamite, and glance pitch
2. Bermudez and other natural deposits
B. With mineral content over 5 percent
1. Rock asphalts
2. Trinidad and other natural deposits
Tars and derivatives
1. Residua from coke-derived coal tars
A. Coal tars reduced to float grades, as
road tar grades for paving purposes
B. Coal-tar pitches, with reduction carried
out to soften-point grades
2. Residua from other pyrogenous distillates as
from water-gas, wood, peat, bone, shale, rosin,
and fatty acid tars
aThe following terms relate to the generic terms
used in defining asphalt composition:
Carboids - highest carbon fraction insoluble in CS2-
Carbenes - insoluble in CCL. but soluble in CS-.
Asphaltenes - insoluble in pentane, hexane, and naptha,
Petrolenes (malthene) - define as nonasphaltenes.
Carbines are not present in blown asphalts.
27
-------
Petroleum asphalts are by far the most important source of
asphalt in the United States today. These asphalts result
from the distillation of crude oil and represent the non-
volatile components remaining in the still after distillation
(bottoms). These asphalts are mainly classified by their
physical characteristics, not their chemical composition.
Most asphalt stock (flux) used in the roofing industry
is air-blown to modify the properties of the flux. Asphalt
o
must have very high viscosity (estimated at 7 x 10 poises
minimum) to hold granules in place in roofing shingles. Granule
movement during the life of the shingle must be small. Air-
blown asphalts have higher viscosity than other types and are
therefore more suitable for shingle manufacture.
Because of their cohesiveness, asphalts also are inherently
waterproof and weather resistant. Air-blown asphalts are par-
ticularly durable. Table 3.2 shows the chemical analyses and
some physical properties of typical asphalts. The relatively
high softening point of air-blown asphalt results from the
removal of some of the more volatile compounds.
Table 3.2
FRACTIONS AND NATURAL ASPHALTS
ELEMENTAL ANALYSES OF ASPHALT
3.3
Fatrolaua
aaphaltl
ftaildual
avphaltanta
p«trol«nca
Air-blowti
•iph«lt«n«i
patrolenai
High cracked
atphaltene*
patrolenas
Natural aaphalta
Trinidad
B«rvund«B
•ncfecr
of
aaphalta
4
4
1
typical
typical
r*rontt
by it. of
aiphalt
23.0-30.6
49.4-77.0
31.7-39.5
60.5-68.3
24.1
7S.J
•oftMlno
point (ring
and ball).
•f
135-165
180-194
124
200-20?
145-160
Elemental anal)
"C1
80.5-83.5
83.0-64.8
80. 7-84.8
82.5-84.3
88.9
87.9
82.}
82.9
H
7.3-8.0
10.0-10.6
7.8-8.2
10.9-11.5
5.9
7.9
10.7
10.8
••«, » by vt
s
4.6-8.3
0.4-5.5
3.7-7.3
2.3-5.4
3.0
3.7
6.2
S.»
N
0.4-0.9
0.5-0.5
0.5-0.8
0.4
0.4
0.5
0.8
0.8
0-1.)
0.7-1.4
2.0-2.8
0.8-1.3
* Oxy9»n d*t«rmin*d by diff«r«nc*.
-------
3.1.1.2 Tars - Tars constitute the volatile oily decomposition
products obtained in the pyrogenous treatment of organic sub-
stances. The most important source of coal tar in the United
States is from coke oven operations.
The use of coal tar and coal-tar pitch in the roofing indus--
try has been almost exclusively confined to built-up roofing,
i.e. tar applied directly to the roof. These tars represent
only a small portion of the total roofing industry materials.
3.1.2 Fillers
Fillers used for roofing products include mineral fillers
such as sand and other fine oxides, silicates, carbonates, and
sulfates; organic fillers such as vegetable starches, grain
dust, coal, and peat; inorganic fibers such as glass and asbestos;
and organic fibers such as wood, rag, and paper. These fillers
impart various physical properties and decorative variations to
roofing products.
3.1.3 Felts and Woven Fabrics
Felts are generally formed of paper, rag, or asbestos fibers,
with or without additions, on a machine similar to that used for
manufacturing paper. Felts are marketed on the basis of weight
in pounds per 480 square feet, known as the "number" ranging
from 15 to as high as 90. Most common weights are in the 27
to 55 pound range. The "number" of the felt multiplied by
0.225 will give its weight in pounds per 108 square feet (100
2
ft of coverage). High-grade rag felt will test approximately
1 mil in thickness, and not less than 0.5 pound on the Mullen
29
-------
strength tester per unit "number". These relations hold approx-
imately constant for all weights. The use of a perforated sheet
of felt has been suggested to provide a change in weight.
Woven fabrics ordinarily used for manufacturing prepared
roofings include burlap or hessian (composed of jute fibers),
sheeting, and osnaburg and duck (composed of cotton fibers).
These are marketed in various weights, expressed in arbitrary
ways. Woven fabrics do not take up nearly so large a percentage
3.5
of bituminous saturation as felted fabrics.
3.2 PRODUCT DESCRIPTION
3.2.1 Prepared Roofing
Prepared roofings are comprised of a single layer or multi-
ple layers of a fabric (woven or felted), saturated, and/or
coated with bituminous compositions. The finished product is
supplied in flat sheets or wound in rolls. The fabrics and
bituminous compositions can be assembled in an extremely large
number of combinations.
Laminated roofing consists of two or more layers of
bituminized felted or woven fabrics, in various combinations
with structural supports (wire mesh, sheet metal, etc.). Roll
roofing can also be decorated with granular materials or cut
to special shingles.
3.2.2 Asphalt Shingles
Asphalt shingles are cut in relatively small units from
roofing coated with mineral granules and are intended to be
laid in overlapping courses. Prepared roofing shingles are
cut in a variety of patterns and finishes.
30
-------
"Individual shingles" are units cut in a single pattern
in distinction to the "strip shingles," which are cut with a
repetition of pattern.
3.2.3 Adhesive Compounds for Built-Up Roofs, Dampproofing,
and Waterproofing
Adhesive compounds are used in three classes of work:
1. Construction of built-up roofs exposed to wide
temperature fluctuations.
2. Construction of above-ground membrane water-
proofing of structures exposed to wide temper-
ature fluctuations and severe vibrations (i.e.,
bridges, culverts).
3. Construction of underground membrane water-
proofing exposed to moderate temperature
conditions (i.e., tunnels, foundations, dams).
The adhesive products are made of tar-pitches and asphalts
similar in composition to the surface coatings of sheet roofings.
Adhesive compounds for built-up roofing are generally of softer
consistency than the coating compounds for prepared roofing, but
are of similar composition.
3.2.4 Bituminous Cements
Bituminous cements are of plastic, troweling consistency
and are used for repairing composition or metal roofing, above-
ground dampproofing, and to a small extent, waterproofing.
Often these products are referred to as "asphalt putty."
Cements may consist of two or more of the following materials: "
1. A base of one or more bituminous materials,
with or without the addition of vegetable
oils and resins.
31
-------
2. Mineral fillers such as those used for filling
the coatings of prepared roofings (clay, cement,
influsorial earth, calcium carbonate, mica,
soapstone) and pigments.
3.3 NEW PRODUCT DEVELOPMENT
Research is under way on producing roofing tiles and
other roofing accessories from molded mixtures of asphalt and
other fibrous and mineral matter. ' Several unsuccessful
attempts have been made to produce such products commercially.
The process generally involves mastication and subsequent
molding under pressure. Mineral fillers with dispersed asphalt
can be formed into sheets, coated, surfaced, and cut into any
desired form of roofing product.
Production of roofing materials by extruding a mastic of
asphalt, mineral filler, and glass fibers in sheet form, coated
with asphalt and surfaced with granules, has been proposed.
This product could be reinforced with a variety of items (bitu-
minized felt, metal, or wooden lathes) and the surface glazed
with fusible glass. Molded units have also been proposed for
roof copings and interlocking roof tiles.
32
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4.0 PROCESS DESCRIPTION AND ATMOSPHERIC EMISSIONS
4.1 GENERAL
Figure 4.1 is a simplified schematic diagram of the
asphalt roofing manufacturing process. Saturated felt is
usually coated on both sides with an asphalt coating of
controlled thickness. In production of shingles, colored
granules are embedded firmly in the surface coating on one
side; a parting agent is applied to the other side; and the
felt is cut into shingles or rolled on a mandrel. The
purpose of the parting agent is to prevent the shingles or
felt surfaces from sticking together. When roofing is made
in rolls, no granules are used. The asphalt used in the
saturator is first prepared by blowing air through the raw
asphalt to achieve selected properties.
The main points of emission of organic particulate in
the roofing process are the saturator, the blowing operation
and the hot asphalt storage tanks. The air-blowing operation
is not always done at the plant site, and the asphalt is fre-
quently purchased in the blown form. The sand dryer and appli-
cation of the mineral parting agent are potential sources of
inorganic particulate. The coating mixer, where the asphalt
sand is blended prior to application, is a minor source of
particulate emissions.
33
-------
ASPHALT
HEATERS
ASPHALT
STORAGE
TANKS
mtiiiitiii
3M BTU'/hr
r
4M BTU/hr
7M BTU/hr
OUST COLLECTOR
TARS RECYCLED
OR BURNED
:Jr
Q Q P Q
a o a a
ORYING-IN
SECTION
\
\
-,
l_
.c
O
o
o
X
o ' —
/ E°!
•too:
0. >- 0
c
T^1 0
TOP /
COATING
TOP
SURFACING
X BACK
COATING
FEED
HOPPER
TALC, MICA
OR SAND
STORAGE
KEY
AB • AFTERBURNER
HEAF • HIGH ENERGY AIR FILTER
ESP - LOW VOLTAGE PRECIPITA'OR
DRIVEN PULLEY FEEDS
FELT TO HOPPER
LOOPING RUNGS DRIVEN
AT CONSTANT SPEED
O O D O
WATE'R
COOLING
CUTTING
PACKAGING
SPROCKET
SATURATING
TANK
Figure 4.1 Asphalt roofing mill process.flowsheet.
-------
4.2 SATURATOR
4.2.1 Process Description
Saturation is accomplished by dipping the felt in asphalt,
spraying it with asphalt, or both. In these operations the
asphalt is maintained at a temperature of 400 to 500°F. Where
both methods are used, the felt is sprayed before dipping.
This spray, applied to one side of the felt only, drives the
moisture out of the opposite side. The felts should contain
less than 7 percent moisture to prevent subsequent blistering
of the asphalt. The trend has been away from spraying and pre-
saturation, since moisture can also be boiled out of the felt
during submersion in the hot liquid asphalt. In any case, the
spray and dipping operations are generally housed together and
form one process.
Standard felt weights (thickness) are 15, 30, and 55 pounds
per 480 square feet of felt material. The felts are a fibrous
paper similar to thin cardboard, as described in Section 3.0.
As shown in Figure 4.1, a saturator line consists of a
large roll of felt (actually paper), a dry looper section that
takes up surges in line speed, a spray section (if used), a
dipping section, a drying section with heated rolls, coating
and surfacing areas, a final cooling section consisting of
both water sprays and water-cooled rolls, a finish looper
area, and finally a roll winder or shingle cutter. Typical
lines are about 5 to 6 feet wide for processing a 4- to 5-foot
width of felt, and they are over 100 feet long.
35
-------
The saturation process is limited by the properties of the
felt and the speed at which the felt can be fed to the saturator,
Maximum speeds are 600 feet per minute (fpm) for 15- to 30-
pound felts and 400 to 500 fpm for the heavier weights; more
-typically, however, the average speeds are 250 to 400 fpm.
Although mechanical breakdowns and changes of the felt roll
cause shutdown of the line, the process is essentially continu-
ous, often over more than one shift per day and for 6 or 7 days
per week.
The entire saturator is enclosed by a hood, which vents
the fumes to a control device or directly to the atmosphere.
These hoods have a wide range of capture efficiencies, depending
on design and ventilation rates. The impact of OSHA regulations
has effected some improvements in hood capture efficiencies;
some saturator rooms, however, are characterized by a hazy
atmosphere.
4.2.2 Atmospheric Emissions From Saturators
Emissions from the saturator consist of water vapor, con-
densed asphalt (hydrocarbon) droplets, and gaseous organic
vapors. These emissions are highly visible and odorous. There
are no available published test results relating emissions to
process production rates.
4.2.2.1 Particulate - Particulate emission rates depend on a
number of factors including weight and moisture content of the
felt, line speed, and the spraying/dipping process. Spraying
probably tends to increase emissions by direct entrainment of
36
-------
asphalt in the vent air stream. Most felts are dipped. Weight
and moisture content of the felt and line speed determine the
total amount of water entering the saturator and also the total
process weight. Moisture in the felt is vaporized by the hot
asphalt, and the vapor carries with it small asphalt droplets
and gaseous products steam-distilled from the asphalt.
Emission data from the literature and from vendors are
summarized in Table 4.1. These data show particulate emissions
in the range of 19 to 71 pounds per hour; the test results did
not include process weight data.
Table 4.1 REPORTED UNCONTROLLED PARTICULATE
EMISSIONS FROM ASPHALT SATURATORS
scfm
20,000
12,500
10,100
12,000
27,300^
Temperature, °F
140
130
260
138
128-134
Grains/scf
0.42
0.59
0.79
0.53
0.08-0.10b
Ib/hr
71
63
68
55
19-24&
Reference
4.1
4.1
4.1
4.1
4.2
aStandard cubic feet per minute corrected to 60°F and
14.7 psia.
In-stack filterable particulate only; other data include
condensable particulate.
Particulate emission data obtained during the field tests
conducted as part of this study are presented in Table 4.2.
The particulate sampling techniques, as described in Appendix B,
followed methods 1 through 5 of the Federal Register of
37
-------
Table 4.2 ASPHALT SATURATOR - PARTICULATE EMISSION DATA
to
oo
Felt
Weight?
Ib
-------
December 23, 1971. The particulate train was, however, modi-
fied by placing the filter after the impingers to collect con-
densible compounds. Tests were conducted at two plants during
processing of two different weights of felt at each plant.
The 55-pound felts were 4 feet wide and ran at line speeds of
approximately 413 fpm at plant A, and from 277 to 317 fpm at
plant B. In all cases the asphalt impregnated on the felt
amounted to approximately 1.6 times the weight of the felt.
The 27-pound felt was 3 feet wide and ran at line speeds of
360 fpm at plant A, and 250 to 340 fpm at plant B. Moisture
contents of the felt at plant B were approximately twice those
at plant A. Asphalt was maintained at a temperature of 430°F
at plant A and 450°F at plant B.
The data in Table 4.2 show that uncontrolled emissions at
plant A were highly variable. Average hourly emissions were
62 pounds for the 55-pound felt and 39 pounds for the 27-pound
felt, yielding averages of 3.9 and 8.7 pounds per ton of satu-
rated felt for the two weighted tested. Emissions from the
saturator were controlled by a HEAP-'system (see Section 5.0)
at plant A. With the larger machine, the HEAP operated at a
pressure drop of 27 inches of water; with the smaller machine
the observed pressure drop was 20.5 inches. Tests at this
plant were not performed simultaneously at the control device
inlet and outlet, since no sampling sites were available at
trademark - Johns-Manville Corp.
39
-------
the inlet. Instead, samples of uncontrolled emissions were
obtained while the control device was bypassed. Controlled
and uncontrolled emissions are thus not directly comparable,
but average values can be compared, since the same product
was being run. Values obtained at the outlet indicated average
hourly emission rates of 18 and 5 pounds for the 55- and 27-
pound felts, respectively. Comparable control device effi-
ciencies were 71 percent and 87 percent by weight. These
emissions averaged 1.2 pounds per ton of saturated felt for
both weights of felt.
The fairly low collection efficiencies for this control
device, which relies mainly on mechanical impaction, are
probably due to the large amount of condensible matter that
passes through the HEAF in gaseous form and to the fine particle
size of the particulate matter. Some HEAF units, however, have
demonstrated measured efficiencies above 98 percent as applied
to asphalt saturators. Differences in sampling procedures
could account for differences in emission rates and collection
efficiencies.
At plant B the two weights of felt were run on the same
line at different times. Uncontrolled emissions from plant B
ranged from 27 to 34 pounds per hour and were essentially the
same for both felt weights. This apparent anomaly is due to
mechanical problems with the 55-pound felt machine, requiring
frequent opening of the hood doors with loss of fume into the
room and thus lower measured emissions from the stack. The
40
-------
machine that ran the 27-pound felt operated much more con-
sistently with the hood tightly closed; the 32.5 pound-per-
hour emission rate is representative of emissions from this
line. The average emission rate of 8.7 pounds per ton of
product is identical to the average obtained with the 27-pound
felt at plant A.
The plant B saturator was controlled with a fume incinera-
tion system, in which the exhaust fumes were passed into a
process heater furnace fired with No. 2 fuel oil. The process
heater was used to heat the saturant in the saturation process.
The heater was regulated by the saturant temperature, auto-
matically reducing the firebox temperature when the saturant
became too hot. Maximum heat input of the furnace was 10
million BTU per hour. The variable operation of the fume
incinerator and the burning of No. 2 fuel oil caused low par-
ticulate collection efficiency. Controlled emissions were 13.5
and 15.5 pounds per hour for the 55- and 27-pound felts, respec-
tively, (0.9 and 4.2 pounds per ton of product) resulting in
collection efficiencies of 56 and 52.3 percent by weight.
Particle size data on saturator emissions are lacking.
Samples obtained during the field testing portion of this study
with a Brink's Impactor yielded the data shown in Figure 4.2.
These limited data show that the particles emitted are very
small, 50 percent measuring less than 0.8 micron in diameter.
This small particle size is evidenced by the high opacity of
the plume when it is not controlled.
41
-------
20.0 r
0.1 •
5 10 20 30 40 50 60 70 80 90
PERCENT BY WEIGHT SMALLER THAN INDICATED SIZE
98 99
Figure 4.2 Particle size distribution
in uncontrolled saturator exhaust.
42
-------
4.2.2.2 PPOM Emissions - Table 4.3 summarizes the PPOM emis-
sions measured in this study. These data were obtained by
using the EPA-5 particulate sampling method with filter relo-
cated to follow the impinger as described in Appendix B. The
collected sample fractions were extracted with methylene
chloride. The remaining sample was separated on a chromato-
graphic column and analyzed by mass spectrometry. These data
show uncontrolled total PPOM emissions of 21 to 114 milligrams
(mgm) per hour at plant A (0.00012 percent to 0.00048 percent
of total particulate matter), the heavier shingle material
yielding the higher emission rate. At this plant the PPOM
emissions were reduced by passage of effluent through a HEAF
unit, the emissions measuring 5.0 and 37.6 mgm per hour (0.0002
to 0.00044 percent of total particulate emissions). Emission
rates for each of the individual PPOM compounds were lower after
passage through the HEAF unit, and overall collection efficiency
was 70 percent.
At plant B, the uncontrolled PPOM emissions ranged from
16.6 to 27 mgm per hour (0.00012 to 0.00018 percent of total
particulate). These emissions were controlled by a fume incine-
rator. This device, however, had essentially no effect on the
PPOM compounds; emissions at the inlet and the outlet, measured
simultaneously, were approximately the same.* Since total par-
ticulate was reduced, the portion of PPOM as a percent of par-
ticulate increased to 0.0003 percent.
*Neglecting the unusually high benz(a)pyrene and benz(e)pyrene
values, which were apparently caused by interferences in
analyses.
43
-------
Table 4.3 PPOM EMISSIONS FROM ASPHALT SATURATORS
Compound
B«ni(c)phenanthr«n«
7,12-Dlmcthylbcnl
(a)anthracena
B«nl
Shlnql*
U9»/«3
0.41
0.12
0.04*
-
0.01
0.01
»"j»/nr
13.0
3.30
1.10"
-
0.27
0.27
17.*
riant B
loll
vgB/»
0.32
0.19
4.20'
--
0.16
0.16
Bjm/\r
9.80
5.10
110.0*
—
4.90
4.90
133.4
* B*ni(a)pyr«n« * BentU)pyran« total. Tb» qm» ehrOBatofripb quantltatlon of
binilalpyren* and b«n(U)pyr«n« waa ha>tMnd by
— flgnlfiaa non-d«t«ctabl«.
•out riant A utilliad BEAT control d«»lca.
riant B utlllicu aftmburiMr
-------
PPOM compounds thus amount to approximately 0.0003 per-
cent of the total.particulate in either controlled or uncon-
trolled emissions. Table 4.4 summarizes the PPOM emissions
measured in this study with relation to total particulate and
product tonnages.
Table 4.4 RELATION OF PPOM TO TOTAL
PARTICULATE AND PRODUCT TONNAGES
Felt weight
55
27
Uncontrolled
% PPOM x 10~4
in particulate
1.2-4.8
1.2-1.8
mg/ton of
product
2-8
5-7
Controlled
% PPOM x 10~4
in particulate
2.8-4.4
2.0-3.3
mg/ton of
product
1.5-2.4
1.1-6.3
4.2.2.3 Gaseous Emissions - Although reported data for gaseous
emissions from the saturator are practically nonexistent, gase-
ous hydrocarbons, carbon oxides, aldehydes, and odorous com-
pounds are emitted because of the nature of the process.
Table 4.5 summarizes the gaseous emission data obtained
during the field tests of two saturators. The saturator ex-
haust is essentially air at a temperature of 140 to 190°F,
containing 1.1 to 3.8 percent moisture. In all cases, multiple
samples of each contaminant were taken during the particulate
tests. Hydrocarbons and carbon monoxide (after conversion to
methane) were analyzed with a flame ionization detector. Alde-
hydes were collected in a solution of MBTH (3-methyl-2-benzo-
thiazolone hydrazone hydrochloride and analyzed colorimetrically.
45
-------
Table 4.5 GASEOUS EMISSIONS FROM ASPHALT SATURATORS
CTi
EMISSIONS
coa
Range
Average
< HCb
.p Range
jjj Average
f\ f
Aldehydes
Range
Average
CO
Range
m Average
S HCb
a! Range
Average
Uncontrolled
ppma
512 - 614
563
43 - 58
51
2.39 - 4.80
3.35
2.3 - 192
50.4
180 - 970
520
Ib/hr
81.7
4.2
0.52
2.2
12.8
Ib/ton
5.1
0.26
0.033
0.14
0.84
Controlled
a
ppm
410 - 466
438
71 - 79
75
0.69 - 2.5
1.96
0-70
36.2
0 - 360
246
Ib/hr
56.6
5.5
0.27
2.5
9.7
Ib/ton
3.5
0.34
0.017
0.16
0.64
, Parts per million by volume.
c Total gaseous hydrocarbons expressed as methane.
Total aldehydes expressed as formaldehyde (CHOH) .
-------
Measurements for gaseous hydrocarbons, aldehydes, and
carbon monoxide were made at plant A. These measurements
showed average carbon monoxide emissions in the range of 57
to 82 pounds per hour (3.5 to 5.1 pounds per ton of saturated
felt), at concentrations of 410 to 614 ppm. Concentrations
after the HEAP unit were lower than the uncontrolled emissions,
but probably because the samples were taken at different times.
Concentrations of gaseous hydrocarbons ranged from 40 to 80 ppm,
with hourly emission rates of 4 to 5.5 pounds (0.25 to 0.34
pound per ton). Concentrations of total aldehydes ranged
from 0.7 to 5 ppm, with hourly emissions of 0.3 to 0.5 pound
(0.02 to 0.03 pound per ton of saturated felt). Emissions of
aldehydes were approximately 50 percent lower after the HEAF
unit. Although tests at the inlet and outlet were not con-
ducted simultaneously, some reduction in aldehydes could be
caused by condensation and adsorption on the fiber mat.
Emissions of CO at plant B were somewhat lower than those
at plant A, measuring 2.2 pounds per hour (0.14 pound per ton
of product) before control. Hydrocarbon concentrations aver-
aged 520 ppm, or 12.8 pounds per hour (0.8 pound per ton).
Use of the fume incinerator gave a 24 percent reduction of
hydrocarbons and no reduction in CO. As mentioned in the dis-
cussion of particulate emissions, this incinerator was burning
No. 2 oil and was not operating under maximum control effi-
ciency conditions.
4.3 ASPHALT BLOWING
4.3.1 Process Description
Although the processes are not always done at the same
47
-------
site, preparation of the asphalt is an integral part of felt
saturating. Preparation consists of oxidizing the asphalt by
bubbling air through liquid (430-500°F) asphalt from 1 to 4
hours. The industry refers to this operation as "blowing".
Blowing may be done either in vertical cylindrical tanks, as
shown in Figure 4.3, or in horizontal chambers. Because
blowing time is shorter than in horizontal chambers, vertical
stills are usually used. One or more blowing vessels may be
operated simultaneously at a plant. They are usually con-
nected to a common vent system and thus form a semicontinuous
process.
In this operation, atmospheric air is compressed to about
10 to 15 psig and piped into a sparger in the bottom of the
blowing vessel. Preheated asphalt is then pumped into the
vessel and blowing is started. Blowing is continued until an
asphalt with the desired melting point is achieved. The
higher the desired melting point, the longer the blowing time.
The blowing operation uses 1.5 to 2 cfm of air per gallon of
asphalt charged.
The blowing operation removes volatile compounds from the
asphalt and also oxidizes some compounds. Because the operation
is exothermic, cooling water is required to control temperatures,
The water is frequently applied to the walls of the vessel.
Air, entrained asphalt droplets, gaseous hydrocarbons, carbon
oxides, and some sulfur compounds are emitted from the blowing
chambers. These emissions pass through a primary control device
48
-------
ASPHALT
FLUX
450°F
_ FUEL
ASPHALT
BLOWING
DRUM
_ STEAM
BLANKET
OIL
RECOVERY
SYSTEM
AIR
ASPHALT
HEATER
& FUME BURNER
AIR
BLOWER
NONCONDENSIBLES
TO CONTROL DEVICE
AND VENT
BLOWN ASPHALT
TO.STORAGE
Figure 4.3 Air blowing of asphalt.
4.3
-------
such as a settling chamber or cyclone-type particulate collec-
tor, and an emission control device (usually a process heater
furnace) before entering the atmosphere. Particulate matter
(oil) captured in the primary control device is generally
burned in an asphalt heater or mixed with raw asphalt.
4.3.2 Emissions
The cyclic nature of the blowing operation results in a
wide range of emissions, which appear very high as the blowing
starts and then decrease as the operation progresses. Par-
ticulate emissions also increase rapidly once the blowing
chamber temperature exceeds 450°F. Uncontrolled asphalt losses
from horizontal stills have been estimated to amount to about
3 to 5 percent of the amount charged. Losses from vertical
stills are generally lower, on the order of 1 to 2 percent of
the amount charged. One single reported field test showed 3.9
pounds of asphalt emitted per ton of asphalt charged after a
4 4
settling chamber, " about 0.2 percent of the amount charged.
4.3.2.1 Particulate - Table 4.6 presents the particulate emis-
sion data obtained during tests at two blowing operations.
Tests were conducted simultaneously before and after a fume
incinerator at each plant. Emission data are presented on a
concentration basis, as pounds per hour, and also as pounds
per 1000 gallons charged (1000 gallons equal about 4 tons,
based on density of 8 pounds per gallon). In all cases except
the third test at plant C, only one still was operated at a
time. Total emissions were thus related to a single batch of
50
-------
Table 4.6 PARTICULATE EMISSIONS FROM ASPHALT BLOWING
Asphalt Charged
1000
gallons
a
4t 17.9
e
5 17-9
0 14- 1«
s l4-14
•H .
* 13.7
Melt
Point, '?
247
132
210
130
130
Blowing
time, mln.
291
132
300
133
127"
Vent Gasb
Flow
MSCFMC
2.2
3.2
2.3
2.1
2.1
Temp . ,
"F
308
263
211
206
202
Hoist. ,
"%
19.5
5.1
17.4
16.9
18.2
Uncontrolled Particulate
gr/DSCFd
11.2
0.3
3.56
1.4B
2.1
Ib/hr
212
8.1
71.5
25
36.6
lb/1000
gallons0
57.4
1.0
25.2
3.9
5.6
Controlled Particulate9
gr/DSCF
0.10
0.43f
0.12
0.023
0.025
Ib/hr
8.8
37. 4f
11.0
1.9
2.0
lb/1000
gallons
2.4
4.6
3.9
0.28
0.31
Two stills - 14,140 gallons for 40 minutes at end of cycle and 13,500 gallons
for 87 minutes (entire cycle), Avg. = 13,703 gallons.
At inlet to afterburner - Outlet flows are 3 to 5 tines as large because of
combustion and dilution.
1000 cubic feet per minute corrected to 70°F and 29.92 in. Hg, dry basis.
Grains per dry standard cubic Coot.
Pounds per hour times total blow time divided by gallons charged.
Apparent afterburner malfunction.
-------
asphalt. The samples of uncontrolled emissions were taken
after a cyclone separator in each case.
As these data show, total uncontrolled vent gas flows
are relatively low, about 2 to 3 thousand scfm. Moisture
content of this gas stream is high, and temperature is in the
200 to 300°F range. Uncontrolled particulate emissions were
much higher for the higher-melt-point asphalts as determined
by tests over the total cycle; these emissions amounted to
25.2 and 57.4 pounds per 1000 gallons of blown asphalt (6.3
to 14.4 pounds per ton). Shorter blowing times required for
the lower-melt-point asphalts resulted in much lower emissions,
from 1 to 5.6 pounds per 1000 gallons (0.25 to 1.4 pounds per
ton). Figure 4.4 shows the relationship between emissions
and melting point. At both plants the vent gas entered a
fume incinerator, which was used both to reduce emissions and
to preheat the asphalt entering the blowing operation.
These units achieved particulate reduction efficiencies
in the 85 to 95 percent range. Controlled emissions for the
high-melt-point asphalt averaged 3.15 pounds per 1000 gallons
(0.79 pound per ton); for the low-melt-point asphalt, emissions
averaged 0.3 pound per 1000 gallons (0.075 pound per ton). The
single outlet test at plant B for the low-melt-point asphalt
yielded extraordinarily high emissions because of an apparent
afterburner malfunction, which caused excessive emissions from
the oil fired in this unit.
4.3.3.2 PPOM Emissions - Table 4.7 summarizes the PPOM emission
52
-------
01
u>
50
0
Ibs per ton of asphalt
:tr ::,
Ibs per 1000 gallon's or 'asphalt charged
7
i
.M
10
20
30
40 50
Figure 4.4 Relation of particulate emissions and asphalt melt point,
-------
Table 4.7 PPOM EMISSIONS FROM ASPHALT BLOWING
Compound
Benz (c) phenanthrene
7 , 12-Dimethylbenz
(a) anthracene
Benz (e) pyrene
Benz (a) pyrene
3-Methylcholanthrene
Dibenz (a,h) pyrene
Oibenz (a, i) pyrene
Total PPOM Emissions
Percent of total .
particulate x 10~
Uncontrolled
Plant B
yg/m
18.0
2.20
14. Oa
--
2.80
2.80
mg/hr
80.0
9.80
62. Oa
--
12.0
12.0
175.8
1.8
Plant C
yg/mj
7.40
4.50
0.17
0.41
—
--
—
mg/hr
29.0
18.0
0.67
1.60
—
--
—
49
1.5
Controlled
Plant B
yg/m
0.79
0.00
0.25s
—
0.40
0.40
mg/hr
14.0
0.00
4.40a
—
7.00
7.00
32.6
8.2
Plant C
pg/m
0.09
2.80
1.00
0.39
0.29
0.02
0.02
mg/hr
1.80
58.0
21.0
7.70
5.40
0.45
0.45
95
19
--- Non-detectable.
a Total benz(e)pyrene and benz(a)pyrene.
Emissions pass through a process heater furnace. Unit B Utilized.
Oil and Unit C utilized gas as auxiliary fuel.
-------
data obtained at the two plants tested. Total hourly emissions
ranged from 49 to 176 milligrams before the control device, and
33 to 95 milligrams after a fume incinerator. Both of these
tests were run while high-melt-point asphalt was being blown
and on the basis of particulate emission data would be expected
to yield emission rates higher than those resulting from blowing
of low-melt-point asphalt.
Tests of controlled and uncontrolled emissions were con-
ducted simultaneously at the fume incinerator inlet and outlets.
At plant B, the incinerator yielded 81 percent reduction in the
total identified PPOM compounds. At plant C, emissions at the
outlet were more than 2 times those detected at the incinerator
inlet. This increase in PPOM emissions is probably due to par-
tial reaction of some organic compounds in the fume burner.
PPOM percent of total particulates is also shown in
Table 4.7. Before the fume incinerator, PPOM accounted for
less than 0.0002 percent of total particulate; after the incin-
erator, PPOM accounted for between 0.00082 and 0.0019 percent
of total particulate.
Published measurements of PPOM emissions from horizontal
asphalt blowing stills showed benz(a)pyrene concentrations of
less than 20 and 4 micrograms per cubic meter of exhaust gas
4 4
before and after a steam spray-baffle control device. " In
measurements before a control device, pyrene and anthracene
were found in much higher concentrations: 5,800 and 310 micro-
grams per cubic meter, respectively.
55
-------
4.3.3.3 Gaseous Emissions - Emissions of carbon monoxide and
gaseous hydrocarbons from asphalt blowing processes cover a
wide range, as shown in Table 4.8. This range is mainly due
to the cyclic nature of the blowing process and the variable
factors such as temperature and oxygen content that affect
these emission rates. Carbon monoxide averaged 62 ppm (0.73
pound per hour) and 341 ppm (15.2 pounds per hour) before and
after the fume incinerator, respectively, at plant B. At
plant C, CO emissions were higher, averaging 1418 to 3956 ppm
at the inlet and outlet, respectively.
At both plants carbon monoxide emissions increased by a
factor of at least 10 after passage of the stream through the
fume incinerator.
Controlled carbon monoxide emissions ranged from 15 pounds
per hour at plant B to 179 pounds per hour at plant C (approx-
imately 2 to 28 pounds per 1000 gallons or 0.5 to 7 pounds per
ton of asphalt).
Gaseous hydrocarbon emissions ranged from 32 to 36.7
pounds per hour before the fume incinerator, and averaged 18.7
pounds per hour at the outlets. Controlled hydrocarbon
emissions were equivalent to an emission factor of 2.5 pounds
per 1000 gallons or 0.65 pound per ton of asphalt.
Data reported earlier on emissions from a horizontal still
showed average concentrations of 900 ppm for CO and 2500 ppm
for gaseous hydrocarbons. These data are similar to those
4 4
found in the current tests on vertical stills.
56
-------
Table 4.8 GASEOUS EMISSIONS FROM ASPHALT BLOWING
EMISSIONS
coa
Range
Average
^ HCb
^ Average
iH
fc Aldehydes0
Average
CO
Range
« Average
-P .
(0 HC
^ Range
Average
Uncontrolled
a
ppm
358 - 7569
1418
6733
7.4
3 - 179
62
3090 - 5900
4796
Ib/hr
13.5
36.7
0.08
0.73
32.4
lb/tond
0. 52
1.4
0.0029
0.022
1.0
Controlled
a
ppm
416 - 9106
3956
656
9
3 - 1018
341
410 - 1150
803
Ib/hr
179
16.9
0.43
15.2
20.4
Ib/ton
6.9
0.66
0.017
0.47
0.63
Parts per million by volume. Controlled (incinerator outlet)
b emissions are more diluted than inlet emissions.
Total gaseous hydrocarbons expressed as methane.
^ Total aldehydes expressed as formaldehyde (CHOH).
Based on a 2.2 hour blowing time. Multiply by 0.615 to convert
to pounds per ton of saturated felt.
Note: Blower units at both plants controlled by fume incinerators
-------
Limited data on aldehydes show emissions in the range of
0.08 to 0.43 pound per hour before and after the fume inciner-
ator. Again partial oxidation of some organic compounds in
the incinerator yielded a higher outlet value.
Measurement of hydrogen sulfide at the fume incinerator
inlet during tests at plant C yielded values of 0.3 to 0.7
part per million. The odor threshold for H-S is approximately
4 5
0.0005 ppm. ' Passage of the effluent through the fume
incinerator would oxidize most of the H_S to S0_ and reduce
the odor level considerably. This gas stream also contained
580 ppm of S02, yielding an average emission rate of 11.5
pounds per hour or 0.43 pound per ton of asphalt. The raw
asphalt contained 2.1 percent sulfur.
4.4 MINERAL SURFACING APPLICATION
Approximately 700 pounds of mineral granules are applied
to a ton of shinglas (finished product). These granules are
purchased from vendors and are virtually dustless. Points
of granule application are not hooded or otherwise exhausted.
The top coating for shingles consists of colored granules,
which are pressed into the hot asphalt coating. The opposite
side of the roll is coated with a parting agent to prevent
sticking.
Parting agents for roll roofing consist of talc, slag,
mica, or sand. Except when sand is used, application of
these materials is extremely dusty. Approximately 3 to 5
pounds of parting agent are applied per 100 square feet of
roofing, depending on whether the agent is applied to one or
58
-------
both sides. Generation of dust is related to the fineness of
the particles rather than the quantity applied. When exces-
sive dust presents a problem at the work area, exhaust nozzles
provide minimum control; ideally the entire application area
is enclosed and equipped with exhaust devices. Emissions from
the area can be captured with a fabric filter and returned to
the system by screw conveyor. Fine washed sand is sometimes
used. This agent is more costly than talc, but creates less
dust.
Emission rates from these application operations are not
reported in the literature. The control devices commonly used
(fabric filter) are more than 99 percent efficient, however,
and emissions from this source should not present a problem.
4.5 HOT ASPHALT STORAGE
Roofing manufacturers generally store asphalt in a liquid
state in fixed-roof tanks. Heaters maintain the asphalt at
a usable temperature of 350 to 400°F. Emissions from storage
areas depend on storage temperature, properties of the asphalt,
and throughput of the tanks. Although emissions are normally
not visible, they are odorous and may be a problem during
filling operations. Some manufacturers vent the tanks to an
afterburner where the hydrocarbons are oxidized. Actual emis-
sions are unknown. Table 4.9 presents an analysis of gases
emitted from a paving asphalt storage tank during filling.
The total quantity emitted would vary directly with the quantity
of asphalt pumped into the tank. Heavy hydrocarbons would thus
59
-------
Table 4.9 ANALYSIS OF VAPORS DISPLACED DURING FILLING
85/100 PAVING-GRADE ASPHALT INTO A FIXED-ROOF TANK*'4'6
Component
Volume,%
Methane
Ethane
Heavy hydrocarbons (28° API gravity)
Nitrogen
Oxygen
Carbon dioxide
Water
Argon
Trace
Trace
0.1
67.3
13.0
1.4
18.2
Trace
aSample was collected over a 3-1/2 hour filling period.
Noncondensables were analyzed by mass spectrometer. Con-
densable hydrocarbons were separated from the steam, and
gravity and distillation curves were determined.
60
-------
amount to about 4 cubic feet per 30,000 gallons of asphalt
(0.01 pound per ton of asphalt, based on an assumed molecular
weight of 120).
4.6 SAND DRYER
Sand, or another type of filler, is blended with asphalt
to form a slurry, which is applied at a controlled thickness
to the saturated felt. The sand acts as a binder to stabilize
the asphalt. Moisture content of the sand is about 5 percent
by weight as stored; before blending, the sand must be dried.
Drying is done either in a direct-fired rotary dryer or, more
commonly, in an indirect, heated, baffled column. Inorganic
particulate emissions in the form of sand result from the
direct-fired drying operation.
61
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5.0 CONTROL TECHNOLOGY AND COSTS
The manufacture of asphalt roofing generates two basic
air pollutants: gaseous and condensible hydrocarbons from
the saturator and blowing operations, and particulate matter
from the application of mineral coating agents. Information
obtained in plant visits and discussions with industry per-
sonnel indicates that the hydrocarbon emissions are by far
the most difficult to control and cause the greatest emission
problem. Small amounts of sulfur compounds and asphaltic odors
are also emitted.
No control techniques have been developed specifically
for PPOM compounds, and no information is available on the
fate of these compounds as they pass through control systems
used in this industry.
5.1 CONTROL OF SATURATOR EMISSIONS
Many systems have been used over the years to reduce
emissions from the saturator, largely on a trial-and-error
basis. Table 5.1 summarizes the devices currently in use and
indicates their relative popularity.
62
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Table 5.1 CONTROL EQUIPMENT USED ON SATURATORS
Device
Low-voltage ESP
ESP/scrubber combination
Scrubber
Afterburner
HEAF (High Energy Air Filter)
Percent of.
total lines'
12
3
3
52
30
aBased on a survey of 61 operating lines in late 1973.
Value is percent of lines surveyed, not percent of
production.
5.1.1 Electrostatic Precipitators
Low-voltage (approximately 10,000 volts) electrostatic
precipitators, as shown in Figure 5.1, have been used with
some success to reduce particulate emissions. * Control
efficiencies are reportedly in the low 90 percent range,
however, and maintenance of electrostatic precipitators is
difficult because of the cohesive tar-like characteristics of
the particulate. Additionally, water sprays used in the ducts
form an oil emulsion that is difficult to break. Recently,
the use of detergents has reduced this problem.
63
-------
OUCTS ' MOV
SAT URA10R
MAILR HI1 URN
(MESH FILTER ,
WATER SPRAYS
xxxx
OUCIS FROM
SATURATOR
WATER TANK
Figure 5.1 Flow diagram for low- 5
voltage electrostatic precipitators. "
The industry has recently renewed its interest in low-
voltage precipitators because of fuel shortages, costs of
afterburners, and the water pollution aspects of scrubbing.
In the newer installations a fiber mesh precleaner is fre-
quently used, and the system is installed in modules to
5 2
facilitate cleaning and maintenance. " Vent gas velocities
across the precipitator are in the range of 2.5 to 3.3 feet
per second.
5.1.2 Scrubbers
Low-energy scrubbers are not ideal for control of satu-
rator emissions, since their collection efficiencies in the 70
percent range are not adequate for eliminating opacity and
odors. Use of more efficient venturi scrubbers has generally
been avoided because of high operating costs and problems of
water pollution control.
5.1.3 Afterburners
The most popular control system currently used for both
particulate and gaseous control is fume incineration or after-
burning. Although incineration can be done in the presence of
64
-------
a catalyst at approximately 800°F, the advantage of this rela-
tively low operating temperature is more than offset by problems
associated with catalyst fouling. Direct-flame afterburners
can remove up to 99 percent of the hydrocarbon emissions when
designed for 0.3 second retention at 1400°F. * Fuel can be
either natural gas or No. 2 fuel oil. Users of direct-flame
afterburners report that odors associated with the saturation
5455
process are completely eliminated. ' If afterburners
are properly designed and operated, they provide a satisfactory
means of controlling saturator emissions. Availability and cost
of fuel are potential problems.
Afterburners are installed both with and without heat
recovery, according to the decision of individual plant opera-
tors. In general, heat recovery is more economical for new
facilities, but it is not always possible to achieve maximum
recovery since the afterburner exhaust oftentimes contains
more heat than the process requires. Maximum heat recovery is
realized only when the roofing manufacturing facility also
produces the paper (dry felt), since the felt-drying process
requires copious quantities of heat for generation of steam
to be used in the drying drums. Afterburner exhaust can be
used for generating this steam or the 200 to 1400°F afterburner
exhausts can be mixed with ambient air, the temperature lowered
to 450°F, and the exhaust stream blown on the exposed side of
the felt as it turns on the drying drum. It has been reported
that a typical felt manufacturing process uses 14 to 18 million
65
-------
5 4
BTU per hour. * About 36 million BTU per hour is required
to treat 25,000 cfm of saturator exhaust at 1400°F. Thus,
maximum heat utilization is in the range of 40 to 50 percent.
Approximately 40 percent recovery is also realized from a
properly designed exhaust gas preheater. Recovered heat can
also be used to preheat asphalt in the saturators and/or in
the blowing operation.
Most afterburners use natural gas as fuel, with light oil
as standby when gas is on an interruptable basis. Fuel costs
are variable and because of the projected scarcity of natural
gas are in a state of flux. Fuel costs were approximately
$1.25 per million BTU for natural gas and $2.10 per million
BTU for No. 2 fuel oil (30C per gallon) in late 1973 in the
Midwest.
Process heaters used to preheat the asphalt (either raw or
blown) can also function as fume incinerators. These devices
should, yield control efficiencies comparable to those of an
afterburner system. High efficiencies, however, require care-
ful introduction of the vent gases to ensure good mixing and
maintenance of a firebox temperature of a least 1300°F. Pro-
cess heaters in which firebox temperatures are controlled by
the exit temperature of the material being heated may yield
low fume control efficiencies when the firebox temperature
is reduced.
r>. 1 .4 Mosh Fi rt<=rs
The search for efficient devices to control oily mists
66
-------
led to the development of the High Energy Air Filter (HEAP).
This device, shown in Figure 5.2, consists of a slowly moving
glass-fiber filter pad through which the process exhausts
pass. The thickness and number of fibers in the pad result
in a high degree of impingement, yielding reported collection
efficiencies as high as 96 to 98 percent at a pressure drop of
5 6
24 inches of water. ' Efficiency is related to face velocity,
As commonly used with a 1-inch-thick pad, the HEAF operates
with pressure drops in the range of 20 to 25 inches of water
and face velocities of 400 to 500 feet per minute. The fiber
pad is in roll form, and as the portion of the pad exposed to
the gas stream becomes loaded with particulate, the roll
advances to expose a clean portion. The entire roll is dis-
posed of after use. Some saturator installations also utilize
a stationary steel wool demister pad after the HEAF to further
reduce carryover. Because of their oil content, disposal of
the rolls may be a problem in some landfill operations.
Cooling of the gas stream is required to collect conden-
sible compounds. Cooling is not generally done by dilution
with ambient air because this greatly increases the amount of
air to be handled. Although the HEAF cannot remove gaseous
emissions and vapors, improvement in odor control has been
reported, with odor unit reductions in the range of 50 to
90 percent.
67
-------
Figure 5.2 Flow diagram for HEAP. *
68
-------
Mist eliminators such as the Brink H-E type have not been
used on saturator emissions because of the high viscosity of
the particulate. These systems are designed so that the par-
ticulate agglomerates in the filter medium and eventually flows
downward to the base for collection. Although the saturator
emissions are believed to be too viscous to flow from the
mesh, operations at slightly increased temperatures could
reduce this problem.
5.1.5 Costs of Saturator Emission Control
Although the costs of controlling emissions from asphalt
saturators depend on many factors, there is generally a direct
relationship between control costs and exhaust volume. Factors
that affect exhaust volume are the area of saturator hood
openings, asphalt characteristics (relating to fire hazards),
width of the felt, and line speed. Based on published data,
estimated installation and operating costs for a "typical"
saturator are given in Table 5.2.
One manufacturer has standardized new saturator exhaust
5 8
rates at 10,000 acfm (8000 scfm). " Compared with a more
typical exhaust rate of 20,000 to 30,000 scfm, such a design
would yield substantial savings in operation of a control
device. There are, however, some conflicting views regarding
minimum exhaust rates. Although asphalt does not have a lower
5 9
explosive limit (LEL), many of the constituents do. * Without
knowledge of specific process weight rates, hood configurations,
and saturator construction details, the required exhaust rates
69
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.Table 5.2 ECONOMICS OF VARIOUS SYSTEMS FOR CONTROLLING
EMISSIONS FROM ROOFING PLANT SATURATORS
(Basis: 6000 hr/yr operation at 30,000 acfm)
PROCESS
Particulate removal
efficiency, %
Opacity removal
Odor removal
Installed cost
Operating cost, S/yr
Maintenance cost,
S/yr
Total operating and
maintenance costs, S/yr
HEAP
96-98
Acceptable
Accpe table
$234,000
22,000
7,000
29,000
Low voltage
precipitator
electrostatic
90-95
Acceptable
Acceptable
$190,000
3,100
14,600
17,700
Mist
eliminator
99
Unknown
Unknown
$162,000
58,600
4,900
63,500
Incinerator
99
Acceptable
Acceptable
$ 87,000
385, 000 K
647,fOOd
1,200
386,300
Incinerator
with heat
exchanger-52%
95-99
Acceptable
Acceptable
$144,000
180, OOO^
203.000°
16,100
186,100
Low- energy
wet scrubber
85
Unacceptable
Unacceptable
$115,000
65,900
6,100
72,000
High-energy
venturi
scrubber
90-95
Unacceptable
Unacceptable
$150,000
13,400
2,400
15,800
aCost upgraded from original table by Chemical Engineering Cost Index, Chem Engineering, November 12,
1973, McGraw-Hill and by vendor contacts.
Operating maintenance upgraded at 5 percent Inflation per year.
^ Based on $1.25 per million BTU fuel cost for natural gas.
Based on $2.10 per million BTU fuel cost for No. 2 oil.
Note: Based on up-dating of data in Reference 5.6.
-------
are difficult to determine. For this reason, operating costs
could vary widely from those shown in Table 5.2. Costs of
operating an incinerator or afterburner are especially vari-
able depending on exhaust gas rates; these costs could be as
low as $70,000 per year instead of $180,000.
In summary, two control systems have proved most effec-
tive to date in controlling particulate emissions from satu-
rator exhausts: direct-flame afterburners and HEAF units.
Low-voltage precipitators have found increased popularity in
the last year and are being installed on some existing plants.
Generally, HEAF's are used on existing plants where heat
recovery is not a practical design consideration. Most new
installations utilize afterburners with heat recovery.
5.2 CONTROL OF ASPHALT BLOWING EMISSIONS
Emissions from asphalt blowing are very similar to those
from saturators; concentrations are much more variable, however,
and tend to be much higher at peak periods. Conversion from
older horizontal stills to vertical blowing stills significantly
reduce emissions and facilitates control. Almost all stills
are now vertical. Existing controls consist almost entirely
of fume incineration in a process heater or afterburner. *
Heat generated by the afterburner is used to preheat asphalt
for the blowing and saturator operations. These furnaces are
oil- or gas-fired, and particulate removal efficiencies
generally range from 80 to 90 percent. In all stills surveyed
during this study, emissions were controlled by combustion in
71
-------
direct-fired units.
One manufacturer is contemplating installation of a HEAF
on an asphalt-blowing operation, but there are no existing
installations from which to collect data. A Brink mist elimi-
nator has reportedly been installed on a blowing operation at
5 8
a west coast refinery, but no test data are available. "
Total exhaust gas flow rates from blowing operations are
in the range of 2000 to 3000 scfm per still (150 scfm per 1000
gallons). Because the volume is considerably smaller than flow
from the saturator, blowing is less expensive to control;
operating costs for an incinerator amount to about one-tenth
of the costs incurred on a saturator.
5.3 CONTROL OF SURFACING AGENTS
Handling of sand, talc, and mica parting agents emits fine
dust particles during receiving operations and application.
These emissions are well controlled with fabric filters. Be-
cause use of a fabric filter with pneumatic receiving and
handling systems is an integral part of the plant process, its
cost cannot be considered a control cost. Particulate control
efficiencies above 99 percent are common for these devices as
applied to these emissions. Installed costs of control equip-
ment are in the range of $2.65 per cfm (1973).
The industry considers sand drying to be a minor source
of particulate (fine sand). Newer plants no longer dry sand
but purchase it at a specified moisture content. Where sand
is dried, however, fabric filters can control particulate
72
-------
emissions very effectively, with efficiencies of approximately
99 percent.
5.4 CONTROL OF HOLDING TANK EMISSIONS
Because emissions from this source are relatively low,
most facilities have no control system. One plant vents 'fumes
from the holding tank to an incinerator. The most common con-
trol method, however, is merely to hold the asphalt at a low
temperature (approximately 350°F) to reduce vapor formation.
73
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6.0 IMPACT OF ATMOSPHERIC EMISSIONS
The impact on the environment of atmospheric emissions
from the manufacture of asphalt roofing depends on: 1) the
types and quantities of emissions, 2) the resulting atmos-
pheric concentrations of the emissions due to dispersion,
3) the location of the plant in regard to surrounding land
use, and 4) the effects of the pollutants. In this chapter
these factors are discussed in relation to the total impact
of an asphalt manufacturing plant upon the surrounding area.
6.1 EMISSION SUMMARY
Emissions from asphalt roofing processes, described
earlier in this report, are summarized in this section.
6.1.1 Particulate Emissions
Organic particulate matter is emitted mainly during
asphalt blowing and saturation of the felt. Emissions from
these operations contain polycyclic hydrocarbons, some of
which are known to be carcinogenic. Consequently, these
emissions are especially significant in evaluating potential
environmental impact.
Table 6.1 summarizes the particulate and PPOM emission
data presented in Chapter 4.0. These data, based on measured
emissions, show that saturators emit on the average 6.3 and
74
-------
Table 6.1 PARTICULATE AND PPOM EMISSION DATA SUMMARY
Operation
Saturating
Average
Blowing
Average
Particulate, Ib/ton of felt
UncontrolTed
3.9-8.7
6.3
3.9-8.9
0.. 15-0. 86
4.5
Controlled
1 .2-4.2
2.7
0.046-0.60
0. 32
PPOM,a % of ' particulate x 10 4
Uncontrolled
1.2-4 .8
3.0
1.5-1.8
1.65
Controlled
2 .0-4 .4
3.2
8-19
13
, Seven identified compounds only. BaP is approximately 10% of this quantity
Pounds per ton of asphalt converted to pounds per ton of saturated felt by
multiplying by 0.615 (product contains 61.5% asphalt).
High-melt-point asphalt.
Low melt point.
NOTE: Range values are averages of test data.
-------
2.7 pounds per ton of saturated felt with no control and with
average control, respectively. A well-controlled plant would
emit about 0.6 pound per ton, at a control efficiency of 90
percent. PPOM emissions average approximately 0.0003 percent
of the particulate both before and after a control device.
Although particulate emissions from asphalt blowing are
more variable, they average 0.27 pound per ton of saturated
felt with a fume incinerator control device. Uncontrolled
blowing operations are not in use. PPOM compounds account
for an average of 0.0013 percent of the particulate.
6.1.2 Gaseous Emissions
Table 6.2 summarizes measured gaseous emission data.
These data show that only limited control is achieved by the
fume incinerators and HEAF unit tested. In blowing operations,
gaseous emissions actually increased after passage of effluent
through fume incinerators. The reported concentrations of
hydrocarbons represent total hydrocarbons as measured with a
flame ionization detector; no further characterization of these
compounds was obtained. Sulfur dioxide emissions vary with
sulfur content of the asphalt. A single measurement of 0.43
pound per ton of asphalt (0.26 pound per ton of saturated felt)
was reported when the asphalt contained 2.1 percent sulfur.
Thus, only a small portion of the sulfur in the asphalt is
emitted.
6.2 POLLUTANT EFFECTS
Effects of pollutants from asphalt roofing manufacturing
76
-------
Table 6.2 GASEOUS EMISSION SUMMARY
(Ib/ton of saturated felt)
Process
Saturating
Range
Average
Blowing
Range
i Average
CO
Uncontrolled
0.14-5.1
2.6
0.013-0.32
0.16
Controlled
0.16-3.5
1.8
0.29-3.2
1.7
KCa
Uncontrolled
0.26-0.84
0.55
0.61-0.86
0.43
Controlled
0.34-0.64
0.49
, 0.39-0.41
0.4
Aldehydes"
Uncontrolled
0.033
0.0017
Controlled
0.017
0.01
^Total gaseous hydrocarbons expressed as methane.
Aldehydes expressed as formaldehyde.
°Pounds per ton of asphalt blown converted to pounds per ton of saturated fat.
NOTE: Range values are averages of test data.
-------
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-------
2!i .50 .75 1 0
2.0 3.0 4.0
Panicle sue (microns!
Figure 6.1 Retention of particulate matter
in lung in relation to particle size. *
79
-------
Table 6.3 CARCINOGENIC POTENTIAL OF SELECTED ASPHALT
6,3
ROOFING EMISSION COMPOUNDS
Compound
Carcinogenicity'
Benz (a)phenanthrene
7,12 - Dimethylbenz(a)anthracene
Benz(e)pyrene
Benz(a)pyrene
3 - Mehtylcholanthrene
Dibenz(a,h)pyrene
Dibenz(a,i)pyrene
- Not carcinogenic
+++, ++++ Strongly carcinogenic
wCode of relative carcinogenicity:
References 6.2 and 6.3 show a weak to inactive
carcinogenic effect for benz(e)pyrene (BeP).
Primary reason for inclusion in the test matrix
is the concurrent presence of BeP and BaP.
80
-------
median value of 6.6 yg/1000 m was obtained for 100 U.S. cities
6 4
in 1959. " Data obtained in 7 U.S. cities (not including
a Birmingham-type city) in 1969 indicated concentrations of
benzene-soluble* particulate (annual average) ranging from 6
to 25 yg/1000 m . An industrial hygiene standard of 150 yg/1000
m for BaP has been proposed in Russia.
The effects of carbon monoxide are health related.
The Federal 1-hour ambient air standard for CO is 40 yg/1000 m .
Gaseous hydrocarbons affect visibility through their par-
ticipation in photochemical smog reactions, cause odors, and
potentially affect health. ' One would expect only a small
percentage of compounds emitted in the asphalt roofing process
to be photochemically reactive. The low efficiencies of the
fume incinerators were probably caused by unburned methane or
light ends in the fuel oil. The Federal standard for nonmethane
hydrocarbons is 160 yg/m , based on a three-hour average.
Sulfur dioxide can affect visibility, construction
materials and other substances, and human health. In conjunction
with the fine particulate matter, SO- produces adverse health
effects that are dependent on concentration. The Federal SO-
standard for a 24-hour period is 260 yg/m ; for a 3-hour period,
it is 1300 yg/m .
Aldehydes, also precursors and products of photochemical
reactions, are assigned a general level of significance at
* Indicative of total amount of organic matter present, not
necessarily equivalent to polycyclic matter.
81
-------
160 ug/m over a 1-hour period. * Formaldehyde, one of the
more significant aldehydes in terms of effects, induces eye
irritation or physiological response (optical chronaxy) at
about 70 ug/m3.6*7
6.3 AMBIENT AIR CONCENTRATIONS
Atmospheric concentrations of pollutants emitted by asphalt
roofing processes must be known before environmental effects
can be assessed. A dispersion model utilizing emission data
provides an estimate of maximum ground-level concentrations at
various times and distances from point of emission.
6.3.1 Method of Calculation
The Gifford-Pasquill atmospheric dispersion model yields
"first approximations" of short-term maximum concentrations
as a function of atmospheric stability and effective stack
fi Q
height. " This dispersion calculation program incorporates
the Briggs plume rise equation, which generally yields a higher
effective stack height than does the Holland equation. In
evaluation of plants for which physical stack heights are
fairly short, changes in effective stack height due to plume
rise have a significant effect on the resulting calculated
ground-level concentrations. Turner concludes that the general
equations are accurate within a factor of 3 for (a) receptors
within several hundred meters exposed under all classes of
atmospheric stabilities, and (b) receptors within several
thousand meters under neutral or moderately unstable condi-
6 8
tions. " The PTMAX computer program, which incorporates this
82
-------
dispersion model, was used to calculate ambient air concen-
trations resulting from asphalt roofing processes under a
variety of conditions.
The following parameters were used as input data for the
dispersion calculation:
physical stack height = 9.1 meters (30 feet)*
stack gas exit velocity = 15 m/sec
inside stack diameter = 1 meter
wind speed = 0.5 to 10 m/sec
atmospheric pressure = 1013 mb (1 atmosphere)
stack gas temperature = 348°K
ambient temperature = 293°K
With these parameters, ambient air concentrations were
determined as functions of various emission rates, wind speeds,
and atmospheric stabilities.
6.3.2 Calculated Ambient Air Concentrations
Figure 6.2 shows the maximum short-term ambient air con-
centrations resulting from selected stack emission rates. These
concentrations are calculated to occur under atmospheric stabil-
ity classes of C and D, and at wind speeds in the 7 to 10
m/second range. Applying this information to asphalt roofing
manufacture requires the use of representative emission rates
for typical process combinations and control efficiencies.
Production rates in the industry vary over a wide range, from
1 to 2 tons per hour to approximately 20 tons of saturated
* Many stacks are higher than 30 feet. However, some emis-
sions such as fugitive leaks from buildings are at points
much lower; 30 feet represents an approximate average height.
83
-------
10
9
8
7
6
5
4
g
o
fc
|lO'
^j
° 7
i 6
Note:
Stability Classes C & D
Emission Rates, Ib/hr
50, 100, 150.
Concentrations are
10 minute values.
10
-1
5 6 7 8 9 10l
56789
IMPACT DISTANCE, Km
Figure 6.2 Estimated atmospheric concentrations
of emissions from asphalt roofing plants.
84
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felt per hour. The average size plant produces less than 5
tons of product per hour. Newer plants tend to operate a
number of saturation lines in parallel, with typical average
production rates between 10 and 20 tons per hour. For these
calculations a rate of 10 tons per hour was selected.
Table 6.4 summarizes the resulting particulate and PPOM
ambient air levels for a 10-ton-per-hour plant employing vari-
ous combinations of processing and control equipment. For a
20-ton-per-hour plant, the resulting concentrations would be
twice those calculated in this illustration. These data show
that uncontrolled particulate concentrations amount to 150
yg/m on a 24-hour basis for a saturator. With a blowing
operation at the same site the concentration would increase to
about 156 pg/m . PPOM concentrations up to 0.45 yg/1000 m
could be reached on a 24-hour basis. These data represent
typical average values. Process difficulties and/or control
equipment malfunctions on the blowing operation could increase
emission levels many times.
The use of a plume rise equation such as the Holland
equation, which gives a lower effective stack height; also
increases the calculated ambient air concentrations by a factor
of 2 or 3 beyond those shown in Table 6.4.
Ambient concentrations of gaseous pollutants emitted
from the hypothetical 10-ton-per-hour plant are shown in
Table 6.5 for various processing and control combinations.
These data show that the maximum 1-hour CO concentration for
85
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Table 6.4 ATMOSPHERIC CONCENTRATIONS OF PARTICULATE POLLUTANTS
FROM A 10-TON/HOUR ASPHALT ROOFING PLANT3
oo
Process and
control
combination
Saturator
uncontrolled
Saturator
controlled
Blower
controlled
Saturator and
blower
controlled
Emission rate
Total
particulate ,
Ib/hr
63
27
6.3d
3.2
30.2
9.5
PPOM
fraction
X 10~6
3
3
13
6.5
Atmospheric concentrations
Total
particulate ,
yg/m
10 min 24 hrc
380 150
160 64
38d 16d
19 6
180 72
58 23d
PPOM,
yg/1000 m
b '
3
24 hr
0.45
0.19
0.05d
0.08
0.5
0.15d
bBased on data in Table 6.1.
Atmospheric stability condition C.
dTwenty-four-hour values are extrapolated from 10-minute values (Ref. 6.8).
Achieved with control device operating at 90% efficiency.
-------
Table 6.5 ATMOSPHERIC CONCENTRATIONS OF GASEOUS POLLUTANTS FROM
A 10-TON/HOUR ROOFING PLANT3
CO
Process and
control
combination
Saturator
uncontrolled
Saturatcr ^
controlled
Blower
controlled
Saturator
and blower
controlled
Emission rates, Ib/hr
CO
26
26
2.6
1.6
27.6
4.2
HC
5.5
5.0
0.5
4
9.0
4.5
Alde-
hydes
0.3
0.17
0.1
0.27
Atmospheric concentrations, ug/m
CO
10 min
160
160
16
10
170
26
1 hrc
115
115
12
7
122
19
HC
10 min
33
30
3
24
54
27
3 hrc
19
18
2
14
31
16
Aldehv
10 min
1.8
1.0
0.5
1.5
'des
1 hrc
)..3
0.7
0.4
1.1
.Based on data in Table 6.2.
Atmospheric- stability condition C.
-Extrapolated from 10-minute values. Note: HC time' is 3 hr; others are 1 hr.
High value is emission with only particulate control device. Lower value
is emission with afterburner at 90% efficiency.
-------
this hypothetical plant is 0.12 mg/m , total hydrocarbons
3 3
(3-hour average) amount to 31 ng/m , and aldehydes 1.3 yg/m .
Again, with respect to larger plants, ambient air concentra-
tions would increase in proportion to emissions.
6.4 EMISSION IMPACT
The overall impact of an average-sized asphalt roofing
plant with controls usually applied in this industry to meet
state and local particulate regulations is not great under
typical operating conditions. Malfunctions and process diffi-
culties could cause ambient air concentrations to exceed the
standards. These plants do, however, contribute to the overall
atmospheric burden, and the potential contribution of plants
located in densely populated areas, even with control equipment,
should not be ignored. Particular attention should be given to
plants with inadequate hooding over the saturator, since this
deficiency causes higher-than-average ground-level emissions
and resulting higher ambient air concentrations, usually with
accompanying odor problems.
Possible synergisms in interactions between the organic
particulate matter and gases in the atmosphere are difficult to
evaluate, since so little is known about effects of these sub-
stances. The presence of PPOM and fine particulate in air
presents the possibility of increased lung retention of car-
cinogenic compounds. The percent of PPOM in the various size
fractions was not determined in the analyses done for this study
because of the large sample volume required for this determina-
88
-------
tion. Therefore, although any extraordinary health effects
of the particulate matter emitted in the manufacture of asphalt
roofing remain unidentified, such effects are possible.
89
-------
7.0 REFERENCES
2.1 Asphalt and Tar Roofing and Siding Products, Summary for
1972. U. S. Dept. of Commerce, Series MA-29A (72)-l, and
earlier summaries.
2.2 Bureau of the Census, Census of Manufacturers: 1972.
2.3 Bureau of the Census, Census of Manufacturers: 1967.
2.4 Statistical Abstract of the United States -1972, 93rd
Edition, U. S. Dept. of Commerce.
2.5 U. S. Bureau of Census, Census of Construction Industries,
1967, Series CC 67-I-1B.
3.1 Berry, G. W. Roofing Materials. In: Kirk-Othmer
Encyclopedia of Chemical Technology, Volume 17, 2nd
Edition, Standen, A. (ed.). New York, John Wiley &
Sons, Inc., 1967.
3.2 Ibid, Volume 2, p. 763-806.
3.3 Ibid, p. 787.
3.4 Abraham, H., Asphalts and Allied Substances; Volume III.
Princeton, D. Van Nostrand Co., Inc., 1963. p. 133-194.
3.5 Ibid, p. 231-241.
3.6 Ibid, p. 366 - 415.
3.7 Ibid, p. 64-119.
4.1 Weiss, S. M. In: Air Pollution Engineering Manual,
Second Edition, Danielson, J. A. (ed.). National Air
Pollution Control Administration. Raleigh, North
Carolina. Public Health Service Publication 999-AP-40.
1967. p. 390.
4.2 Bay Area Air Pollution Control District. Test Report
; Submitted to Johns-Manville on March 9, 1973.
4.3 Hoiberg, A. J., et. al. Asphalt. In: Kirk-Othmer
Encyclopedia of Chemical Technology, Volume 2, 2nd
Edition, Standen, A. (ed.). New York, John Wiley & Sons,
Inc., 1967. p. 762-806.
4.4 Von Lehmden, D. J., R. P. Hangebrauck, and; J. E. Meeker.
Polynuclear Hydrocarbon Emissions from Selected Industrial
Processes. J. Air Pollution Control Assoc. 15: 306-312,
July 1965.
90
-------
REFERENCES (Continued)
4.5 Leonardes, G. et. al. Odor Threshold Determination
of 53 Odorant Chemicals. J. Air Pollution Control
Assoc. 19^91-95, February 1969.
4.6 Weiss, S. M. In: Air Pollution Engineering Manual,
Second Edition, Danielson, J. A. (ed.). National Air
Pollution Control Administration. Raleigh, North
Carolina. Public Health Service Publication 999-AP-40.
1967. pp. 642 & 644.
5.1 Goldfield, J., and R. G. McAnlis. Low Voltage Electro-
static Precipitators to Collect Oil Mists from Roofing
Felt Asphalt Saturators and Stills. American Industrial
Hygiene Assoc. J., p. 411, July-August 1963.
5.2 Private communication. United Air Specialists Inc.,
Cincinnati, Ohio. Feb., 1972.
5.3 Rolke, R. W. et al. Afterburner Systems Study. Shell
Development Company. Emeryville, California. EPA
Contract EHS D-71-3. p. 18-20; 169-178. Aug., 1972
NTIS No. PB-212 560.
5.4 Private communication with industry spokesman, November
1972.
5.5 Private communication with Mr. William Greig, GAF
Corp., New York, New York. November 16, 1972.
5.6 Goldfield, J., V. Greco, and; K. Gandhi. Glass Fiber
Mats to Reduce Effluents from Industrial Processes. J.
Air Pollution Control Assoc. 2_0:466-469, July 1970.
5.7 High Energy Air Filter for Reducing Industrial Effluents,
Filtration Engineering. May 1970.
5.8 Private communication with Mr. David R. Duros, Monsanto
Enviro-Chem Systems, Inc., Cincinnati, Ohio. November
21, 1972.
5.9 Handbook of Industrial Loss Prevention (2nd Edition).
Factory Mutual Engineering Corp., New York, 1967. p. 42-4
5.10 American Fume Burner Cleans Air. The Oil and Gas
Journal, p. 57-58, March 20, 1972.
91
-------
REFERENCES (Continued)
6.1 Federal Register, Vol 36, No. 84, April 30, 1971.
6.2 Preliminary Air Pollution Survey of Organic Carcinogens,
NAPCA Pub. No. APTD 69-43, Oct., 1969, Raleigh, N. C.
6.3 Particulate Polycyclic Organic Matter. National Academy
of Sciences. Washington, D. C., 1972.
6.4 Sawicki, E. , et. al . Benzo (a) pyrene content of the air.
American Ind. Hyg. Assoc. J. 21; 443-451, 1960.
6.5 Shabad, L. M. , et. al. Possibility of Establishing Maximum
Permissible Concentration of Benzpyrene in Air of Industrial
Enterprises. Gigienai Sanitariya, _38. (4) : 78-80, 1973.
6.6 Air Quality Criteria for Carbon Monoxide. National Air
Pollution Control Administration, Washington, D. C.
Publication Number AP-62. March 1970.
6.7 Air Quality Criteria for Hydrocarbons, National Air Pollution
Control Administration, Washington, D. C. Publication
Number AP-64. March 1970.
6.8 Turner, D. B. Workbook of Atmospheric Dispersion Estimates.
National Air Pollution Control Administration, Cincinnati,
Ohio. Public Health Service Publication No. 999-AP-26.
1969. 84p.
92
-------
8.0 APPENDICES
A. Asphalt Roofing Plants in 1973 - SIC 2952
B. Emission Test Procedures and Results
93
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APPENDIX A. LOCATION OF ASPHALT ROOFING PLANTS
Table A-l presents a listing of asphalt roofing manufacturing
plants by state in 1973. Total annual sales are also shown for
each state. This listing is comprised mainly of plants with 20
or more employees. Plants which only produce blown asphalt are
not included in this table.
This tabulation shows a grand total of 202 installations
with annual sales of approximately $881 million. The 1972 Depart-
ment of Commerce's Census of Manufacturers shows 233 establish-
ments with total production value of approximately $1,00.0 million.
Information for Table A-l was obtained from: 1) Asphalt
Roofing Manufacturers' Association, 2) Economic Information
Systems Inc. Report on SIC 2952 of April 22, 1974, and 3) the
U.S. EPA National Emission Data Survey for 1972.
94
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Table A-l LISTING OF ASPHALT ROOFING PLANTS IN 1973a
SIC 2952
Company Name and Location
Alabama
Celotex Corp.
Birmingham, Jefferson, 35200
GAF
Mobile, Baldwin, 36600
Koppers Co.
Woodard, Jefferson, 35189
Logan Long Co.
Tuscaloosa, Tuscaloosa 35401
Total Plants and Sales x 10 4 $4.5
Arkansas
Bear Brand Roofing Inc.
Bearden, Quachita 71720
Celotex Corp.
Camden, Columbia 71701
Elk Roofing Co.
Stephens, Quachita 71746
Southern Asphalt Roofing Corp.
Little Rock, Pulaski 72200
Total Plants and Sales x 10 4 $23
California
Bird & Son, Inc.
San Mateo, San Mateo 94403
Bird & Son, Inc.
Wilmington, Lake 90744
Celotex Corp.
Los Angeles, Los Angeles 90031
Certain Teed Products Corp.
Richmond, Contra Costa 94804
95
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Table A-l (Continued) . LISTING OF ASPHALT ROOFING PLANTS IN 1-973
SIC 2952
Company Name and Location
California, (Continued)
Fibreboard Corp.
Martinez, Contra Costa 94553
Fibreboard Corp.
Oakland, Alameda 94600
Flintkote Co.
Los Angeles, Los Angeles 90000
Flintkote Co.
San Andreas, Calaveras 95249
Johns-Manville Products
Los Angeles, Los Angeles 90058
and Pittsburg, Contra Costa
Lloyd A. Fry Roofing Co.
Compton, Los Angeles 90223
Lloyd A. Fry Roofing Co.
San Leandro, Alameda 94577
Lunday-Thagard Oil Co.
South Gate, Los Angeles 90280
Nicolet Industries
Hollister, Santa Cruz 95023
Owens Corning Fiberglas
Santa Clara, Santa Clara 95000
Rigid Mfg. Co., Inc.
Los Angeles, Los Angeles 90022
Mrs. Paul Smithwick
Los Angeles, Los Angeles 90066
Standard Materials Co., Inc.
Merced, Merced 95340
Thermo Materials, Inc.
San Diego, San Diego 92109
United States Gypsum Co.
South Gate, Los Angeles 90280
Total Plants and'Sales x 10 20 $70
96
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Table A-l(Continued). LISTING OF ASPHALT ROOFING PLANTS IN 1973
SIC 2952
Company Name and Location
Colorado
Colorado Bitumuls Co.
Denver, Denver 80216
GAF Corp.
Denver, Denver 80216
Lloyd A. Fry Roofing Co.
Denver, Denver 80216
Total Plants and'Sales x 10 3 $9.5
Connecticut
Allied Chemical Corp.
Mountville, New London 06353
Tilo Co., Inc.
Stratford, Fairfield 06497
Total Plants and Sales x 10 2 $13
Delaware
Artie Roofings, Inc.
Edge Moore, New Castle 19809
Artie Roofings, Inc.
Wilmington, New Castle 19809
Total Plants and Sales x 106 2 $9
Florida
GAF Corp.
Tampa, Hillsborough
Gardner Martin Asphalt Corp.
Tampa, Hillsborough 33605
Lloyd A. Fry Roofing Co., Inc.
Ft. Lauderdale, Broward 33316
97
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Table A-l(Continued). LISTING OF ASPHALT ROOFING PLANTS IN 1973
SIC 2952
Company Name and Location
Florida (Continued)
Lloyd A. Fry Roofing Co., Inc.
Jacksonville, Duval 32206
Total Plants and Sales x 10 4 $7
Georgia
Certain Teed Products Corp.
Port Wentworth, Effingham 91407
Certain Teed Products Corp.
Savannah, Chatham 31402
GAF Corp.
Savannah, Chatham 31402
Gibson Romans Co.
Conyers, Rockdale 30207
Johns-Manville Products
Savannah, Chatham 31402
Lloyd A. Fry Roofing Co.
Atlanta, Fulton 30311
Mullins Bros. Pvgn. Cntrc.
E. Point, Fulton 30044
Southern Paint Products
Atlanta, Fulton 30310
The Ruberoid Co.
Savannah, Chatham 31402
Total Plants and Sales x 10 9 $55
Illinois
Allied Asphalt Paving Co,
Hillside, Cook 60162
Allied Chemical Corp.
Chicago, Cook 60623
98
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Table A-1(Continued). LISTING OF ASPHALT ROOFING PLANTS IN 1973
SIC 2952
Compnny Name and Location
Illinois (Continued)
Amalgamated Roofing Div.
Bedford Park, Cook 60501
Becker Roofing Co. (2 plants)
Chicago, Cook 60647
Bird & Son Inc.
Chicago, Cook 60620
Celotex Co.
Elk Grove Village, Cook 60007
Celotex Co.
Peoria, Peoria 61600
Celotex Co.
Wilmington, Kankakee 60481
Certain Teed Products Corp.
Chicago Heights, Cook 60411
Certain Teed Products Corp.
E. Saint Louis, Saint Clair 62205
Crown Trygg Corp.
Joliet, Will 60434
Flintkote Co.
Chicago Heights, Cook
FS Services, Inc.
Kingston Mines, Peoria 61533
GAF Corp.
Joliet, Will 60433
Globe Industries, Inc.
Chicago, Cook 60600
J. W. Mortell Co. Inc.
Kankakee, Kankakee 60901
Johns-Manville Corp.
Madison, Madison 62060
Johns-Manville Corp.
Waukegan, Lake 60085
Koppers Co.
Chicago, Cook 60000
99
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Table A-l(Continued). LISTING OF ASPHALT ROOFING PLANTS IN 1973
SIC 2952
Company Name and Location
Illinois (Continued)
Lloyd A. Fry Roofing Co.
Argo, Cook 60501
Lloyd A. Fry Roofing Co.
Summit, Clay 60501
Logan Long Co.
Chicago, Cook 60638
McCalman Construction Co.
Danville, Vermilion 61832
Midwest Products Co., Inc.
Chicago, Cook 60619
Nicolet Industries
Union, Boone 62635
Rock Road Constructioa Co.
Chicago, Cook
Seneca Petroleum Co., Inc.
Chicago, Cook 60616
Triangle Construction Co.
Kankakee, Kankakee 60901
Washington Paint Products
Chicago, Cook 60624
Total Plants and Sales x 10 30 $145
Indiana
Asbestos Mfg. Corp.
Michigan City, La Porte 46360
GAF Corp.
Mount Vernon, Posey 47620
Globe Industries , Inc.
Lowell, Lake 46356
H. B. Reed & Co. , Inc.
Gary, Lake 46406
100
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Table A-l(Continued). LISTING OF ASPHALT ROOFING PLANTS IN 1973
SIC 2952
Company Name and Location
Indiana (Continued)
Lloyd A. Fry
Brookville, Franklin 47021
Total Plants and Sales x 10 5 $20
Iowa
Becker Roofing Co., Inc.
Burlington, Des Moines 52601
Celotex Corp.
Dubuque, Dubuque 52001
Tufcrete Co., Inc.
Des Moines, Polk 50309
Total Plants and Sales x 10 3 $13
Kansas
Royal Brank Roofing, Inc.
Phillipsburg, Phillips 67661
Total Plants and Sales x 10 1 $4.5
Louisiana
Bird & Son, inc.
Shreveport, Caddo 71102
Delta Roofing Mills , Inc.
Slidill, Saint Tammann 70458
Johns-Manville Corp.
Marrero, Jefferson 70072
Slidell Felt Mills , Inc.
Slidell, Saint Tammann 70458
Total Plants and Sales x 10 4 $46
101
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Table A-l(Continued). LISTING OF ASPHALT ROOFING PLANTS IN 1973
SIC 2952
Company Name and Location
Maryland
Congoleum-Nairn, Inc.
Finksburg, Carroll 21048
GAF Corp.
Baltimore, Baltimore 21224
Lloyd A. Fry Roofing Co.
Jessup 20794
Total Plants and Sales x 106 3 $22
Massachusetts
Bird & Son, Inc.
Norwood, Norfolk 02062
Essex Chemical Corp.
Peabody, Essex 01960
GAF Corp.
Millis, Norfolk 02054
Lloyd A. Fry Roofing Co., Inc.
Waltham, Middlesex 02154
Patrick Ross Co.
Cambridge, Middlesex 02142
Total Plants and Sales x 10 5 $15
Michigan
Lloyd A. Fry Roofing Co.
Detroit, Wayne 48217
GAF Corp.
Warren, Macomb 48089
Minnesota
Duval Mfg. Co., Inc.
Minneapolis, Hennepin 55426
102
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Table A-l(Continued). LISTING OF ASPHALT ROOFING PLANTS IN 1973
SIC 2952
Company Name and Location
Minnesota (Continued)
Duvall Mfg. Co., Inc.
Minneapolis, Hennepin 55412
EDCO Products, Inc.
Hopkins, Hennepin 55343
GAF Corp.
Minneapolis, Hennepin 55411
Lloyd A. Fry Roofing Co.
Minneapolis, Hennepin 55412
B. F. Nelson Mfg. Co., Inc.
Minneapolis, Hennepin 55413
E. J. Pennig Co., Inc.
St. Paul, Ramsey 55103
United States Gypsum Co.
St. Paul, Ramsey 55100
Total Plants and Sales x 10 8 $35
Mississippi
Atlas Roofing Mfg. Co.
Meridian, Lauderdale 39301
Lloyd A. Fry Roofing Co.
Hazelwood
Total Plants and Sales x 10 2 $12
Missouri
Certain Teed Products Corp.
Kansas City, Jackson 64126
GAF Corp.
Kansas City, Jackson 64126
Lloyd A. Fry Roofing Co., Inc.
Hazelwood, St. Louis 63042
103
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Table A-l(Continued). LISTING OF ASPHALT ROOFING PLANTS IN 1973
SIC 2952
Company Name and Location
Missouri (Continued)
Lloyd A. Fry Roofing Co., Inc.
N. Kansas City, Clay 64116
Midwest Pre Cote Co.
Kansas City, Clay , 64119
Tamko Asphalt Products/ Inc.
Joplin, Jasper 64801
Total Plants and Sales x 10 6 $34
New Hampshire
Tilo Co., Inc.
Manchester, Hillsboro 03101
Total Plants and Sales x 10 1 $2
New Jersey
Atlantic Cement Co.
Bayonne, Hudson 07002
Bird & Son, Inc.
Perth Amboy, Middlesex 08862
Celotex Corp.
Edgewater, Middlesex 07020
Celotex Corp.
Perth Amboy, Middlesex 08862
Flintkote Co., Inc.
E. Rutherford, Bergen 07073
Flintkote Co., Inc.
Whippany, Morris 07981
GAF Corp.
South Bound Brook, Somerset 08880
Johns-Manville Corp.
Manville, Somerset 08835
Karnak Chemical Corp.
Clark, Union 07066
104
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Table A-l(Continued). LISTING OF ASPHALT ROOFING PLANTS IN 1973
SIC 2952
Company Name and Location
New Jersey (Continued)
Congoleum Nairm, Inc.
Kearny, Bergen 07032
Koppers Co., Inc.
Westfield, Union 07090
Lloyd A. Fry Roofing Co.
Kearny, Bergen 07032
Inc.
Middlesex CNC Products Excv.
Woodbridge, Middlesex 07095
Tilo Co., Inc.
Westfield, Union 07092
United States Gypsum Co.
Jersey City, Hudson 07300
Total Plants and Sales x 10
15
$52
New Mexico
Dura Roofing Mfg. Inc.
Albuquerque, Bernalillo 87103
Total Plants and Sales x 10
$4.5
New York
Alken-Murry Corp.
New York, New York
Allied Chemical Corp.
Binghamton, Broome 13902
Durok Bldg. Materials
Hastings-Hdsn., Westchester 10706
Tilo Co. Inc.
Poughkeepsie, Dutchess 12603
Tilo Co., Inc.
Watertown, Jefferson 13601
Weatherpanel Sidings, Inc.
Buffalo, Erie 14207
Total Plants and Sales x 10
105
$14
-------
Table A-l(Continued). LISTING OF ASPHALT ROOFING PLANTS IN 1973
SIC 2952
Company Name and Location
North Carolina
Celotex Corp.
Goldsboro, Sampson 07530
Lloyd A. Fry Roofing Co., Inc.
Morehead City, Carteret 28557
Rike Roofing & Mfg. Co.
Charlotte, Mecklenburg 28201
Total Plants and Sales x 10 3 $8
Ohio
Celotex Corp.
Cincinnati, Hamilton 45215
Certain Products Co.
Milan, Erie 44846
Consolidated Paint Varnish
Cleveland, Cuyahoga 44114
Gibson Homans Co., Inc.
Cleveland, Cuyahoga 44106
Johns-Manville Corp.
Cleveland, Cuyahoga 44134
Koppers Co., Inc.
Cleveland, Cuyahoga 44106
Koppers Co., Inc.
Youngstown, Mahoning 44500
Lloyd A. Fry Roofing Co.
Medina, Cuyahoga 44256
Logan Long Co., Inc.
Franklin, Warren 45005
Midwest Products Co., Inc.
Cleveland, Cuyahoga 44110
Overall Paint, Inc.
Cleveland, Cuyahoga 44146
Ranco Industrial Products
Cleveland, Cuyahoga 44120
106
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Table A-l(Continued). LISTING OF ASPHALT ROOFING PLANTS IN 1973
SIC 2952
Company Name and Location
Ohio (Continued)
SET Products, Inc.
Cleveland, Cuyahoga 44106
Tremco Mfg. Co.
Cleveland, Cuyahoga 44104
i ~
Total Plants and Sales x 10 14 $60
Oklahoma
Allied Materials Corp.
Stroud, Lincoln 74079
Big Chief Roofing Co., Inc.
Ardmore, Carter 73401
Lloyd A. Fry Roofing Co., Inc.
Oklahoma City, Caradian 73117
Total Plants and Sales x 10 3 $12
Oregon
Bird & Son, Inc.
Portland, Multnomah 97200
Fibreboard Corp.
Portland, Multnomah 97210
Flintkote Co./ Inc.
Portland, Multnomah 97208
Herbert Malarkey Roofing Co.
Portland, Multnomah 97217
Lloyd A. Fry Roofing Co., Inc.
Portland, Multnomah 97210
Shell Oil Co..
Portland, Multnomah 97210
Total Plants and Sales x 10 6 $16
107
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Table A-l(Continued). LISTING OF ASPHALT ROOFING PLANTS IN 1973
SIC 2952
Company Name and Location
Pennsylvania
Allied Chemical Corp.
Philadelphia, Philadelphia 19146
Celotex Corp.
Philadelphia, Philadelphia 19146
Celotex Corp.
Sunbury, Northumberland 17801
Certain Teed Products Corp.
York, York 17303
and St. Gobian, Luzerne, 18707
ESB Inc. Del.
Mertztown, Berks 19539
GAF Corp.
Erie, Erie 16500
Keystone Roofing Mfg. Co.
York, York 17403
Lloyd A. Fry Roofing Co.
Emmaus, Lehigh 18049
Lloyd A. Fry Roofing Co.
York, York 17404
Monsey Products Co., inc.
Philadelphia, Philadelphia 19128
H. C. Price Co.
Philadelphia, Philadelphia 19115
Tilo Co./ Inc.
Philadelphia, Philadelphia 19118
Total Plants and Sales x 10 13 $63
South Carolina
Bird & Son, Inc.
Charleston Hts., Charleston 29405
Total Plants and Sales x 10 1 $14
108
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Table A-l(Continued). LISTING OF ASPHALT ROOFING PLANTS IN 1973
SIC 2952
Company Name and Location
Tennessee
Celotex Corp.
Memphis, Shelby 38100
Lloyd A. Fry Roofing Co.
Memphis, Shelby 38107
Total Plants and Sales x 10 2 $3
Texas
American Petrofina Tex.
Mt. Pleasant, Titus 75455
Celotex Corp.
Houston, Liberty 77000
Celotex Corp.
San Antonio, Bexar 78200
Certain Teed Pdts. Corp.
Dallas, Dallas 75216
Daingerfield Mfg. Co.
Daingerfield, Morris 75638
Flintkote Co.
Ennis, Ellis 75119
GAF Corp.
Dallas, Dallas
Gulf States Asphalt Co. , Inc.
Beaumont, Jefferson 77704
Johns-Manville Corp.
Ft. Worth, Tarrant 76107
Lloyd A. Fry Roofing Co.
Irving, Dallas 75060
Lloyd A. Fry Roofing Co.
Houston, Harris 77029
Lloyd A. Fry Roofing Co.
Lubbock, Lubbock 79408
109
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Table A-l(Continued). LISTING OF ASPHALT ROOFING PLANTS IN 1973
SIC 2952
Company Name and Location
Texas (Continued)
Ruberoid Co.
Dallas, Dallas 75222
Southwestern Petroleum
Fort Worth, Tarrant 76106
Texas Sash & Door
Ft. Worth, Tarrant 76101
Total Plants and Sales x 10 15 $84
Utah
Lloyd A. Fry Roofing Co.
Woods Cross, Davis 84087
Total Plants and Sales x 106 1 $1.5
Washington
Certain Teed Products Corp.
Tacoma, Pierce 98421
Kollogg Co.,Inc.
Washington
B. F. Nelson Mfg. Co. Inc.
Washington
Total Plants and Sales x 10 3 $5
West Virginia
Celotex Corp.
Chester, Hancock 26034
Total Plants and Sales x 10
Total United States Plants and 202 $881
Sales x 106
110
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APPENDIX B. EMISSION TEST PROCEDURES AND RESULTS
INTRODUCTION
To obtain quantitative emission data, tests were conducted
at three plants. The following tests were made:
Plant A - Particulate, PPOM, and gaseous emissions from
felt saturators running 27- and 55-pound felt. Tests were
made with and without a HEAF collector in the vent stream.
Plant B - Particulate, PPOM, and gaseous emission from
a felt saturator running 27- and 55-pound felt, and from
an asphalt blowing operation. Tests were made simultane-
ously before and after process heaters used as fume
incinerators on each process.
Plant C - Particulate, PPOM, and gaseous emissions from
an asphalt blowing operation. Tests were made simultane-
ously before and after a process heater used as a fume
incinerator.
This appendix describes the test procedures used, and the raw
data used to calculate the emissions summarized in this report.
TEST PROCEDURES
Emission testing procedures followed those described in
B.I
EPA methods 1 through 5. Method 1 was used to locate sampling
sites. The selected sites, which were at times not ideal,
are shown in Figures B-l through B-9 along with the number of
sampling points utilized at each site.
Particulate
Particulate matter was sampled isokinetically by using the
sampling trains illustrated in Figures B-10 and B-ll.
Ill
-------
L3 BYPASS STACK
L 3 EXIT STACK
i
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T
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Figure B-2. Line 1 saturator bypass stack - Plant A,
113
-------
f
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Figure B-3. Asphalt blowing inlet - Plant B.
114
-------
80
295
•41.5"
FROM
INCINERATOR
Figure B-4. Asphalt blowing outlet - Plant B.
115
-------
FROM
ASPHALT STILL
29.5"
o
72"
32"
TO
INCINERATOR
Figure B-5. Saturator inlet - Plant B,
116
-------
16
60
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INCINERATOR
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27"
1 '
1 1
c
Figure B-6. Saturator outlet - Plant B.
117
-------
00
DILUTION
AIR
OUTLET FAN
SAMPLE
PORTS
STACK
M CYCLONE
COLLECTOR
V
-« —« ~*. ~*
\ \
NO.l
1 1
VERTIC
NO. 2
AL
1 1
STILLS
NO. 3
1
N0.4
AIR
COMPRESSOR
Figure B-7. Air blowing operation - Plant C.
-------
12'
8'
o
24 SAMPLING POINTS
30 in. 10
£ oooooo ooooo
rFUME INCINERATOR
Figure B-8. Asphalt blowing inlet - Plant C.
119
-------
24 SAMPLING POINTS
30.375 in. ID
-7'4—-12' —
FAN
.STACK
Figure B-9. Asphalt blowing outlet - Plant C,
120
-------
FIBER
m.TER
NOZZLE
1,445 MODIFIED C-S IMPINCERS
243 G-S IMPINCERS
Figure B-10. Sampling Train for particulate in uncontrolled streams
-------
FILTER
K)
HEATED
GLASS
PROBE '
STACs WALL
MANOMETER
I HEATED
SECT I ON r
|
l_LO_Q_m-L_ OF WATER
THERMOMETERS
/
CALIBRATED ORIFICE
CONTROL
MANOMETER
UMBILICAL
CORD
VACUUM
GAUGE
Figure B-ll. Particulate sampling train used in controlled streams
-------
For uncontrolled emission streams, the sampling train in
Figure B-10 was used. With this train, the organic particulate
Wcis condensed in the impingers which contained water (Impingers 1,
2 and 3). The final filter was used as a back-up to ensure
complete particulate collection. After sampling, the filter was
removed and placed into a container for transfer to the laboratory,
The impinger contents were measured and placed in glass containers
for later analysis, and the entire sampling train was rinsed with
acetone and methylene chloride. These rinsings were placed into a
third container for later analysis.
For gas streams with relatively low particulate concen-
trations as found after a control device the EPA Method 5 sampling
train as shown in Figure B-ll was used. Sample recovery in this
case yielded: 1) an acetone and methylene chloride rinse of the
probe and front half of the filter holder, 2) the filter, 3) the
impinger contents, and 4) an acetone and methylene chloride rinse
of the impingers and connecting glassware. The filterable parti-
culate was considered to be that portion caught in the probe and
en the filter. Analysis consisted of drying the acetone/methy-
lene chloride fraction in a tared beaker at room temperature and
weighing the residue. The filters were desiccated and weighed.
The impinger solutions were extracted with ether and chloroform
j.n a separatory funnel. This extract was placed in tared beakers
and dried at room temperature and weighed. The remaining
:.mpinger solution was boiled to dryness and weighed. Total
particulate was the sum of these individual fractions.
123
-------
When using the EPA Method 5 train considerable seepage of
liquid organic matter through the filter occurred, and a true
breakdown between filterable and non-filterable or condensible
particulate could not be made. Also, in all cases, drying of
the collected particulate residues was a problem since the
samples continually lost weight in a desiccator. This was due
to loss of the lighter organic portions of the sample. To
prevent undue sample loss, all final sample weights were recorded
after 48 hours in a desiccator.
Polycyclic Particulate Organic Matter
Previous studies on the collection of these compounds
have shown the necessity for cooling the sample to at least
65° F. before all PPOM compounds can be collected.B'2/B'3
This was accomplished by utilizing the particulate sampling
train shown in Figure B-10, With the impingers contained in an
ice-water bath, the final filter was maintained at less than
65°F. PPOM collection was accomplished by isokinetically
traversing the ducts as required for particulate sampling. Sample
recovery consisted of three fractions: namely, the filter,
the impinger contents, and an acetone and methylene chloride rinse
of the entire train interior, up to the final filter. The samples
were kept in dark glass containers and refrigerated during
storage.
B 4
PPOM analysis consisted of the following steps: "
The used filters were soxhlet extracted for 30 hours
with methylene chloride, and the aqueous impinger solutions
were extracted four times with methylene chloride.
124
-------
These extracts were combined and reduced to a small volume
on a rotary evaporator, at which stage the acetone and
methylene chloride rinses supplied were added to the
evaporator and the whole reduced in volume. When no further
solvent could be removed, the volume remaining was approxi-
mately 20 ml of black oily liquid. One ml of this solution
was subjected to quantitative liquid chromatography on an
alumina column. Following elution of-the aliphatic hydro-
carbons with 25 ml of petroleum ether, the sample was eluted
with 50 mis of 10% methylene chloride in petroleum ether.
This latter fraction would contain the compounds of interest
that were present. This sample was evaporated with a stream
of nitrogen to a volume of about 25 Ml for further analyses.
The sample was then analyzed by gas chromatographic-mass
spectrometry using chemical ionization with methane. The
chromatographic separation was accomplished using 6 to 18
foot long, 2.5% Dexil 300 columns programmed from 240°
to 300° C at 1°C per min. A Varian 1700 chromatograph
was interfaced with a Finnigan 1015 quadruple mass spectro-
meter equipped with a System Industries 1500 data acquisi-
tion system. The total ion chromatogram was displayed on
the CRT unit. Individual ion chromatograms for the nominal
masses of the protonated molecular ions of the compounds
of interest were overlayed with this chromatogram to locate
the desired polynuclear aromatic compounds. Benzpyrenes
were quantitated by this layer chromatography and spectro-
fluorescence.
The detection limit for this procedure is on the order of
3 nanograms, and the accuracy for well defined peaks is + 10%.
ALDEHYDES
Aldehydes were collected in a solution of MBTH (3-methyl-2-
benzothiazolone hydrazone hydrochloride) contained in 2-liter
B 5
flasks. ' Samples were collected by following procedures
B 1
described in EPA Method 7. ' Analysis was performed colori-
metrically.
HYDROGEN SULFIDE
These compounds were collected in a solution of cadmium
sulfate and hydroxide contained in a set of midget impingers:
The resulting concentration was determined colorimetrically.B-6
125
-------
Gaseous Hydrocarbons and Carbon Monoxide
j^
These compounds were collected in Tedlar plastic bags
and analyzed with a flame ionization detector calibrated With
a methane/air mixture. CO was catalytically converted to CH4
in the presence of hydrogen and analyzed as CH..
TEST RESULTS
Tables B-l through B-21 contain the field data and analytical
results obtained during the studies. These data were summarized
in the body of this report.
Registered Trademark
126
-------
REFERENCES FOR APPENDIX B
B.I Federal Register, Vol. 36, No. 247, Part II, December
:>3, 1971.
B.2 Stenburg, R. L., et al., Sample Collection Techniques
::or Combustion Source-Benzopyrene Determination.
Industrial Hygiene Journal. August 1961.
B.3 Diehl, E. K., et al., Polynuclear Hydrocarbon Emission
from Coal-Fired Installations. ASME Paper 66-Pw-2. J.
of Engineering for Power, 1966.
B.4 Jones, P.W. and P.E. Strop, Analysis of Carcinogenic
PNA's from Asphalt Roofing Industry. Battelle Columbus
Laboratories, March 11, 1974, May 30, 1974 and July 18,
1974.
B.5 Selected Methods for the Measurement of Air Pollutants.
U.S. Department of Health, Education and Welfare, May
1965. Publication 99-AP-ll.
B.6 Jacobs, M.B., et al., Analytical Chemistry, 29 (9),
September 1957.
127
-------
Table B-1 SUMMARY OF PROCESS DATA FOR NUMBER 3
ROLL ROOFING MACHINE - PLANT A
Date
Test No.
Felt weight
Felt width, inches
Felt moisture, %
Felt speed, fpm
Felt, tons/hr
Saturant temperature, °F
Softening point, °F
Saturant, tons/hr
Total process wt., tons/hr
HEAF Control Device
2
Filter media speed, ft /hr
Pressure drop across HEAF and
demister, inches H_0
3/26/74
BP3-1&2
27
36
3.5
350-400b
1.85
427
105-115
2.66
4.51
48.5
20.5
3/27/74
L3-1&2
27
36
3.7
350-400b
1.77
426
105-115
2.52
4.29
New Design
48.5
20.5
3/28/74
BP3-3&4 L3-:
27
36
3.4
350-400b
1.80
431
105-115
2.60
4.40
48.5
20.5
a' Pounds per 480 sq. ft.
Felt rate determined by plant personnel
128
-------
Table B-2 SUMMARY OF PROCESS DATA FOR NUMBER 1
SHINGLE MACHINE - PLANT A
Date
Tes.t No.
Felt weight
Felt width, inches
Felt moisture, %
Fe!.t speed, fpm
Fe!i.t, tons/hr
Saturant temperature, °F
So::tening point, °F
Sazurant, tons/hr
Total process wt., tons/hr
HEAF Control Device
Filter media speed, ft /hr
Pressure drop across HEAF and
demister, inches of H_0
3/26/74
Ll-1 to 4
55
48
3.4
350
5.69
435
120-130
10.25
15.94
New
47.1
27.0
3/27/74
BP1-1 to 4
55
48
3.1
h
-440°
5.78
435
120-130
10.25
16.03
Design
47.1
27.0
a)
b)
Pounds per 480 sq. ft.
Felt rate determined by plant personnel
129
-------
Table B-3 DATA SUMMARY FOR ASPHALT SATURATOR - PLANT A, Line 3 (27 Ib. felt)
Run Number
Date, 1974
Volume of Gas Sampled - DSCFa
Average Stack Temperature - °F
Percent Moisture by Volume - %
Stack Volumetric Flow Rate - DSCFMb
Stack Volumetric Flow Rate - ACFM°
Percent Isokinetic
Particulate - Filterable Catch
milligrams
gr/DSCFd
gr/ACF
Ib/hr
Ib/ton of felt
Particulate - Total
milligrams
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of felt
BP3-1
BP3-2
BP3-4 BP3-3
Uncontrolled
3/26
79.936
140
0.83
33,605
33,886
95.6
_
-
-
1206.3
.233
.200
67.1
36.3
3/26
80.184
140
1.08
34,018
34,388
94.8
_
-
-
629.0
.121
.104
35.3
19.1
3/28 3/28
83.435 77.428
130 131
1.44 0.90
33,114 32,834
33,598 33,133
101.3 102.9
_
-
-
o en
a w
291.9
..0540
.047
15.3
8.51
L3-1
L3-2
L3-4
L3-3
Controlled
3/27
102.284
154
1.12
29,012
29,341
99.4
11.3
.00170
.00144
.423
0.24
139.2
.021
.0177
5.22
2.95
1.22
3/27
107.214
146
1.16
30,316
30,673
99.8
24.8
.00356
.00305
.927
0.52
109.7
0.0158
0.0135
4.10
2.31
0.96
3/28
104.515
135
1.07
30,533
30,862
96.6
8.6
.00126
.00109
.332
0.18
145.5
0.0215
0.0185
5.62
3.12
1.28
3/28
102.776
135
1.00
29,436
29,734
98.5
2 8
CU H
U)
o
a) Dry standard cubic feet at 70°F, 29.92 in Hg.
b) Dry'standard cubic feet per minute at 70°F, 29.92 in Hg.
c) Actual cubic feet per minute.
d) Grains per dry standard cubic foot.
-------
Table B-4 DATA SUMMARY FOR ASPHALT SATURATOR - PLANT A, Line 1 (55 Ib. felt)
Run Number
Date, 1974
Volume of Gas Sampled - DSCFa
Average Stack Temperature - °F
Percent Moisture by Volume - %
Stack Volumetric Flow Rate - DSCFMb
Stack Volumetric Flow Rate - ACFMC
Percent Isokinetic
Particulate - Filterable Catch
milligrams
gr/DSCFd
gr/ACF
Ib/hr
Ib/ton of felt
Particulate - Total
milligrams
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of felt
BP1-1
BP1-2
BP1-4
BP1-3
Uncontrolled
3/27
21713
165
2.4
29,806
30,539
-
-
48. 4e
0.275
0.223
68.7
12.1
3/27
89.050
158
1.08
29,825
30,151
98.1
-
-
1845.1
0.32
0.26
81.7
14.1
3/27
93.792
171
1.02
30,394
30,707
101.4
'
-
824.7
0.136
0.112
35.4
6.11
3/27
91.964
176
1.75
29,184
29,704
103.5
5S H
O W
On W
O. H
Ll-1
Ll-2
Ll-4
Ll-3
Controlled
3/26
82.678
178
1.18
30,415
30,777
99.9
17.2
.00321
.00258
0.836
0.15
366. T
0.068
0.055
17.8
3.1
3/26
84.982
180
1.05
31,139
31,471
100.3
16.7
.00303
.00244
0.809
0.14
439.8
0.080
0.064
21.3
3.8
3/26
69.230
174
1.40
26,591
26,970
95.7
76.2
.01698
.01378
3.871
0.68
302.2
0.067
0.055
15.3
2.7
3/26
82.879
174
1.02
29,950
30,260
101.7
S H
,O W
Ou U
0. H
a) Dry standard cubic feet at 70°F, 29.92 in Hg.
b) Dry etandard cubic feet per minute at 70°F, 29.92 in Hg.
c) Actual cubic feet per minute.
d) Grains per dry standard cubic foot.
e) Based on data obtained during particle sizing run
-------
Table B-5 PPOM EMISSIONS-SATURATOR - PLANT A
(Net weight in sample, micrograms)
u>
ro
Compound
Benz (c) phenanthrene
7 , 12-Dimethylbenz
(a) anthracene
Benz (e) pyrene
Benz (a) pyrene
3-Methylchol-
anthrene
Dibenz (a,h) pyrene
Dibenz (a, i) pyrene
Test LI- 3
3/26/74
0.78
0.23
0.58
0.12
0
0.06
0
Test BP1-3
3/27/74
1.3
0.91
0.88
0.66
1.00
0.50
0.50
Test L3-3
3/28/74
0.075
0.065
0.035
0.130
0.070
0
0
Test BP3-3
3/28/74
0.15
0.065
0.05
0.20
0.115
0
0
NOTE: BP test numbers designate uncontrolled emissions.
-------
Table B-6 GASEOUS EMISSION DATA
ASPHALT SATURATOR - PLANT A
Compound
HCa
CO
CHOHb
HCa
CO
CHOHb
Uncontrolled
Line
58 ppm
614
2.39
4.80
Line
43 ppm
512
3.3
2.9
Controlled
1
79 ppm
410
2.46
0.69
3
71 ppm
466
2.5
2.2
a) Total gaseous hydrocarbons expressed as CH
b) Total aldehydes expressed as formaldehyde.
NOTE: H~S not detectable in any sample.
133
-------
Plant B
Table B-7 PROCESS DATA FOR FELT SATURATOR-ROLL ROOFING
Test No.
Felt
Felt Weight3
Felt Width, inches
Felt moisture, %
Felt speed, fpm
Felt rates, tons/hr
Saturant temp. , °F
Softening point, °F
Saturant, tons/hr
Total process wt., tons/hr
Afterburner Control Device
1 & 2
27
36
7
251
1.27
450
130-150
1.90
3.17
3 & 4 (PPOM)
27
36
7
326
1.65
455
130-150
2.47
4.12
5 & 6
27
36
7
340
1.72
448
130-150
2.58
4.3
Fuel rate 71 gal/hr of
Inlet temp. , °F
Outlet temp. , °F
175
1200
#2 fuel oil = 10.3 X 106 BTU/hr
175
1200
175
1150
a) Pounds per 480 sq. ft.
134
-------
Plant B
Table B-8 PROCESS DATA FOR FELT SATURATOR-SHINGLE LINE
Test No.
Felt
Felt Weight3
Felt Width, inches
Felt mo.Lsture, %
Felt sp<;ed, fpm
Felt, tons/hr
Saturanl: temp. , °F
Softening point, °F
Saturanl:, tons/hr
Total process wt., tons/hr
Afterburner Control Device
9 & 10
51.5
48
6.5
277
5.35
440
130-150
8.83
14.18
Fuel rate 71 gal/hr #2
Inlet temp. , °F
Outlet temp. , °F
175
1100
11 & 12
51.5
48
6.5
317
6.12
445
130-150
10.10
16.22
13 & 14 (PPOM)
51.5
48
6.5
180
3.48
460
130-150
5.24
9.22
fuel oil - 10. 3x 106 BTU/hr
175
1250
175
1200-550
a) Pounds per 480 sq. ft.
135
-------
Table B-9 PROCESS DATA FOR ASPHALT BLOWING - PLANT B
Plant
B
Location
Test No.
Still No.
7 & 8
1
Quantity of Asphalt, gallons
Charged 17,920
After Blowing
Still Temp. °F
Date May 10 & 14, 1974
Observer DeWees
15 & 16
1
17,920
17 & 18
1
17,920
Middle
450-490
450-480 450-490
Air Blowing Pressure, psig
Blowing Time, minutes
Product Asphalt
Melt Point, °F
Afterburner
Fuel Rate/#2 oil gal/hr
Inlet Temp. °F
Outlet Temp. °F
291
247
254
223
45
132
53
300
1000
53
325
1000
53
270
1000
136
-------
c er<
Table B- 10. DATA SUMMARY FOR ASPHALT SATURATOR - PLANT B
Run Number
Date, 1974
Volume of Gas Sampled - DSCFa
Average Stack Temperature - °F
Percent Moisture by Volume - %
Stack Volumetric Flow Rate -
DSCFMb
Stack Volumetric Flow Rate -
ACFMC
Percent Isokinetic
Particulate - Filterable Catch
milligrams
gr/DSCF
gr/ACF
Ib/hr
Particulate - Total
milligrams
gr/DSCF
gr/ACF
Ib/hr
Uncontrol led
1
5/7
89.670
187
1.4
9905
12,272
991
2626.6
0.452
0.365
33.4
5
5/8
100.12
198
1.6
10,761
13,525
101.8
2219.6
0.342
0.272
31.6
a
5/13
103.878
141
3.8
10,769
12,700
98.7
1854.4
0.295
0.250
27.2
11
5/13
77.353
153
3.5
8317
9962
101.8
2384.7
0.478
0.397
33.9
Controlled
2
5/7
92.110
546
3.1
16,114
31,504
105.0
153.8
0.0262
0.0134
3.62
695.0
0.119
0.0607
16.4
c 1
5/8
98.298
541
3.4
17,040
33,139
107.9
185.2
0.0291
0.0150
4.25
637.3
0.100
0.0514
14.6
in 1
5/13
89.032
555
1.7
16,932
32.913
98.3
359.5
0.0623
0.0321
9.04
703.9
0.122
0.0628
17.7
10
5/13
87.365
950
3.0
13,684
37,478
119.4
101.4
0.0179
0.0065
2.10
450.1
0.0795
0.0290
9.3
u>
-------
Table B-ll. DATA SUMMARY FOR ASPHALT SATURATOR - PPOM TESTS PLANT B
Run Number
Date, 1974
Volume of Gas Sampled - DSCFa
Average Stack Temperature - °F
Percent Moisture by Volume - %
Stack Volumetric Flow Rate - DSCFM^
Stack Volumetric Flow Rate - ACFMC
Percent Isokinetic
PPOM Compounds, micrograms
Ben z ( c ) phenanthr ene
7 , 12-Dimethy Ibenz (a) anthracene
Benz(a)pyrene + Benz (e) pyrene
Dibenz (a,h) pyrene
Dibenz (a, i) pyrene
Uncontrolled
3
5/8
93.491
168
1.5
10,266
12,305
99.7
2.2
2.3
—
—
—
13
5/13
86.895
162
3.3
9206
11,183
103
0.85
0.85
0.30
0.15
0.15
Controlled
4
5/8
99.907
535
2.9
18,006
34,604
104
0.9
0.55
12.0
0.45
0.45
14
5/13
98.736
553
4.9
16,041
32,180
102
1.2
0.3
0.009
0.003
0.003
U)
00
a) Dry standard cubic feet at 70°F, 29.92 in. Hg.
b) Dry standard cubic feet per minute at 70°F, 29.92 in. Hg.
c) Actual cubic feet per minute.
-------
Table B-12. DATA SUMMARY FOR ASPHALT BLOWING - PLANT B
u>
ID
Run Number
Date, 1974
Volume of Gas Sampled - DSCFa
Average Stack Temperature - °F
Percent Moisture by Volume - %
Stack Volumetric Flow Rate -
DSCFMa
Stack Volumetric Flow Rate -
ACFMC
Percent Isokinetic
Particulate - Filterable Catch
milligrams
gr/DSCFd
gr/ACF
Ib/hr
Particulate - Total
milligrams
gr/DSCF
gr/ACF
Ib/hr
Uncont rol led
7
5/10
113.099
308
19.5
2212
3987
113
82280.1
11.227
6.216
212.8
17
5/14
34.923
263
5.1
3237
4642
83
659.0
0.291
0.203
8.1
15
5/14
106.449
323
20.8
2613
4869
107
EH
CO
53 W
O E-<
PM
Pn
Controlled
8 18 16
5/10
201.265
931
8.5
10,272
29,322
103
332.0
0.0255
0.0089
2.24
1298.4
0.0995
0.0349
8.765
5/14
30.068
950
11.5
10,207
30,402
97.1
459.8
0.236
0.0792
20.65
832.8
0.427
0.143
37.4
5/14
183.41
950
6.9
10,319
29,241
97.7
EH
CO
s w
0 EH
CU
O4
a) Dry standard cubic feet at 70°F, 29.92 in Hg.
b) Dry standard cubic feet per minute at 70°F, 29.92 in Hg.
c) Actual qubic feet per minute.
d) Grains per dry standard cubic foot.
-------
-Table B-13 . PPOM EMISSIONS ASPHALT BLOWING ^ PLANT B
(net weight in sample, micrograms)
Compound
Benz (c) phenanthrene
7 , 12-Dimethylbenz (a) anthracene
Benz (a)pyrene + Benz (e)pyrene
Dibenz (a,h) pyrene
Dibenz (a , i ) pyrene
Test No. 15
Inlet
5/14/74
57.0
6.6
42.0
8.5
8.5
Test No. 16
Outlet
5/14/74
4.1
--
1.3
2.1
2.1
140
-------
Table B- 14 GASEOUS EMISSION DATA - PLANT B
Test Number
Saturator
1 Inlet
2 Outlet
3 Inlet
4 Outlet
5 Inlet
6 Outlet
9 Inlet
10 Outlet
11 Inlet
12 Outlet
13 Inlet
14 Outlet
Asphalt Blowing
7 Inlet
8 Outlet
15 Inlet
16 Outlet
17 Inlet
18 Outlet
CO
ppm
2.3
2.4
6.8
4.7
36
70
15
-
192
40
-
—
179
1018
4
3
3
4
Gaseous HC
ppm
800
300
970
240
180
360
310
— -•
340
330
-
•
5900
410
5400
850
3090
1150
141
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Table B-15. PROCESS DATA FOR ASPHALT BLOWING - PLANT C
Plant
Plant C
Date 3/1/74
Location Cincinnati
Observer
Test #1
DeWees
Still No. 3
Quantity of Asphalt, gallons
Charged 3980 A oil @ 370; 10160 D oil @ 380 = 14140 gallons
0 Ikr
(START TUT)
TIK
4hr Shr
(COOUTE TEST)
Air Blowing Rate 1500 CFM @ 5 psi
Blowing Time, minutes 300 = 5 hours
Product Asphalt Coating ; Melt Point, °F 200-270
Afterburner - U.I.P. Eclipse Burner Model 42 Fl-capacity
15 million BTU/hour.
Fuel Rate - could not determine (firebox at 1200 °F)
Inlet Temp., °F 180
Outlet Temp., °F 740
No Visible Emissions
142
-------
Table B-lf.. (continued) . PROCESS DATA FOR ASPHALT BLOWING - PLANT C
Plant
Plant C
Date
3/5/74
Location
Cincinnati
Observer
Test #2
DeWees
Still No. 3
Quantity of Asphalt, gallons
Cha::ged 3980 A oil @ 370; 10160 D oil @ 380 = 14140 gallons
(00.
•JTILL BOTTOM
TEMPERATURE
400
B 100
TEWtRATURE
STILL I)
0 Ihr
(STMT TEST)'
tor ttr
(COMPUTE TOT)
TIK
Air Blowing Rate 1500 CFM @__5__psi
Blowing rime, minutes 133 =2.22 hours
Product Asphalt Saturant; Melt Point, °F 130
Afterburner - U.I.P. Eclipse Burner Model 42 Fl-capacity
15 million BTU/hour.
Fuel Rate - could not determine (firebox at 1200 °F)
Inlet Tenp., °F 160-240
Outlet Temp., ?F 660-700
No Visible Emissions
143
-------
Table B-15. (continued). PROCESS DATA FOR ASPHALT BLOWING - PLANT C
Plant
Plant C
Date
3/6/74
Location
Cincinnati
Still No. 4, 3
Quantity of Asphalt, gallons
Observer_
Test #3
DeWees
Charged 3980 A oil and 10160 D oil #4(for 40min.); 13500 A oil #3
Average charge blown = 13,700 gallons
500
u.
P 400
£
X
g 30°
w
l-
g ?00
.. 100
0
{
1
^fitftf^
±$£^
•
1
j
i '
i
1 u
i
Yj
5
ITILL 14
STIU BOTTOM
I
1
1
i!. ,.,!
7
/
i
1
STILL
^
STILL TOP
TEMPERATURE
1
'
n
-
i
Ihr Zhr Ihr
STWT TEST) (OKini TfST)
TINE
Air Blowing Rate 1500 CFM @ 5 psi
Blowing Time, minutes 127 =2.1 hours
Product Asphalt Saturant; Melt Point, °F 130
Afterburner - U.I.P. Eclipse Burner Model 42 Fl-capacity
15 million BTU/hour.
Fuel Rate - could not determine (firebox at 1200 °F)
Inlet Tenp., °F 225-180
Outlet Temp., °F 705
No Visible Emissions
144
-------
Table B-15. (continued). PROCESS DATA FOR ASPHALT BLOWING - PLANT C
Plant
Plant C
Date 4/5/74
Location
Cincinnati
Observer
Test #4
DeWees
Still No. 3
Quantity of Asphalt, gallons
Charcied 3980 A oil @ 370; 10160 D oil @ 380 = 14140 gallons
100
400
BOTTOM
WTURE
n
STIU TOP
TtMPCRATUtf
100
200
100
0 Ihr
(SUIT TOT)
»r Jhr
(uvim TOT)
me
Air Blowir.g Rate 1500 CFM @_5__psi
Blowing Time, minutes 135 = 2.25 hours
Product Asphalt Coating . Melt Point, °F 200-270
Afterburner - U.I.P. Eclipse Burner Model 42 Fl-capacity
15 million BTU/hour.
Fuel Rate - could not determine (firebox at 1200 °F)
Inlet Temp., °F 170
Outlet Temp., °F 550
No Visible Emissions
145
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Table B-16.. DATA SUMMARY FOR ASPHALT BLOWING - PLANT C
Run Number
Date, 1974
Volume of Gas Sampled - DSCFa
Average Stack Temperature - °F
Percent Moisture by Volume -
Stack Volumetric Flow Rate - DSCFMb
Stack Volumetric Flow Rate - ACFMC
Percent Isokinetic
Particulate - Filterable Catch
milligrams
gr/DSCFa
gr/ACF
Ib/hr
Particulate - Total
milligrams
gr/DSCF
gr/ACF
Ib/hr
Uncontrolled
1
3/1
121.208
211
17.4
2341
3623
114
27979
3.56
2.31
71.5
2
3/5
74.982
206
16.9
1962
3004
110
7221.7
1.49
0.967
25.0
3
3/6
79.853
202
18.2
2072
3210
116
10669
2.06
1.33
36.6
4
4/5
85.572
169
14.3
2313
3328
109
EH
W
s w
O H
Controlled
1
3/1
219.889
736
7.0
10334
25159
95.8
286.2
0.020
0.0083
1.78
1765.4
0.124
0.051
10.97
2
3/5
87.762
696
7.9
9750
23580
96.2
36.1
3
3/6
89.480
705
8.6
9551
23291
100.1
32.4
.0063 0.0056
.0026 (
0.53
131.5
0.023
.0096
1.93
K0023
0.457
143.0
0.247
0.101
2.02
4
4/5
106.373
544
5.9
12030
24450
94.9
1^
a) Dry standard cubic feet at 70°F, 29.92 in Hg.
b) Dry standard cubic feet per minute at 70°F, 29.92 in Hg.
c) Actual cubic feet per minute.
d) Grains per dry standard cubic foot.
-------
Taole B-17. PPOM EMISSIONS ASPHALT BLOWING - PLANT C
(net weight in sample, micrograms)
Compound
Benz (c) phenanthrene
7, 12-Din;ethylbenz
(a) anthracene
Benz (e) pyrene
Benz (a) pyrene
3-Methylchol-
anthrene
Dibenz (a,h) pyrene
Oibenz (a , i) pyrene
Test 4
Inlet
4/5/74
18
11
0.4
1.0
Test 4
Outlet
4/5/74
0.3
8.5
3.1
1.2
0.865
0.07
0.07
147
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Table B-18. GASEOUS EMISSION DATA - PLANT C
Test Number
1 Inlet
1 Outlet
2 Inlet
2 Outlet
3 Inlet
3 Outlet
4 Inlet
4 Outlet
CO
ppm
358, 416
497
416, 428
416, 8933
532, 7669
3351, 9106
210
1436
Gaseous HCa
ppm
6733
656
Aldehydes
ppm
0.6, 14.2
3.65, 15.1
V
ppm
<0.02
0.7, 0.3
<0.02
0.1
-
a) Expressed as methane
b) Expressed as formaldehyde
148
-------
TECHNICAL REPORT DATA
(Please read Inunctions on the reverse before completing}
1. REPORT NO. ,
EPA-650/2-74-101
2.
3. RECIPIENT'S ACCESSION-NO.
4. TITLE AND SUBTITLE
Atmospheric Emissions from Asphalt Roofing
Processes
5. REPORT DATE
October 1974
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
8. PERFORMING ORGANIZATION REPORT NO.
R.W. Gerstle
D. PERFORMING ORGANIZATION NAME ANO ADDRESS
PEDCo-Environmental, Inc.
Atkinson Square (Suite 13)
Cincinnati, Ohio 45246
10. PROGRAM ELEMENT NO..
1AB015; ROAP 21AXM-011
11. CONTRACT/GRANT NO.
68-02-0237 (Task 30) and
68-02-1321 (Task 15)
12. SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
NERC-RTP, Control Systems Laboratory
Research Triangle Park, NC 27711
ERIOD COVERED
14. SPONSORING AGENCY CODE
18. SUPPLEMENTARY NOTES
16. ABSTRACT
Asphalt roofing manufacturing processes and the types of air pollution
control devices applied to them are described. Quantitative data on
controlled and uncontrolled particulate and gaseous emissions, including
polycyclic compounds, from the asphalt blowing and felt saturating
processes are provided. Information on plant locations, production
rates, and industry growth is included. Total uncontrolled particulate
emissions from felt saturating, consisting largely of organic partic-
ulate compounds, averaged from 3.9 to 8.7 Ib per ton of saturated felt;
CO and gaseous hydrocarbons were also emitted. Control devices reduced
these emissions by about 50%. Seven identified polycyclic organic
compounds accounted for 0.0003% of the particulate matter both before
and after control. Particulate matter was mostly smaller than 1 micron.
For asphalt blowing operations controlled by fume incineration, par-
ticulate emissions amounted to 0.3 to 3.1 Ib per 1000 gal. (0.075 to
0.79 Ib per ton) of asphalt; polycyclic organic matter ranged between
O.OOD8 and 0.0019% of the total particulate; CO and gaseous hydrocarbons
are .jlso emitted. These data indicate that a well-operated plant
equipped with available control devices does not have a major impact on
ambient air concentrations.
7.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS C. COS AT I Field/Group
Air Pollution
Asphalt Plants
Roofing
Polycyclic Compounds
Carbon Monoxide
Hydrocarbons
Gases
Air Pollution Control
Stationary Sources
Polycyclic Organic Mat-
ter
Particulates
Felt Saturation
13B, 07D
13H
13C
07C
07B
8. DISTRIBUTION STATEMENT
Unlimited
19. SECURITY CLASS (ThisReport)
Unclassified
21. NO. OF PAGES
159
20. SECURITY CLASS (Thispage)
Unclassified
22. PRICE
EPA Form 2220-1 (9- '3)
149
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