Professional Documents
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Norlite Dust Plan
Norlite Dust Plan
Prepared for:
Norlite, LLC
A Division of Tradebe Environmental Services, LLC
October 2014
Prepared by:
Note that superscripted numbers relate to an equivalent numbered reference in Section 11.0 References of
this Plan.
NYSDEC issued an Order on Consent (R4-2000-0420-27) in July 2000, requesting Norlite re-evaluate the
existing Plan to ensure it was being properly implemented and to include any recommendations for
revisions to the Plan to address new emission sources or changes in operations. Sci-Tech, Inc., on
Norlite’s behalf, submitted a Fugitive Dust Control Evaluation report, dated August 18, 2000, to
NYSDEC. After a NYSDEC August 31, 2001, comment/response letter; a NYSDEC October 30, 2001,
bucket loader procedure letter; and a NYSDEC November 26, 2001, bucket loader procedure revision
letter (all responses to the August 18, 2000, report), Norlite included a 2002 Addendum to their Plan.
This 2002 Addendum included a December 14, 2001, letter from Sci-Tech, Inc., which addressed the
2000 Evaluation results. In 2002, the results were revised or additional controls were recommended at the
facility to further control fugitive dust emissions, including the implementation of recommendations from
the 1995 Plan update. Sketches of various proposed control changes around the facility are part of this
2002 Addendum, along with copies of NYSDEC correspondence with Norlite. A December 31, 2002,
letter from Sci-Tech, Inc. was included at the end of the 2002 Addendum to confirm a recent inspection of
the facility verified that the changes from the December 14, 2001, letter were implemented. None of
these letters or addenda included a recalculation of fugitive dust emissions to account for changes to the
facility or process modifications to reduce potential dust emissions. As in 1995, the 2002 and 2010
Addenda did not include re-calculations of estimated fugitive dust emissions.
The 2010 Addendum, with a detailed photograph log, includes a February 9, 2011, letter from Norlite to
NYSDEC in response to NYSDEC not approving the July 16, 2010, Fugitive Dust Plan Addendum
submittal. The Addendum itself discusses additional changes that were made at the facility since the
2002 Addendum, including the 2007 addition of a lightweight fines wind screen, control methods used for
the block mix processing area, and the discussion of road watering at the Southern Overburden Storage
Area to reduce potential dust emissions.
The Norlite facility, which was acquired by Tradebe Environmental Services, LLC (Tradebe) on April 15,
2011, was inspected by the NYSDEC in early 2012 and a Notice of Violation (NOV) letter was issued on
May 9, 2013. As part of this NOV letter, NYSDEC requested upgrades to the facility’s Fugitive Dust Plan
due to purported inadequacies in the existing plan and Addenda. Norlite retained the services of SPEC
Engineering, PLLC to reanalyze dust sources at the facility. This report describes SPEC’s analysis of the
site and presents the results of the current study.
Title 40 - Protection of Environment Subpart EEE - National Emission Standards for Hazardous
Air Pollutants from Hazardous Waste Combustors
Title 40 - Protection of Environment. Chapter I - Environmental Protection Agency Subchapter C
- Air Programs Part 63 - National Emission Standards for Hazardous Air Pollutants for Source
Categories
New York State NYCRR Chapter III, all applicable subparts
New York State NYCRR Part 211
US EPA AP-42, Chapter 13
US EPA-450/3-77-010 Technical Guidance for Control of Industrial Process Fugitive Particulate
Emissions (1977)
US EPA-450/2-92-004 Fugitive Dust Background Document and Technical Information
Document For Best Available Control Measures (1992)
From AP-42, Chapter 13 defines Fugitive Dust as atmospheric dust that arises from the mechanical
disturbance of granular materials exposed to the air that is not discharged to the atmosphere in a confined
flow stream. AP-42 goes on to state that common sources of fugitive dust include unpaved roadways,
agricultural tilling operations, aggregate storage piles, and heavy construction operations. Norlite
currently has an active quarry operation and lightweight aggregate manufacturing and processing facility
on-site. Sources of fugitive dust across Norlite’s facility are consistent with the AP-42 definition of
fugitive dust and its potential sources.
The purpose of this Fugitive Dust Plan is to provide a review of current aggregate processes, potential
fugitive dust emission sources, and existing fugitive dust control practices at the Norlite facility. The
current review project, culminating in this Fugitive Dust Plan, is a continuation of work started in 1990,
continued in 1995 and supplemented in 2002 and 2010. The review project brings the current Plan into
general compliance with AP-42 guidance standards for calculating and estimating potential fugitive dust
sources. The facility review conducted and descriptions provided in this current Plan present an account
of the facility and aggregate processing for current, existing operations only and does not address past
practices or future conditions should processes change. When calculations are presented in this review,
the input data for which each formula/calculation is based is derived from historic averages over the past
five years (2009-2013). Previous fugitive dust plans are retained for reference purposes and are available
at the facility for review.
The storage and handling of the raw materials and products, as well as vehicular traffic throughout the
site, result in the potential for the emission of fugitive dust, as defined in AP-42, Chapter 13.
Particle size – Particle size affects the threshold velocity because particle size is correlated with
particle weight. Larger, and therefore heavier, particles require more force in order to become
airborne. Particles that are 75 microns or smaller are generally considered to be suspendable in air
due to wind because silt is typically considered to be particles that are 75 micros or smaller, silt
content is often used in calculations for fugitive dust emissions.
Moisture content – Higher moisture content of material correlates to stronger cohesive forces
between particles. Therefore, materials with high moisture content are less likely to produce
fugitive dust emissions. Conversely, when the material moisture content is low, cohesive forces
are reduced and dust emission potential increases.
Surface crust – If a material storage pile has a natural or man-made crust on its outer surface, the
cohesive forces between surface particles is stronger and less material is released into the air by
wind erosion.
Wind speed – Wind speed is a significant variable for dust emissions due to wind erosion. Dust is
generated only if the wind speed is high enough to dislodge dust particles from aggregate storage
piles by the processes described above.
The following factors affect dust emissions that result from vehicles traveling on facility roadways:
Vehicle speed – Higher tire speeds result in greater forces being exerted upon surface dust
particles. Higher speeds also result in greater turbulence in the “wake” zone around the vehicle.
The following factors affect dust emissions that result from material handling.
Material silt and moisture content – As with wind erosion and vehicle re-entrainment, material
silt and moisture content have an effect on the amount of dust generated.
Drop height of the material – Greater drop heights result in greater potential dust emissions
because of greater impact force and because the material is subject to windstripping for a longer
period of time.
Quantity of material being handled – Potential fugitive dust emissions increase as more material
is handled.
Windbreaks – Porous windbreaks are able to reduce wind speed. Trees and shrubs are examples
of natural windbreaks. Windscreens are an example of artificial windbreaks and the use of an
artificial windbreak allows for porosity control.
Keeping a product, and therefore dust, contained to its source can prevent dust emissions from vehicle re-
entrainment. This means that reducing dust emissions from storage piles and material handling can
indirectly reduce the dust emissions from vehicle re-entrainment on roadways close to storage areas.
Broom sweepers, vacuum sweepers, or flushing are methods that can be used to remove dust particles
from paved road surfaces. Coarse aggregate placed on roadways helps reduce dust from unpaved
surfaces.
Road emissions can also be reduced by reducing vehicle loads and reducing the number of vehicles using
the roads. Paving, gravel, and chemical stabilizers can also be used for unpaved roads.
5.5 Roads
5.5.1 Closing Saratoga Street Entrance to Heavy Vehicles
Since the 1990 Plan, heavy vehicles are no longer allowed to enter the facility from the Saratoga Street
entrance and are exclusively using the Elm Street entrance. There are defined, dedicated roads for large
equipment travel at the facility. All LGF and aggregate trucks enter and exit from the Elm Street entrance
(Gate 1) on the south-western portion of the facility. These actions moved all heavy traffic away from the
residences on the eastern border of the facility and cut down on the potential distance (in miles) heavy
traffic may travel on the facility. Cutting down on miles traveled by heavy vehicles helps mitigate the
potential fugitive dust emissions at the facility.
5.6 Conveyors
5.6.1 Covers on Conveyors
Covers were added to conveyors at the facility to shield material from wind erosion and particulate
entrainment.
5.7 Trees
5.7.1 Tree Barrier
As of the 1995 Plan Update, a tree line has been added to the eastern side of the facility to mitigate
fugitive dust near a neighboring residential area.
5.8 Baghouses
5.8.1 Elimination of Baghouse Dust Pile and Transfer Points
Since the 1995 Plan Update, Norlite no longer collects dust from baghouses onto an open pile, and any
related activities, such as loading onto trucks and on-site open transport, no longer occur.
Eliminating coal use at the facility removed 1,500 tons of coal storage on-site, as well as the processing
equipment.
Quarry (QA)
Primary (PR)
Kiln Feed (KF)
Kiln (KL)
Finish Plant (FP)
Fines Processing (FN)
Block Mix (BM)
Boneyard (BY)
Southern Overburden Storage (OS)
Island (IS)
Roads (RD)
The current operations at the Norlite facility are summarized in the flowcharts presented in this report as
Sheets 1 through 11 in Appendix B. The flowcharts are organized into the above areas and show the
material flow through each area along with fugitive dust emission points, identified by unique source ID
numbers. Figures 2 through 12 in Appendix A show the geographical locations of the emission points on
a series of aerial photographs.
Information on operations in each area and their associated controls is based on site visits by SPEC and
on conversations with facility employees. Information on each fugitive dust emission source, including
existing controls and estimated annual emissions, can be found in the summary table in Section 9.0
below, as well as in Appendix C. A photo log that points out each emission source through a series of
photographs is included as Appendix E.
In addition to the mining operations in the rock quarry itself, overburden stripping occurs in order to
expose new shale areas for mining. The overburden material, which consists primarily of clay and sand, is
stripped using bulldozers and front end loaders, loaded onto haul trucks, and transported to the Southern
Overburden Storage Area. In this operation, three to four haul trucks make 30 to 40 trips hauling
overburden from the quarry to the Southern Overburden Storage Area.
Fugitive dust emission sources in the Quarry Area include drilling, blasting, overburden stripping, and
handling of raw material shale and overburden.
The crushers in the Primary Area typically run only during the week, although they will run for 2 to 3
hours on Saturdays if the need arises. When the Primary Area is active, the crushed raw shale is taken
directly from the kiln feed pile that forms at the output of the crushers. Otherwise, the crushed raw shale
from the Canal stockpile is used to feed the kilns. It should be noted that up to 15% of the material
introduced to the primary crusher can be rejected and is put back through the crusher for reprocessing.
Fugitive dust emissions sources in the Primary Area include the jaw crusher, double deck screen, cone
crusher, conveyor belts, material transfer points, material stockpiles, and material handling by front end
loaders.
At the end of the #4 conveyor, the material is dropped onto the #5 conveyor and then onto the kiln feed
storage pile. A drop point exists underneath the kiln feed storage pile, giving the pile a concave shape that
keeps pile height to a minimum.
From the drop point underneath the kiln feed storage pile, the raw shale is transferred onto two
underground conveyors (Kiln 1 feeder belt and Kiln 2 feeder belt), each feeding one of the two kilns. The
raw shale is transported to Kiln 1 via a total of three conveyors (Kiln 1 feeder belt, Kiln 1 lower belt, and
Kiln 1 top belt), while the raw shale is transported to Kiln 2 using four conveyors (Kiln 2 feeder belt, Kiln
2 lower belt, Kiln 2 middle belt, and Kiln 2 top belt). The feeder belts are completely underground and the
The raw shale is fed into the back end of the kilns by AccuRate feeders, which also have dust covers,
acting as partial enclosures. From this point the shale passes through a chute into each kiln, respectively.
The material is heated inside the kiln to 2000°F to 2100°F and then transferred to the clinker coolers. It
then exits the clinker coolers and is added to the clinker piles near the Finish Plant Area. The double seal
rim seals at the back of the kilns are typically cleaned out once a day. This is done through a hopper on
the underside of the back end of the two kilns. This hopper is connected to both seals and has a hinged
chute door. When the door is opened, rim seal dust drops onto the ground and Norlite personnel manually
move it to the muck pile for later reincorporation into the product stream. See Appendix G for an
engineering drawing of the chute and seal system.
Fugitive dust emission sources in the Kiln Feed Area include conveyor belts, material transfer points, the
kiln feed storage pile, and maintenance work, including cleaning out the rim seals and the use of vacuum
trucks to clean out baghouse plugs.
When crushed raw shale is added to the #4 conveyor from the Canal pile, water is added to the #4 belt as
a method of dust suppression. This is due to the fact that the material dries out while being stored in the
Canal pile and therefore has the potential to generate dust. Water is not added to the #4 belt when crushed
raw shale is taken directly from the kiln feed pile because the material in that pile is already wet from the
water sprayers in the Primary Area. Operators may add water if this pile is excessively dry.
A pile height sensor that hangs down from the metal overhang triggers an alarm light at the top of the kiln
feed storage pile to alert facility personnel to stop feeding the kiln feed storage pile. Keeping the pile from
overflowing aids in controlling potential fugitive dust by keeping pile height to a minimum.
Both of the kiln feeder belts that transport material from the kiln feed storage pile are located
underground, which significantly reduces dust emissions. The Kiln 1 lower belt and Kiln 2 lower belt are
both partially located underground, with dust covers over the conveyors after they transition to an area
aboveground. Additionally, the entrance to the underground enclosure for the feeder and lower belts is
covered in a “meat-locker style” curtain to prevent dust from escaping the enclosure. All conveyor-to-
conveyor drops in the Kiln Feed Area are conducted through chutes, which also reduces potential dust
emissions.
After the material goes through the kilns and clinker coolers, it is transferred onto conveyors (Kiln 1
clinker belt or Kiln 2 clinker belt) and deposited onto clinker piles (Kiln 1 clinker pile or Kiln 2 clinker
pile). The drop point between each kiln and conveyor, which ends underground, exists on the outside of
the kiln building and is open to the outside. This transfer point contains a grizzly and can be seen in
Figure 6.
A front end loader is used to transfer clinker from the Kiln 2 clinker pile onto the Kiln 1 clinker pile.
From there, it is transferred via an underground drop point onto the #1 conveyor that marks the beginning
The Kiln Area also contains the muck pile, which is a collection of material including baghouse dust,
aggregate fines, and other rejected or off-spec product. When material is added to the pile, it is typically
from a vacuum truck and is in the form of a wet slurry. Norlite actively feeds back this material into the
beginning of the finish plant. The kilns are operational 24 hours a day, 7 days a week, 365 days a year,
except during maintenance.
Fugitive dust emission sources in the Kiln Area include the conveyor belts, material transfer points,
material stockpiles, material handling by front end loaders, the kilns, and clinker coolers.
All dust collected by the baghouses is pneumatically conveyed to the dust silos in the Finish Plant Area.
Because this system is an enclosed system, there are no dust emissions from the baghouses and pneumatic
conveyance system, with the exception of maintenance work to clean out the baghouses.
Material from the two baghouse dust silos (baghouse dust silo 1 and baghouse dust silo 2) are dropped
onto a conveyor in the underground shipping tunnel (shipping belt) and are then deposited onto a short
term block mix pile by way of the stationary belt and radial stacker. Norlite personnel are able to control
the drop height off of the radial stacker.
The Finish Plant operates two 8 hour shifts every weekday and one 8 to 10 hour shift on Saturdays. This
schedule can be adjusted slightly to accommodate customer demand as needed.
Fugitive dust emissions sources in the Finish Plant Area include the conveyor belts, material transfer
points, material stockpiles, and material handling by front end loaders.
The following emission points in the Finish Plant Area have baghouse dust control: triple deck finish mill
screen, 3/4” discharge conveyor, 3/8” discharge conveyor, oversize discharge conveyor, El Jay crusher,
fines to silo conveyor, stationary belt, and radial stacker. However, the baghouse unit located adjacent to
the screen building is currently not operational, leaving everything but the stationary belt and radial
stacker without any baghouse dust control. Most of the conveyors have dust covers on them to reduce
dust emissions. Larger aggregate fractions are also mixed into the process in this area, which helps
mitigate the potential for fugitive dust.
The drop point to the 3/4” short term storage pile is enclosed by a watered chute, which can be seen in
Figure 7. The water trickles down the entire length of the chute and onto the storage pile, thus providing
dust suppression to the storage pile itself as well.
The 3/8” short term storage pile has a water sprayer that sprays both the drop point onto the pile and the
pile itself.
The enclosed fines storage pile structure provides the storage pile protection from wind erosion, while the
chute above it provides fugitive dust emission reduction during the transfer of material from the conveyor
to the storage pile. The banded wind screen northwest of the structure provides some emission control for
the open fines pile.
The radial stacker that transports material from the baghouse silos to the short term block mix short term
storage pile can be adjusted in height in order to control the material drop height. This is manually
controlled by facility personnel.
All of the short term storage piles that the various conveyors load onto are cleared by front end loader
onto customer trucks as they are being formed. Thus, the size of each pile stays relatively constant
The covered storage structure was installed in June 2010 and is 55 feet wide, 80 feet long, and has an arch
height of 25 feet. The frame is a steel tube arch structure with a rubberized canvas covering.
Approximately 1,200 tons of material can be stored in the structure, which is approximately a two week
supply based on 2013 demand for the product. The supply this represents may fluctuate with market
conditions. This structure is a significant mitigation measure for minimizing potential fugitive dust.
The Fines Processing area typically operates one shift per day, Monday through Friday. During peak
demand periods, additional run hours may be required, including weekends.
The size of the piles in this area fluctuates based on customer product demand and the output rate of the
kilns. Therefore, there are times when one or more of these storage piles is non-existent. The stockpile
inventory is attached as Appendix F.
6.11 Roads
Various roads are present at the Norlite facility, most of which are unpaved. These roads connect the
various areas to each other and are used by haul trucks, front end loaders, customer delivery trucks, a
water truck, maintenance trucks, LFG delivery trucks, and passenger vehicles.
The Saratoga Street entrance, located at the northeast area of the facility, is paved and is used by
employees and visitors to access the site. The other paved road at the facility is the beginning of the Elm
Street Access Road, used by customer delivery trucks, although this paved portion’s length is negligible.
The Norlite facility uses four front end loaders during day-to-day operations. The loader used in the
Quarry operates for 3 to 4 hours each day and transports shot rock between the quarry wall and haul truck.
Another loader is used in the Primary Area to transport shot rock from the shot rock pile to the jaw
To calculate potential fugitive dust emissions, SPEC primarily used equations from AP-42 Compilation
of Air Pollutant Emission Factors, Fifth Edition 1. These equations are industry standards for calculating
emissions in the aggregate industry. The following is the general equation for emissions estimation.
ER (1)
E EF A 1
100
E emissions (ton/yr)
A activity rate
EF emission factor
ER overall emission reduction efficiency (%)
The emission factor (EF) is a representative value that relates the quantity of a material released to the
atmosphere with an activity associated with the release of that material. The factors are usually expressed
as the weight of material divided by a unit weight, volume, distance, or duration of the activity emitting
the material. Most of the emission factors contained in this report have the units pounds of dust emitted
per ton of material processed, i.e., lb/ton. The activity rate’s units are dependent on the emission factor’s
units.
The overall reduction efficiency (based on facility controls) can be a combination of one or more
efficiency value resulting from one or more control measures applied to a potential fugitive dust emission
source. In the case with multiple emission reduction efficiencies, the following equation is used to
compound them into one overall emission factor.
This overall reduction efficiency can then be used in Equation (1) to determine the emissions from a
single source.
When an equation for the emission factor was available, SPEC used it to calculate a site-specific emission
factor, and then used it in Equation (1), along with an activity rate, in order to estimate the emissions from
the source. In the case that an equation is not available, or if SPEC deemed the equation not applicable to
the Norlite site, a general emission factor provided by AP-42 was used. These general emission factors
were obtained from the United States Environmental Protection Agency’s (EPA) WebFIRE online
emissions factor repository, retrieval, and development tool 2. SPEC chose to favor the use of site-specific
equations over the use of AP-42 emission factors because the AP-42 emission factors are generalized
factors based on EPA studies that may not be suitable for all processes and locations. Conversely,
equations using site-specific information are preferred because they use site- or process-specific values to
calculate the emission factors, and are therefore more accurate.
The particle size multiplier varies with aerodynamic particle size range according to the following table.
However, rather than using one of the listed aerodynamic particle size multipliers, SPEC has used k=1 in
order to account for larger total suspended particulate matter (TSP), which results in a conservative
estimate of emissions by capturing particles larger than 30 µm.
s 365 p f (4)
EF 1.7
1.5 235 15
The values used for s, p, and f are site-specific values that are detailed in Section 8.0 Site-Specific Values.
The units for the emission factor for wind erosion are not the typical lb/ton but are in lb/day/acre.
Therefore, calculating the emissions from storage piles requires information on the number of days each
stock pile is present annually as well as the surface area of the stockpile.
Most of the stockpile surface areas have been estimated using the surface area of a cone. However, some
stockpiles required different estimation methods. An example of a deviation from the conical assumption
is the open fines storage pile whose surface area has been estimated using a wedge shape.
a b
s W p
EF k 1 365 (5)
2 3
SPEC has used the empirical constants provided by AP-42 for PM-30 on industrial roads because PM-30
is assumed to be equivalent to total suspended particulate matter 1. These values can be seen in the
following table.
This emission factor has the units of pounds of emission per vehicle mile traveled (VMT), or lb/VMT.
When plugging the emission factor into the general equation for emissions estimation, the activity rate is
then the total number of miles that the particular vehicle type travels annually.
p (6)
EF k ( sL)0.91 (W )1.02 1
4 N
Similar to the calculations for unpaved roads, SPEC used the particle size multiplier for PM-30 because it
is assumed to be equivalent to total suspended particulate matter. Unlike the equation for unpaved road
emission factor, the paved road equation takes into account silt loading of the road rather than the silt
content of the road. Although the silt loading value has units of grams per square meter, the particle size
multiplier k includes unit conversions in order to obtain results in lb/VMT. Like calculating emissions
from unpaved roads, the activity rate to determine the tons of annual emissions from paved roads is
required to be in miles.
Because SPEC wanted estimated annual emissions from the Norlite facility, a value of 365 days was used
for N, the number of days in the averaging period.
The value for silt loading used in SPEC’s calculations is 70 g/m2. This is the average value listed in AP-
42 1. An average value was used because an actual site measurement was not available. However, Norlite
personnel stated that silt loading on paved surfaces is minimal and therefore the value used should
provide a conservative estimate of potential fugitive dust emissions from these surfaces.
0.0021 H
1.1
EF (7)
M
0.3
Because this equation produces an emission factor in pounds per cubic yard (lb/yd3), the volume of
overburden stripped annually was required to calculate the annual emissions from overburden stripping
using the general equation for emissions estimation.
5.7 s
1.2
EF
M
1.3
An estimated number of hours during which bulldozing activities occur is used in calculating the annual
emissions from bulldozing.
The value for p was obtained by counting the number of days with a total precipitation greater than 0.01
inches and dividing by the number of years in the sample, i.e., ten years. The value for U was determined
by taking the average of the daily wind speeds. The value for f was calculated in a similar manner to p:
the number of days with average wind speeds greater than 12 miles per hour were counted and then
divided by the total number of days in the sample. Airport anemometers are typically located at heights of
20 feet to 50 feet 7 while the average storage pile height at the Norlite facility is 10-15 feet. This results in
conservative fugitive dust emission values obtained from SPEC’s calculations because wind speed is
typically lower at lower elevations.
The topography around the Norlite facility is dominated by low hills to the west and the Hudson River to
the east. Small hills and ridges occur on either side of the river and elevations are approximately 50 to 300
feet above sea level within a mile of the facility. The elevation within half a mile of the facility is
approximately 150 feet above sea level. There is a gradual increase in elevation with increased distance
from the river. The highest elevation in the area is five miles northwest of the facility on the west-
northwest side of Mt. Rafinesque at approximately 600 to 700 feet above sea level. The prevalent wind
direction is from west to east year-round.
Kiln clinker cooler multiclone dust 32.90% ≤1.00% 30.00% (in muck pile)
Overburden silt content was determined through sieve analysis data collected on the various layers of
overburden (see summary table in Appendix D).
Because the amount of overburden stripped annually was given to SPEC in volume (cubic yards per
year), it was necessary to convert the average annual volume into average annual weight. The
composition of overburden can vary greatly within the mine site, so SPEC made the assumption that 60-
70% of the overburden is clay and the remainder is sand. This is supported by work conducted in the
Southern Overburden Storage Area. The clay portions are made of up several different layers of clay, so
SPEC used the average density of various clays from Pocket Ref 10. The sand layers are also made up of
several layers of sand types, so an average density was used for sand as well.
Average
Production
Location Rate Units Information Provided by Norlite Personnel
Of the material that passes through the Primary crusher,
Primary 282,900 ton/yr 15% passes through a second time.
50% of clinker entering Finish Plant is screened off
naturally while the other 50% passes through the El Jay
El Jay cone crusher. Of the material that passes through the El Jay
crusher 133,975 ton/yr crusher, 15% passes through a second time.
Grizzly
oversize pile 1,167 ton/yr 5 tons per 12 hour shift on average.
QA3 Quarried stone pile 246,000 tpy Water suppression 50% 5.10E-03 4.00E-02 lb/ton 0.31336
QA4 Load stone into truck 246,000 tpy None 0% 5.10E-03 2.37E-03 lb/ton 0.62671
QA5 Overburden stripping 161,000 cu yd/yr None 0% 3.48E-02 6.00E-02 lb/yd3 2.80154
QA6 Load overburden into truck 206,265 tpy None 0% 7.69E-05 3.70E-02 lb/ton 0.00793
PR1 Loading onto shot rock pile (Canal) 246,000 tpy None 0% 5.10E-03 -- -- 0.62671
PR2 Shot rock pile (Canal) 246,000 tpy None 0% 1.05E-04 -- -- 0.00000
PR3 Unloading shot rock pile 246,000 tpy None 0% 5.10E-03 -- -- 0.62671
PR4 Loading onto shale stockpile 246,000 tpy Water suppression 20% 5.10E-03 3.00E-03 lb/ton 0.50137
PR5 Shale stockpile 246,000 tpy Water suppression 50% 2.10E-01 -- -- 0.00264
PR7 Drop point, raw shale drop to jaw crusher 282,900 tpy None 0% 5.10E-03 3.00E-03 lb/ton 0.72072
PR8 Jaw crusher 282,900 tpy Partially enclosed 75% -- 2.80E-01 lb/ton 9.90150
PR9 Drop point, jaw crusher to crusher belt 282,900 tpy Enclosed 90% 5.10E-03 3.00E-03 lb/ton 0.07207
PR10 Crusher belt 282,900 tpy None 0% -- 3.00E-03 lb/ton per 300 ft 0.02166
PR11 Drop point, crusher belt to screen belt 282,900 tpy Enclosed 90% 5.10E-03 3.00E-03 lb/ton 0.07207
PR12 Screen belt 282,900 tpy None 0% -- 3.00E-03 lb/ton per 300 ft 0.02829
PR13 Drop point, screen belt to primary double deck screen 282,900 tpy None 0% 5.10E-03 3.00E-03 lb/ton 0.72072
PR14 Primary double deck screen 282,900 tpy Water suppression, spray bar; Partially enclosed 85% -- 2.20E-03 lb/ton 0.04668
PR15 Drop point, primary double deck screen to primary cone crusher 282,900 tpy Enclosed 0% 5.10E-03 3.00E-03 lb/ton 0.72072
PR16 Primary cone crusher 282,900 tpy Partially enclosed 50% -- 3.00E-03 lb/ton 0.21218
PR17 Drop point, primary cone crusher to primary double deck screen 282,900 tpy None 0% 5.10E-03 -- -- 0.72072
PR18 Drop point, primary double deck screen to shale conveyor 282,900 tpy Enclosed 90% 5.10E-03 3.00E-03 lb/ton 0.07207
PR19 Shale conveyor 233,000 tpy None 0% -- 3.00E-03 lb/ton per 300 ft 0.06191
PR20 Drop point, shale conveyor to kiln feed pile 233,000 tpy None 0% 5.10E-03 3.00E-03 lb/ton 0.59360
PR22 Drop point, double deck screen to shale fines conveyor 13,000 tpy Enclosed 90% 5.10E-03 3.00E-03 lb/ton 0.00331
PR23 Shale fines conveyor 13,000 tpy None 0% -- 3.00E-03 lb/ton per 300 ft 0.00255
PR24 Drop point, shale fines conveyor to shale fines pile 13,000 tpy None 0% 7.32E-04 3.00E-03 lb/ton 0.00476
PR25 Shale fines pile 13,000 tpy Low pile height/wetted material 20% 1.68E-01 -- -- 0.00088
PR26 Loading from shale fines pile to trucks 13,000 tpy None 0% 7.32E-04 3.00E-03 lb/ton 0.00476
KF1 Drop point, shale pile to #4 conveyor 116,500 tpy Enclosed 99% 5.10E-03 3.00E-03 lb/ton 0.00297
KF2 Drop point, loader to #4 conveyor 116,500 tpy None 0% 5.10E-03 -- -- 0.29680
KF3 #4 conveyor 233,000 tpy Partially underground; Dust cover; Water suppression, spray 85% -- 3.00E-03 lb/ton per 300 ft 0.01419
bar
KF4 Drop point, #4 conveyor to #5 conveyor 233,000 tpy Enclosed 90% 5.10E-03 3.00E-03 lb/ton 0.05936
KF5 #5 conveyor 233,000 tpy Dust cover 70% -- 3.00E-03 lb/ton per 300 ft 0.04349
KF6 Drop point, #5 conveyor to shale storage pile 233,000 tpy Enclosed 97% 5.10E-03 3.00E-03 lb/ton 0.01781
KF7 Kiln feed storage pile 233,000 tpy Partially enclosed; Low pile height 90% 2.10E-01 -- -- 0.00034
KF8 Drop point, shale storage pile to kiln 1 feeder belt 121,000 tpy Underground 99% 5.10E-03 3.00E-03 lb/ton 0.00308
KF9 Kiln 1 feeder belt 121,000 tpy Underground 90% -- 3.00E-03 lb/ton per 300 ft 0.00149
KF10 Drop point, kiln 1 feeder belt to kiln 1 lower belt 121,000 tpy Enclosed 80% 5.10E-03 3.00E-03 lb/ton 0.06165
KF11 Kiln 1 lower belt 121,000 tpy Dust cover; Partially underground; Meat locker curtain 70% -- 3.00E-03 lb/ton per 300 ft 0.01104
KF12 Drop point, kiln 1 lower belt to kiln 1 top belt 121,000 tpy Enclosed 80% 5.10E-03 3.00E-03 lb/ton 0.06165
KF13 Kiln 1 top belt 121,000 tpy Dust cover 70% -- 3.00E-03 lb/ton per 300 ft 0.00381
KF14 Drop point, kiln 1 top belt to kiln 1 feed 121,000 tpy Chute 90% 5.10E-03 3.00E-03 lb/ton 0.03083
KF15 Kiln 1 feed (AccuRate feeder) 121,000 tpy Dust cover 0% 5.10E-03 3.00E-03 lb/ton 0.30826
KF16 Kiln 1 rear chamber system (rim seal) 121,000 tpy Dust cover 99% -- 8.40E-01 lb/ton 0.50820
KF17 Kiln 1 front seal 121,000 tpy Vacuum 99% -- 8.40E-01 lb/ton 0.50820
KF18 Drop point, shale storage pile to kiln 2 feeder belt 112,000 tpy Underground 99% 5.10E-03 3.00E-03 lb/ton 0.00285
KF19 Kiln 2 feeder belt 112,000 tpy Underground 90% -- 3.00E-03 lb/ton per 300 ft 0.00138
KF21 Kiln 2 lower belt 112,000 tpy Dust cover; Partially underground; Meat locker curtain 70% -- 3.00E-03 lb/ton per 300 ft 0.01065
KF22 Drop point, kiln 2 lower belt to kiln 2 middle belt 112,000 tpy Chute 80% 5.10E-03 3.00E-03 lb/ton 0.05707
KF23 Kiln 2 middle belt 112,000 tpy Dust cover 70% -- 3.00E-03 lb/ton per 300 ft 0.00449
KF24 Drop point, kiln 2 middle belt to kiln 2 top belt 112,000 tpy Chute 80% 5.10E-03 3.00E-03 lb/ton 0.05707
KF25 Kiln 2 top belt 112,000 tpy Dust cover 70% -- 3.00E-03 lb/ton per 300 ft 0.00564
KF26 Drop point, kiln 2 top belt to kiln 2 feed 112,000 tpy Chute 80% 5.10E-03 3.00E-03 lb/ton 0.05707
KF27 Kiln 2 feed (AccuRate feeder) 112,000 tpy Dust cover 0% 5.10E-03 3.00E-03 lb/ton 0.28533
KF28 Kiln 2 rear chamber system (rim seal) 112,000 tpy Dust cover 99% -- 8.40E-01 lb/ton 0.47040
KF29 Kiln 2 front seal 112,000 tpy Vacuum 99% -- 8.40E-01 lb/ton 0.47040
KF30 Opening of kiln rim seals for cleaning 438 tpy None 0% -- 3.00E-03 lb/ton 0.00066
KF31 Removal of bag house plug (vacuum truck unloading) 338 tpy Water suppression; Baghouse 0% -- 3.00E-03 lb/ton 0.00051
KL1 Drop point, kiln 1 to kiln 1 clinker cooler 121,000 tpy Enclosed 99% -- 3.00E-03 lb/ton 0.00182
KL2 Kiln 1 clinker cooler 121,000 tpy Enclosed 90% -- 3.00E-01 lb/ton 1.81500
KL3 Drop point, kiln 1 clinker cooler to kiln 1 clinker belt 121,000 tpy Partially enclosed 80% -- 3.00E-03 lb/ton 0.03630
KL4 Kiln 1 clinker belt 121,000 tpy Partially underground; Dust cover; Water suppression, as 70% -- 3.00E-03 lb/ton per 300 ft 0.02122
needed
KL5 Drop point, kiln 1 clinker belt to kiln 1 clinker pile 121,000 tpy Water suppression 50% 1.34E-02 3.00E-03 lb/ton 0.40675
KL6 Kiln 1 clinker pile 121,000 tpy Water suppression 50% 2.78E+00 -- -- 0.01549
KL7 Drop point, kiln 2 to kiln 2 clinker cooler 112,000 tpy Enclosed 99% -- 3.00E-03 lb/ton 0.00168
KL8 Kiln 2 clinker cooler 112,000 tpy Enclosed 90% -- 3.00E-01 lb/ton 1.68000
KL9 Drop point, kiln 2 clinker cooler to kiln 2 clinker belt 112,000 tpy Partially enclosed 80% -- 3.00E-03 lb/ton 0.03360
KL10 Kiln 2 clinker belt 112,000 tpy Partially underground; Dust cover; Water suppression, as 70% -- 3.00E-03 lb/ton per 300 ft 0.01895
needed
KL11 Drop point, kiln 2 clinker belt to kiln 2 clinker pile 112,000 tpy Water suppression, mist 50% 1.34E-02 3.00E-03 lb/ton 0.37650
KL13 Transfer kiln 2 clinker pile to kiln 1 clinker pile 112,000 tpy Loader Operator Protocol 0% 1.34E-02 3.00E-03 lb/ton 0.75300
KL14 Muck pile 8,160 tpy Moisture; Pile shaping; Compaction 50% 8.42E+01 -- -- 1.05615
KL15 Loading onto muck pile 8,160 tpy None 0% 1.15E-04 -- -- 0.00047
FP1 Drop point, kiln 1 clinker pile to transfer to #1 conveyor 233,000 tpy Underground 90% -- 3.00E-03 lb/ton 0.03495
FP2 #1 conveyor 233,000 tpy Dust cover; Partially underground 70% -- 3.00E-03 lb/ton per 300 ft 0.01599
FP3 Drop point, #1 conveyor to grizzly 233,000 tpy None 80% 1.34E-02 3.00E-03 lb/ton 0.31330
FP4 Grizzly on lightweight aggregate feed platform 233,000 tpy Partially enclosed 70% 1.34E-02 3.00E-03 lb/ton 0.46995
FP5 Drop point, grizzly to grizzly pile 233,000 tpy None 0% 1.34E-02 3.00E-03 lb/ton 1.56651
FP7 Drop point, grizzly to #2 conveyor 233,000 tpy Enclosed 90% 1.34E-02 3.00E-03 lb/ton 0.15665
FP8 #2 conveyor 233,000 tpy Dust cover 70% -- 3.00E-03 lb/ton per 300 ft 0.03155
FP9 Drop point, #2 conveyor to triple deck finish mill screen 233,000 tpy Enclosed 90% 1.34E-02 3.00E-03 lb/ton 0.15665
FP10 Triple deck finish mill screen 233,000 tpy Baghouse 0% -- 2.20E-03 lb/ton 0.25630
FP11 Drop point, triple deck finish mill screen to 3/4" discharge conveyor 69,000 tpy Enclosed 90% 3.73E-03 3.00E-03 lb/ton 0.01286
FP12 3/4" discharge conveyor 69,000 tpy Dust cover; Baghouse 70% -- 3.00E-03 lb/ton per 300 ft 0.00647
FP13 Drop point, 3/4" discharge conveyor to 3/4" to stockpile conveyor 69,000 tpy Enclosed 80% 3.73E-03 3.00E-03 lb/ton 0.02572
FP14 3/4" to stockpile conveyor 69,000 tpy Dust cover 70% -- 3.00E-03 lb/ton per 300 ft 0.01273
FP15 Drop point, 3/4" to stockpile conveyor to 3/4" short term storage pile 69,000 tpy Tube; Water suppression 95% 3.73E-03 3.00E-03 lb/ton 0.00643
FP16 3/4" short term storage pile 98,185 tpy Water suppression 50% 1.14E+00 -- -- 0.00449
FP17 Drop point, triple deck finish mill screen to 3/8" discharge conveyor 46,000 tpy Enclosed 80% 3.73E-03 3.00E-03 lb/ton 0.01715
FP18 3/8" discharge conveyor 46,000 tpy Dust cover; Baghouse 70% -- 3.00E-03 lb/ton per 300 ft 0.00289
FP20 3/8" to stockpile conveyor 46,000 tpy Dust cover 70% -- 3.00E-03 lb/ton per 300 ft 0.00660
FP21 Drop point, 3/8" stockpile conveyor to 3/8" short term storage pile 46,000 tpy Water suppression, spray head 50% 3.73E-03 3.00E-03 lb/ton 0.04287
FP22 3/8" short term storage pile 25,550 tpy Water suppression, spray head 70% 1.24E+00 -- -- 0.05191
FP23 Drop point, triple deck finish mill screen to oversize discharge conveyor 133,975 tpy Enclosed 90% 1.34E-02 3.00E-03 lb/ton 0.09007
FP24 Oversize discharge conveyor 133,975 tpy Partially covered; Baghouse 70% -- 3.00E-03 lb/ton per 300 ft 0.01122
FP25 Drop point, oversize discharge conveyor to oversize hopper 133,975 tpy None 0% 1.34E-02 3.00E-03 lb/ton 0.90074
FP27 Drop point, oversize hopper to El Jay crusher speed conveyor 133,975 tpy Partially enclosed 70% 1.34E-02 3.00E-03 lb/ton 0.27022
FP28 El Jay crusher speed conveyor 133,975 tpy Dust cover 70% -- 3.00E-03 lb/ton per 300 ft 0.01151
FP29 Drop point, El Jay crusher speed conveyor to El Jay crusher 133,975 tpy Enclosed 90% 1.34E-02 3.00E-03 lb/ton 0.09007
FP30 El Jay crusher 133,975 tpy Baghouse 90% -- 2.50E-02 lb/ton 0.16747
FP31 Drop point, El Jay crusher to El Jay discharge conveyor 133,975 tpy Enclosed 90% 1.34E-02 3.00E-03 lb/ton 0.09007
FP32 El Jay discharge conveyor 133,975 tpy None 0% -- 3.00E-03 lb/ton per 300 ft 0.00804
FP33 Drop point, El Jay discharge conveyor to #2 return conveyor 133,975 tpy Enclosed 80% 1.34E-02 3.00E-03 lb/ton 0.18015
FP34 #2 return conveyor 133,975 tpy Dust cover 70% -- 3.00E-03 lb/ton per 300 ft 0.01398
FP35 Drop point, #2 return conveyor to #2 conveyor 133,975 tpy Enclosed 80% 1.34E-02 3.00E-03 lb/ton 0.18015
FP36 Drop point, triple deck finish mill screen to fines to silo conveyor 28,000 tpy Enclosed 90% 3.73E-03 3.00E-03 lb/ton 0.00522
FP37 Fines to silo conveyor 28,000 tpy Dust cover; Baghouse 70% -- 3.00E-03 lb/ton per 300 ft 0.00840
FP38 Drop point, fines to silo conveyor to enclosed fines storage pile 85,000 tpy Chute 94% 3.73E-03 3.00E-03 lb/ton 0.00951
FP39 Enclosed fines storage pile 85,000 tpy Roof; Concrete enclosure at bottom; Tarps 80% 5.85E+00 -- -- 0.03001
FP40 Open fines storage pile 85,000 tpy Enclosed; Concrete wall to south; Wind screen 80% 5.85E+00 -- -- 0.00981
FP41 Baghouse dust silo 1 85,000 tpy Enclosed 97% 7.83E+00 9.90E-03 lb/ton 0.00153
FP43 Baghouse dust silo 2 85,000 tpy Enclosed 97% 7.83E+00 9.90E-03 lb/ton 0.00153
FP44 Drop point, baghouse dust silo 2 to shipping belt 85,000 tpy Enclosed 99% 3.73E-03 3.00E-03 lb/ton 0.00158
FP45 Shipping belt 27,094 tpy Partially underground; Dust cover 90% -- 3.00E-03 lb/ton per 300 ft 0.00102
FP46 Drop point, shipping belt to stationary belt 27,094 tpy Enclosed 90% 3.73E-03 3.00E-03 lb/ton 0.00505
FP47 Stationary belt 27,094 tpy Dust cover; Baghouse; Improved maintenance 70% -- 3.00E-03 lb/ton per 300 ft 0.00369
FP48 Drop point, stationary belt to radial stacker 27,094 tpy Enclosed 90% 3.73E-03 3.00E-03 lb/ton 0.00505
FP49 Radial stacker 27,094 tpy Dust cover; Spray head adjustment 70% -- 3.00E-03 lb/ton per 300 ft 0.00301
FP50 Drop point, radial stacker to block mix short term storage pile 1 27,094 tpy Baghouse; Water suppression; Adjustable discharge height 99% 3.73E-03 3.00E-03 lb/ton 0.00063
FP51 Block mix short term storage pile 1 15,133 tpy Low pile height/bldg 20% 7.83E+00 -- -- 0.07249
FP52 Block mix short term storage pile 2 14,764 tpy Low pile height/bldg 20% 7.83E+00 -- -- 0.07249
FP53 Block mix short term storage pile 3 2,147 tpy Low pile height/small pile/bldg 50% 7.83E+00 -- -- 0.03096
FP54 Block mix short term storage pile 4 13,421 tpy Low pile height/bldg 20% 7.83E+00 -- -- 0.11829
FP55 Block mix short term storage pile 5 33,788 tpy Low pile height 20% 7.83E+00 -- -- 0.27841
FP56 Block mix short term storage pile 6 2,550 tpy Low pile height/small pile 50% 7.83E+00 -- -- 0.05963
FP57 3/4" long term storage pile 5 37,531 tpy Low pile height 20% 1.14E+00 -- -- 0.01717
FP58 Loading 3/4" onto trucks 69,000 tpy Loader Operator Protocol 0% 8.01E-04 3.00E-03 lb/ton 0.02763
FP59 Loading 3/8" onto trucks 46,000 tpy Loader Operator Protocol 0% 8.01E-04 3.00E-03 lb/ton 0.01842
FP60 Loading clinker onto trucks 233,000 tpy Loader Operator Protocol 0% 1.41E-03 3.00E-03 lb/ton 0.16458
FP61 Loading block mix onto piles 92,000 tpy Loader Operator Protocol 0% 8.01E-04 3.00E-03 lb/ton 0.03684
FP62 Loading block mix onto trucks 92,000 tpy Loader Operator Protocol 0% 8.01E-04 3.00E-03 lb/ton 0.03684
FN1 8 X 0 long term storage pile 27,094 tpy Enclosed 85% 7.83E+00 -- -- 0.02218
FN2 4 X 0 fines feed pile 66,839 tpy Low pile height 20% 5.85E+00 -- -- 0.01975
FN4 Cedarapids feed hopper (surge bin) 66,839 tpy None 0% -- 3.00E-03 lb/ton 0.10026
FN5 Drop point, Cedarapids feed hopper to feeder belt 66,839 tpy None 0% 3.73E-03 3.00E-03 lb/ton 0.12459
FN6 Feeder belt 66,839 tpy None 0% -- 3.00E-03 lb/ton per 300 ft 0.01702
FN7 Drop point, feeder belt to screen feed belt 66,839 tpy None 0% 3.73E-03 3.00E-03 lb/ton 0.12459
FN8 Screen feed belt 66,839 tpy None 0% -- 3.00E-03 lb/ton per 300 ft 0.01154
FN9 Drop point, screen feed belt to Astec 2618 fines screen 66,839 tpy None 0% 3.73E-03 3.00E-03 lb/ton 0.12459
FN10 Astec 2618 fines screen 66,839 tpy None 0% -- 2.00E-03 lb/ton 0.06684
FN11 Drop point, fines screen to #4s belt 66,839 tpy None 0% 3.73E-03 3.00E-03 lb/ton 0.12459
FN12 #4s belt 66,839 tpy None 0% -- 3.00E-03 lb/ton per 300 ft 0.01421
FN13 Drop point, #4s belt to 4 mesh reject pile 66,839 tpy None 0% 3.73E-03 3.00E-03 lb/ton 0.12459
FN14 4 mesh reject pile 27,094 tpy Low pile height 20% 5.85E+00 -- -- 0.01975
FN15 Drop point, fines screen to fines #8s belt 27,094 tpy None 0% 3.73E-03 3.00E-03 lb/ton 0.05050
FN16 #8s belt 27,094 tpy None 0% -- 3.00E-03 lb/ton per 300 ft 0.00580
FN17 Drop point, #8s belt to fines 8 X 0 pile 27,094 tpy None 0% 3.73E-03 3.00E-03 lb/ton 0.05050
FN18 8 X 0 pile 27,094 tpy Low pile height 20% 7.53E+00 -- -- 0.02543
FN19 3/4" long term storage pile 6 9,847 tpy Low pile height 20% 1.14E+00 -- -- 0.00384
FN20 Loading screened fines onto trucks (8 X 0, 4 X 0, 4 mesh reject) 27,094 tpy Loader Operator Protocol 0% 8.01E-04 3.00E-03 lb/ton 0.01085
BM1 Block mix long term storage pile 1 8,376 tpy None 0% 7.83E+00 -- -- 0.25272
BM2 Block mix long term storage pile 2 8,376 tpy Low pile height 20% 7.83E+00 -- -- 0.01598
BM3 Block mix long term storage pile 3 8,376 tpy Low pile height 20% 7.83E+00 -- -- 0.01862
BM4 Block mix long term storage pile 4 11,341 tpy Low pile height 20% 7.83E+00 -- -- 0.20980
BM5 Loading block mix into portable screen 89,118 tpy Loader Operator Protocol 0% 8.01E-04 3.00E-03 lb/ton 0.03568
BM9 Temporary block mix pile for customer pickup 89,118 tpy Low pile height 20% 7.83E+00 -- -- 0.04084
BM10 Loading block mix onto trucks 89,118 tpy Loader Operator Protocol 0% 8.01E-04 3.00E-03 lb/ton 0.03568
BM11 Loading onto block mix pile 89,118 tpy None 0% 8.01E-04 3.00E-03 lb/ton 0.03568
IS1 3/4" long term storage pile 1 2,840 tpy Low pile height 20% 1.14E+00 -- -- 0.00719
IS2 3/4" long term storage pile 2 70,138 tpy Low pile height 20% 1.14E+00 -- -- 0.01052
IS3 3/4" long term storage pile 3 4,014 tpy Low pile height 20% 1.14E+00 -- -- 0.02381
IS4 3/4" long term storage pile 4 10,528 tpy Low pile height 20% 1.14E+00 -- -- 0.04041
IS5 3/8" long term storage pile 45,642 tpy Low pile height 20% 1.24E+00 -- -- 0.01876
IS6 Block mix long term storage pile 5 2,147 tpy Low pile height 20% 7.83E+00 -- -- 0.02643
IS7 Loading onto 3/4" pile 69,000 tpy None 0% 8.01E-04 3.00E-03 lb/ton 0.02763
IS8 Loading 3/4" onto trucks 69,000 tpy Loader Operator Protocol 0% 8.01E-04 3.00E-03 lb/ton 0.02763
IS9 Loading onto 3/8" pile 46,000 tpy None 0% 8.01E-04 3.00E-03 lb/ton 0.01842
IS10 Loading 3/8" onto trucks 46,000 tpy Loader Operator Protocol 0% 8.01E-04 3.00E-03 lb/ton 0.01842
BY3 Loading shale fines onto boneyard shale piles 9,446 tpy None 0% 7.32E-04 3.00E-03 lb/ton 0.00346
BY4 Loading boneyard shale piles onto trucks 9,446 tpy Loader Operator Protocol 0% 7.32E-04 3.00E-03 lb/ton 0.00346
OS2 Receiving overburden from quarry 206,265 tpy None 0% 7.69E-05 2.00E-03 lb/ton 0.00793
OS3 Wind erosion in overburden storage area -- -- None 0% -- 3.80E-01 ton/acre-year 1.90000
RD1 Transport of stone from quarry to primary 15,504 mi Water 50% 5.68E-01 6.20E+00 lb/mi 2.20290
RD2 Transfer of overburden from quarry to overburden storage area 15,875 mi Water 50% 5.68E-01 6.20E+00 lb/mi 2.25566
RD3 Transport of shales fines to boneyard 1,043 mi Water 50% 5.68E-01 6.20E+00 lb/mi 0.14819
RD4 Transport of product off-site by truck 7,992 mi Water 50% 5.53E-01 6.20E+00 lb/mi 1.10499
RD5 Travel of LGF delivery trucks 550 mi Water 50% 5.53E-01 6.20E+00 lb/mi 0.07598
RD8 Transport of shale fines to overburden storage area 1,427 mi Water 50% 5.68E-01 6.20E+00 lb/mi 0.20276
RD9 Water truck movement 3,686 mi Water 50% 3.58E-01 6.20E+00 lb/mi 0.32983
RD10 On-site product movement via front end loader 4,493 mi Water 50% 3.22E-01 6.20E+00 lb/mi 0.36139
Total 61.40307
Material silt content was estimated based on both 100 and 200 sieve data for each product;
General EPA AP-42 factors were used for several sources, which provide inherently conservative
emission estimates;
Re-processed material was included each time it went through a particular process without
reduction in estimated silt content; and
Conservatively low control factors were used for covered conveyors and low stockpile height.
Areas within the Norlite facility that contribute the largest amount of potential fugitive dust emissions are:
Quarry Blasting;
Wind erosion off select areas, including the Southern Overburden Storage Area and muck
pile.
Quarry blasting emissions have a conservatively high estimate because the calculation is based on an AP-
42 emission factor, which provides consistently high emission estimates when applied in an aggregate
setting. Potential dust emissions, as estimated, are not a significant concern due to the location of the
quarry excavation relative to the facility property line and thick vegetative buffer surrounding the active
blasting area.
Primary jaw crushing and fines screening represent a significant fraction of the calculated potential
fugitive dust emissions at the Norlite facility. Potential dust emissions, as estimated for these sources, are
not of significant concern due to the location of the primary area relative to the facility property line, and
the conservative particle size range used to generate the emissions estimate. A vast majority of the
potential fugitive dust generated from the primary and screens settles within the quarry and facility
itself. These estimates, however, can be reduced by improved water spray application and/or wind
screens in both areas.
Wind erosion from material drop points and open stockpiles represent the last of the major potential
fugitive dust sources. Continued use of water control devices, conveyor covers, low pile height, and good
housekeeping practices can effectively manage these potential sources of fugitive dust.
The following table (Table 12) identifies each control device for each identified emission source across
Norlite’s facility along with a statement of the functionality of each control device. The table also
identifies when or where additional controls may be useful in reducing potential fugitive dust emissions.
3. U.S. Environmental Protection Agency, Office Of Air And Radiation, Office of Air Quality Planning
And Standards, AP-42 Compilation of Air Pollutant Emission Factors, Fourth Edition.
4. U.S. Environmental Protection Agency, Office of Air and Waste Management, Office of Air Quality
Planning and Standards, EPA-450/3-77-010 Technical Guidance For Control Of Industrial Process
Fugitive Particulate Emissions (1977).
5. U.S. Environmental Protection Agency, Office Of Air And Radiation, Office of Air Quality Planning
And Standards, EPA-450/2-92-004 Fugitive Dust Background Document And Technical Information
Document For Best Available Control Measures (1992).
6. National Oceanic and Atomspheric Administration, National Climate Data Center, Available at
http://www.ncdc.noaa.gov/ (2014).
8. U.S. Department of the Interior Bureau of Reclamation, Engineering Geology Field Manual, 2nd ed.
(2001).
9. ASTM International, D2487-11 Standard Practice for Classification of Soils for Engineering Purposes
(Unified Soil Classification System). ASTM International (2011).
10. Glover, T. J., Pocket Ref, 4th ed. (Sequoia Publishing, Inc., Littleton, CO, 2012).
11. Texas Commission on Environmental Quality, Air Permits Division, New Source Review (NSR)
Emission Calculations (2008).
ENGINEERING, PLLC
1
•
ENGINEERING, PLLC
2
•
ENGINEERING, PLLC
3
•
ENGINEERING, PLLC
4
•
ENGINEERING, PLLC
5
•
ENGINEERING, PLLC
6
•
ENGINEERING, PLLC
7
•
ENGINEERING, PLLC
8
•
ENGINEERING, PLLC
9
APPENDIX B
PROCESS FLOW DIAGRAMS
10
11
12
13
14
15
16
17
18
19
20
21
APPENDIX C
FUGITIVE DUST EMISSION CALCULATIONS
22
Norlite Fugitive Dust Sources and Calculations Calc AP 42
Area Source ID Source Name Source Type Product In/Post Proces P - Production Rate Units Control Condition ER - emissions reduction efficiency, %Emission Factor Type Emission Factor (EF) EF Units EF - Calculated Emission Factor (1-ER/100) E - Emissions, ton/yr via calculations E - Emissions, ton/yr via AP-42 facCombined Emissions
Quarry QA1 Drilling General Raw shale In process 246,000 tpy Water suppression, mist Functional 50% Controlled 8.00E-05 lb/ton No calculated value 0.5 No calculated value 0.00492 0.00492
Quarry QA2 Blasting Blasting Raw shale In process 246,000 tpy None None 0% Uncontrolled 0.08 lb/ton No calculated value 1 No calculated value 9.84000 9.84000
Quarry QA3 Quarried stone pile Drop Operation Raw shale In process 246,000 tpy Water suppression Functional 50% Uncontrolled 0.04 lb/ton 0.00510 0.5 0.31336 2.46000 0.31336
Quarry QA4 Load stone into truck Drop Operation Raw shale In process 246,000 tpy None None 0% Uncontrolled 0.002368 lb/ton 0.00510 1 0.62671 0.29126 0.62671
Quarry QA5 Overburden stripping Dragline Overburden In process 161,000 cu yd/yr None None 0% Uncontrolled 6.00E-02 lb/yd3 0.03480 1 2.80154 4.83000 2.80154
Quarry QA6 Load overburden into truck Drop Operation Overburden In process 206,265 tpy None None 0% Uncontrolled 3.70E-02 lb/ton 0.00008 1 0.00793 3.81591 0.00793
Primary PR1 Loading onto shot rock pile (Canal) Drop Operation Raw shale In process 246,000 tpy None None 0.00510 1 0.62671 #N/A 0.62671
Primary PR2 Shot rock pile (Canal) Storage Pile Raw shale In process 246,000 tpy None None 0% 0.00011 1 0.00000 #N/A 0.00000
Primary PR3 Unloading shot rock pile Drop Operation Raw shale In process 246,000 tpy None None 0.00510 1 0.62671 #N/A 0.62671
Primary PR4 Loading onto shale stockpile Drop Operation Raw shale In process 246,000 tpy Water suppression Functional 20% 3.00E-03 lb/ton 0.00510 0.8 0.50137 0.29520 0.50137
Primary PR5 Shale stockpile Storage Pile Raw shale In process 246,000 tpy Water suppression Functional 50% 0.21047 0.5 0.00264 #N/A 0.00264
Primary PR6 Unloading shale stockpile Drop Operation Raw shale In process 246,000 tpy None None 0.00510 1 0.62671 #N/A 0.62671
Primary PR7 Drop point, raw shale drop to jaw crusher Drop Operation Raw shale In process 282,900 tpy None None 0% Uncontrolled 0.003 lb/ton 0.00510 1 0.72072 0.42435 0.72072
Primary PR8 Jaw crusher General Raw shale In process 282,900 tpy Partially enclosed Functional 75% Uncontrolled 0.28 lb/ton No calculated value 0.25 No calculated value 9.90150 9.90150
Primary PR9 Drop point, jaw crusher to crusher belt Drop Operation Raw shale In process 282,900 tpy Enclosed Functional 90% Uncontrolled 0.003 lb/ton 0.00510 0.1 0.07207 0.04244 0.07207
Primary PR10 Crusher belt Conveyor Raw shale In process 282,900 tpy None None 0% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 1 No calculated value 0.02166 0.02166
Primary PR11 Drop point, crusher belt to screen belt Drop Operation Raw shale In process 282,900 tpy Enclosed Functional 90% Uncontrolled 0.003 lb/ton 0.00510 0.1 0.07207 0.04244 0.07207
Primary PR12 Screen belt Conveyor Raw shale In process 282,900 tpy None None 0% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 1 No calculated value 0.02829 0.02829
Primary PR13 Drop point, screen belt to primary double deck screen Drop Operation Raw shale In process 282,900 tpy None None 0% Uncontrolled 3.00E-03 lb/ton 0.00510 1 0.72072 0.42435 0.72072
Primary PR14 Primary double deck screen General Raw shale In process 282,900 tpy Water suppression, spray bar Functional 50% Uncontrolled 0.0022 lb/ton No calculated value 0.15 No calculated value 0.04668 0.04668
Primary (PR14) Partially enclosed Functional 70% (Additional control) (Additional control) (Additional control) #N/A (Additional control)
Primary PR15 Drop point, primary double deck screen to primary cone crusher Drop Operation Raw shale In process 282,900 tpy Enclosed Functional 0.003 lb/ton 0.00510 1 0.72072 0.42435 0.72072
Primary PR16 Primary cone crusher General Raw shale In process 282,900 tpy Partially enclosed Functional 50% 3.00E-03 lb/ton No calculated value 0.5 No calculated value 0.21218 0.21218
Primary PR17 Drop point, primary cone crusher to primary double deck screen Drop Operation Raw shale In process 282,900 tpy None None 0.00510 1 0.72072 #N/A 0.72072
Primary PR18 Drop point, primary double deck screen to shale conveyor Drop Operation Raw shale In process 282,900 tpy Enclosed Functional 90% Uncontrolled 0.003 lb/ton 0.00510 0.1 0.07207 0.04244 0.07207
Primary PR19 Shale conveyor Conveyor Raw shale In process 233,000 tpy None None 0% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 1 No calculated value 0.06191 0.06191
Primary PR20 Drop point, shale conveyor to kiln feed pile Drop Operation Raw shale In process 233,000 tpy None None 0% Uncontrolled 0.003 lb/ton 0.00510 1 0.59360 0.34950 0.59360
Primary PR21 Kiln feed pile Storage Pile Raw shale In process 233,000 tpy None None 0% 0.21047 1 0.00332 #N/A 0.00332
Primary PR22 Drop point, double deck screen to shale fines conveyor Drop Operation Raw shale In process 13,000 tpy Enclosed Functional 90% Uncontrolled 0.003 lb/ton 0.00510 0.1 0.00331 0.00195 0.00331
Primary PR23 Shale fines conveyor Conveyor Shale fines In process 13,000 tpy None None 0% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 1 No calculated value 0.00255 0.00255
Primary PR24 Drop point, shale fines conveyor to shale fines pile Drop Operation Shale fines In process 13,000 tpy None None 0% Uncontrolled 0.003 lb/ton 0.00073 1 0.00476 0.01950 0.00476
Primary PR25 Shale fines pile Storage Pile Shale fines In process 13,000 tpy Low pile height/wetted material Functional 20% 0.16838 0.8 0.00088 #N/A 0.00088
Primary PR26 Loading from shale fines pile to trucks Drop Operation Shale fines In process 13,000 tpy None None 0% Uncontrolled 3.00E-03 lb/ton 0.00073 1 0.00476 0.01950 0.00476
Kiln Feed KF1 Drop point, shale pile to #4 conveyor Drop Operation Raw shale In process 116,500 tpy Enclosed Functional 99% Uncontrolled 0.003 lb/ton 0.00510 0.01 0.00297 0.00175 0.00297
Kiln Feed KF2 Drop point, loader to #4 conveyor Drop Operation Raw shale In process 116,500 tpy None None 0.00510 1 0.29680 #N/A 0.29680
Kiln Feed KF3 #4 conveyor Conveyor Raw shale In process 233,000 tpy Partially underground Functional 70% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 0.15 No calculated value 0.01419 0.01419
Kiln Feed (KF3) Dust cover Functional (Additional control) (Additional control) (Additional control) #N/A (Additional control)
Kiln Feed (KF3) Water suppression, spray bar Functional 50% (Additional control) (Additional control) (Additional control) #N/A (Additional control)
Kiln Feed KF4 Drop point, #4 conveyor to #5 conveyor Drop Operation Raw shale In process 233,000 tpy Enclosed Functional 90% Uncontrolled 0.003 lb/ton 0.00510 0.1 0.05936 0.03495 0.05936
Kiln Feed KF5 #5 conveyor Conveyor Raw shale In process 233,000 tpy Dust cover Functional 70% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 0.3 No calculated value 0.04349 0.04349
Kiln Feed KF6 Drop point, #5 conveyor to shale storage pile Drop Operation Raw shale In process 233,000 tpy Enclosed Functional 97% Uncontrolled 0.003 lb/ton 0.00510 0.03 0.01781 0.01049 0.01781
Kiln Feed KF7 Kiln feed storage pile Storage Pile Raw shale In process 233,000 tpy Partially enclosed Functional 88% 0.21047 0.1 0.00034 #N/A 0.00034
Kiln Feed (KF7) Low pile height Functional 20% (Additional control) (Additional control) (Additional control) #N/A (Additional control)
Kiln Feed KF8 Drop point, shale storage pile to kiln 1 feeder belt Drop Operation Raw shale In process 121,000 tpy Underground Functional 99% 0.003 lb/ton 0.00510 0.01 0.00308 0.00182 0.00308
Kiln Feed KF9 Kiln 1 feeder belt Conveyor Raw shale In process 121,000 tpy Underground Functional 90% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 0.1 No calculated value 0.00149 0.00149
Kiln Feed KF10 Drop point, kiln 1 feeder belt to kiln 1 lower belt Drop Operation Raw shale In process 121,000 tpy Enclosed Functional 80% Uncontrolled 0.003 lb/ton 0.00510 0.2 0.06165 0.03630 0.06165
Kiln Feed KF11 Kiln 1 lower belt Conveyor Raw shale In process 121,000 tpy Dust cover Functional 70% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 0.3 No calculated value 0.01104 0.01104
Kiln Feed (KF11) Partially underground Functional (Additional control) (Additional control) (Additional control) #N/A (Additional control)
Kiln Feed (KF11) Meat locker curtain Functional (Additional control) (Additional control) (Additional control) #N/A (Additional control)
Kiln Feed KF12 Drop point, kiln 1 lower belt to kiln 1 top belt Drop Operation Raw shale In process 121,000 tpy Enclosed Functional 80% Uncontrolled 0.003 lb/ton 0.00510 0.2 0.06165 0.03630 0.06165
Kiln Feed KF13 Kiln 1 top belt Conveyor Raw shale In process 121,000 tpy Dust cover Functional 70% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 0.3 No calculated value 0.00381 0.00381
Kiln Feed KF14 Drop point, kiln 1 top belt to kiln 1 feed Drop Operation Raw shale In process 121,000 tpy Chute Functional 90% Uncontrolled 0.003 lb/ton 0.00510 0.1 0.03083 0.01815 0.03083
Kiln Feed KF15 Kiln 1 feed (AccuRate feeder) Drop Operation Raw shale In process 121,000 tpy Dust cover Functional 0% Uncontrolled 3.00E-03 lb/ton 0.00510 1 0.30826 0.18150 0.30826
Kiln Feed KF16 Kiln 1 rear chamber system (rim seal) General Kiln rear chamber seal d In process 121,000 tpy Dust cover Functional 99% Uncontrolled 8.40E-01 lb/ton No calculated value 0.01 No calculated value 0.50820 0.50820
Kiln Feed KF17 Kiln 1 front seal General Raw shale In process 121,000 tpy Vacuum Functional 99% Uncontrolled 8.40E-01 lb/ton No calculated value 0.01 No calculated value 0.50820 0.50820
Kiln Feed KF18 Drop point, shale storage pile to kiln 2 feeder belt Drop Operation Raw shale In process 112,000 tpy Underground Functional 99% 0.003 lb/ton 0.00510 0.01 0.00285 0.00168 0.00285
Kiln Feed KF19 Kiln 2 feeder belt Conveyor Raw shale In process 112,000 tpy Underground Functional 90% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 0.1 No calculated value 0.00138 0.00138
Kiln Feed KF20 Drop point, kiln 2 feeder belt to kiln 2 lower belt Drop Operation Raw shale In process 112,000 tpy Enclosed Functional 90% Uncontrolled 0.003 lb/ton 0.00510 0.1 0.02853 0.01680 0.02853
Kiln Feed KF21 Kiln 2 lower belt Conveyor Raw shale In process 112,000 tpy Dust cover Functional 70% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 0.3 No calculated value 0.01065 0.01065
Kiln Feed (KF21) Partially underground Functional (Additional control) (Additional control) (Additional control) #N/A (Additional control)
Kiln Feed (KF21) Meat locker curtain Functional (Additional control) (Additional control) (Additional control) #N/A (Additional control)
Kiln Feed KF22 Drop point, kiln 2 lower belt to kiln 2 middle belt Drop Operation Raw shale In process 112,000 tpy Chute Functional 80% Uncontrolled 0.003 lb/ton 0.00510 0.2 0.05707 0.03360 0.05707
Kiln Feed KF23 Kiln 2 middle belt Conveyor Raw shale In process 112,000 tpy Dust cover Functional 70% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 0.3 No calculated value 0.00449 0.00449
Kiln Feed KF24 Drop point, kiln 2 middle belt to kiln 2 top belt Drop Operation Raw shale In process 112,000 tpy Chute Functional 80% Uncontrolled 0.003 lb/ton 0.00510 0.2 0.05707 0.03360 0.05707
Kiln Feed KF25 Kiln 2 top belt Conveyor Raw shale In process 112,000 tpy Dust cover Functional 70% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 0.3 No calculated value 0.00564 0.00564
Kiln Feed KF26 Drop point, kiln 2 top belt to kiln 2 feed Drop Operation Raw shale In process 112,000 tpy Chute Functional 80% Uncontrolled 0.003 lb/ton 0.00510 0.2 0.05707 0.03360 0.05707
Kiln Feed KF27 Kiln 2 feed (AccuRate feeder) Drop Operation Raw shale In process 112,000 tpy Dust cover Functional 0% Uncontrolled 3.00E-03 lb/ton 0.00510 1 0.28533 0.16800 0.28533
Kiln Feed KF28 Kiln 2 rear chamber system (rim seal) General Kiln rear chamber seal d In process 112,000 tpy Dust cover Functional 99% Uncontrolled 8.40E-01 lb/ton No calculated value 0.01 No calculated value 0.47040 0.47040
Kiln Feed KF29 Kiln 2 front seal General Raw shale In process 112,000 tpy Vacuum Functional 99% Uncontrolled 8.40E-01 lb/ton No calculated value 0.01 No calculated value 0.47040 0.47040
Kiln Feed KF30 Opening of kiln rim seals for cleaning General Kiln rear chamber seal d In process 438 tpy None None 0% Uncontrolled 3.00E-03 lb/ton No calculated value 1 No calculated value 0.00066 0.00066
Kiln Feed KF31 Removal of bag house plug (vacuum truck unloading) General Kiln rear chamber seal d In process 338 tpy Water suppression Functional 0% Uncontrolled 3.00E-03 lb/ton No calculated value 1 No calculated value 0.00051 0.00051
Kiln Feed (KF31) Baghouse Functional (Additional control) (Additional control) (Additional control) #N/A (Additional control)
Kiln KL1 Drop point, kiln 1 to kiln 1 clinker cooler General Clinker In process 121,000 tpy Enclosed Functional 99% Uncontrolled 0.003 lb/ton No calculated value 0.01 No calculated value 0.00182 0.00182
Kiln KL2 Kiln 1 clinker cooler General Clinker In process 121,000 tpy Enclosed Functional 90% Uncontrolled 3.00E-01 lb/ton No calculated value 0.1 No calculated value 1.81500 1.81500
Kiln KL3 Drop point, kiln 1 clinker cooler to kiln 1 clinker belt General Clinker In process 121,000 tpy Partially enclosed Functional 80% Uncontrolled 0.003 lb/ton No calculated value 0.2 No calculated value 0.03630 0.03630
Kiln KL4 Kiln 1 clinker belt Conveyor Clinker In process 121,000 tpy Partially underground Functional 70% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 0.3 No calculated value 0.02122 0.02122
Kiln (KL4) Dust cover Functional (Additional control) (Additional control) (Additional control) #N/A (Additional control)
Kiln (KL4) Water suppression, as needed Functional 0% (Additional control) (Additional control) (Additional control) #N/A (Additional control)
Kiln KL5 Drop point, kiln 1 clinker belt to kiln 1 clinker pile Drop Operation Clinker In process 121,000 tpy Water suppression Not functional 50% Uncontrolled 0.003 lb/ton 0.01345 0.5 0.40675 0.09075 0.40675
Kiln KL6 Kiln 1 clinker pile Storage Pile Clinker In process 121,000 tpy Water suppression Partially functional 50% 2.77823 0.5 0.01549 #N/A 0.01549
Kiln KL7 Drop point, kiln 2 to kiln 2 clinker cooler General Clinker In process 112,000 tpy Enclosed Functional 99% Uncontrolled 0.003 lb/ton No calculated value 0.01 No calculated value 0.00168 0.00168
Kiln KL8 Kiln 2 clinker cooler General Clinker In process 112,000 tpy Enclosed Functional 90% Uncontrolled 3.00E-01 lb/ton No calculated value 0.1 No calculated value 1.68000 1.68000
Kiln KL9 Drop point, kiln 2 clinker cooler to kiln 2 clinker belt General Clinker In process 112,000 tpy Partially enclosed Functional 80% Uncontrolled 0.003 lb/ton No calculated value 0.2 No calculated value 0.03360 0.03360
Kiln KL10 Kiln 2 clinker belt Conveyor Clinker In process 112,000 tpy Partially underground Functional 70% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 0.3 No calculated value 0.01895 0.01895
Kiln (KL10) Dust cover Functional 0% (Additional control) (Additional control) (Additional control) #N/A (Additional control)
Kiln (KL10) Water suppression, as needed Functional (Additional control) (Additional control) (Additional control) #N/A (Additional control)
Kiln KL11 Drop point, kiln 2 clinker belt to kiln 2 clinker pile Drop Operation Clinker In process 112,000 tpy Water suppression, mist Not functional 50% Uncontrolled 0.003 lb/ton 0.01345 0.5 0.37650 0.08400 0.37650
Kiln KL12 Kiln 2 clinker pile Storage Pile Clinker In process 112,000 tpy Water suppression, mist Partially functional 50% 2.77823 0.5 0.01549 #N/A 0.01549
Kiln KL13 Transfer kiln 2 clinker pile to kiln 1 clinker pile Drop Operation Clinker In process 112,000 tpy Loader Operator Protocol Functional 0% Uncontrolled 3.00E-03 lb/ton 0.01345 1 0.75300 0.16800 0.75300
Kiln KL14 Muck pile Storage Pile Kiln baghouse dust Post process 8,160 tpy Moisture; Pile shaping; Compaction Functional; Functional; Functional 50% 84.18870 0.5 1.05615 #N/A 1.05615
Kiln KL15 Loading onto muck pile Drop Operation Kiln baghouse dust Post process 8,160 tpy None None 0% 0.00011 1 0.00047 #N/A 0.00047
Kiln KL16 Unloading muck pile Drop Operation Kiln baghouse dust Post process 8,160 tpy None None 0% 0.00011 1 0.00047 #N/A 0.00047
Finish Plant FP1 Drop point, kiln 1 clinker pile to transfer to #1 conveyor General Clinker In process 233,000 tpy Underground Functional 90% Uncontrolled 3.00E-03 lb/ton No calculated value 0.1 No calculated value 0.03495 0.03495
Finish Plant FP2 #1 conveyor Conveyor Clinker In process 233,000 tpy Dust cover Functional 70% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 0.3 No calculated value 0.01599 0.01599
Finish Plant (FP2) Partially underground Functional (Additional control) (Additional control) (Additional control) #N/A (Additional control)
Finish Plant FP3 Drop point, #1 conveyor to grizzly Drop Operation Clinker In process 233,000 tpy None None 80% Uncontrolled 0.003 lb/ton 0.01345 0.2 0.31330 0.06990 0.31330
Finish Plant FP4 Grizzly on lightweight aggregate feed platform Drop Operation Clinker In process 233,000 tpy Partially enclosed Functional 70% Uncontrolled 3.00E-03 lb/ton 0.01345 0.3 0.46995 0.10485 0.46995
Finish Plant FP5 Drop point, grizzly to grizzly pile Drop Operation Clinker In process 233,000 tpy None None 0% Uncontrolled 0.003 lb/ton 0.01345 1 1.56651 0.34950 1.56651
Finish Plant FP6 Grizzly reject pile Storage Pile Clinker In process 1,167 tpy None None 0% 2.77823 1 0.00510 #N/A 0.00510
Finish Plant FP7 Drop point, grizzly to #2 conveyor Drop Operation Clinker In process 233,000 tpy Enclosed Functional 90% Uncontrolled 0.003 lb/ton 0.01345 0.1 0.15665 0.03495 0.15665
Finish Plant FP8 #2 conveyor Conveyor Clinker In process 233,000 tpy Dust cover Functional 70% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 0.3 No calculated value 0.03155 0.03155
Finish Plant FP9 Drop point, #2 conveyor to triple deck finish mill screen Drop Operation Clinker In process 233,000 tpy Enclosed Functional 90% Uncontrolled 0.003 lb/ton 0.01345 0.1 0.15665 0.03495 0.15665
Finish Plant FP10 Triple deck finish mill screen General Clinker In process 233,000 tpy Baghouse Not functional 0% Uncontrolled 2.20E-03 lb/ton No calculated value 1 No calculated value 0.25630 0.25630
Finish Plant FP11 Drop point, triple deck finish mill screen to 3/4" discharge conveyor Drop Operation 3/4" In process 69,000 tpy Enclosed Functional 90% Uncontrolled 0.003 lb/ton 0.00373 0.1 0.01286 0.01035 0.01286
Finish Plant FP12 3/4" discharge conveyor Conveyor 3/4" In process 69,000 tpy Dust cover Functional 70% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 0.3 No calculated value 0.00647 0.00647
Finish Plant (FP12) Baghouse Not functional 0% (Additional control) (Additional control) (Additional control) #N/A (Additional control)
Finish Plant FP13 Drop point, 3/4" discharge conveyor to 3/4" to stockpile conveyor Drop Operation 3/4" In process 69,000 tpy Enclosed Functional 80% Uncontrolled 0.003 lb/ton 0.00373 0.2 0.02572 0.02070 0.02572
Finish Plant FP14 3/4" to stockpile conveyor Conveyor 3/4" In process 69,000 tpy Dust cover Functional 70% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 0.3 No calculated value 0.01273 0.01273
Finish Plant FP15 Drop point, 3/4" to stockpile conveyor to 3/4" short term storage pile Drop Operation 3/4" In process 69,000 tpy Tube Functional 90% Uncontrolled 0.003 lb/ton 0.00373 0.05 0.00643 0.00518 0.00643
Finish Plant (FP15) Water suppression Functional 50% (Additional control) (Additional control) (Additional control) #N/A (Additional control)
Finish Plant FP16 3/4" short term storage pile Storage Pile 3/4" In process 98,185 tpy Water suppression Functional 50% 1.13655 0.5 0.00449 #N/A 0.00449
Finish Plant FP17 Drop point, triple deck finish mill screen to 3/8" discharge conveyor Drop Operation 3/8" In process 46,000 tpy Enclosed Functional 80% Uncontrolled 0.003 lb/ton 0.00373 0.2 0.01715 0.01380 0.01715
Finish Plant FP18 3/8" discharge conveyor Conveyor 3/8" In process 46,000 tpy Dust cover Functional 70% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 0.3 No calculated value 0.00289 0.00289
Finish Plant (FP18) Baghouse Not functional 0% (Additional control) (Additional control) (Additional control) #N/A (Additional control)
Finish Plant FP19 Drop point, 3/8" discharge conveyor to 3/8" to stockpile conveyor Drop Operation 3/8" In process 46,000 tpy Enclosed Functional 0% Uncontrolled 0.003 lb/ton 0.00373 1 0.08575 0.06900 0.08575
Finish Plant FP20 3/8" to stockpile conveyor Conveyor 3/8" In process 46,000 tpy Dust cover Functional 70% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 0.3 No calculated value 0.00660 0.00660
Finish Plant FP21 Drop point, 3/8" stockpile conveyor to 3/8" short term storage pile Drop Operation 3/8" In process 46,000 tpy Water suppression, spray head Functional 50% Uncontrolled 0.003 lb/ton 0.00373 0.5 0.04287 0.03450 0.04287
Finish Plant FP22 3/8" short term storage pile Storage Pile 3/8" In process 25,550 tpy Water suppression, spray head Functional 70% 1.24178 0.3 0.05191 #N/A 0.05191
Finish Plant FP23 Drop point, triple deck finish mill screen to oversize discharge conveyor Drop Operation Clinker In process 133,975 tpy Enclosed Functional 90% Uncontrolled 0.003 lb/ton 0.01345 0.1 0.09007 0.02010 0.09007
Finish Plant FP24 Oversize discharge conveyor Conveyor Clinker In process 133,975 tpy Partially covered Functional 70% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 0.3 No calculated value 0.01122 0.01122
23
Norlite Fugitive Dust Sources and Calculations Calc AP 42
Area Source ID Source Name Source Type Product In/Post Proces P - Production Rate Units Control Condition ER - emissions reduction efficiency, %Emission Factor Type Emission Factor (EF) EF Units EF - Calculated Emission Factor (1-ER/100) E - Emissions, ton/yr via calculations E - Emissions, ton/yr via AP-42 facCombined Emissions
Finish Plant (FP24) Baghouse Not functional 0% (Additional control) (Additional control) (Additional control) #N/A (Additional control)
Finish Plant FP25 Drop point, oversize discharge conveyor to oversize hopper Drop Operation Clinker In process 133,975 tpy None None 0% Uncontrolled 0.003 lb/ton 0.01345 1 0.90074 0.20096 0.90074
Finish Plant FP26 Oversize hopper General Clinker In process 133,975 tpy None None 0% Uncontrolled 3.00E-03 lb/ton No calculated value 1 No calculated value 0.20096 0.20096
Finish Plant FP27 Drop point, oversize hopper to El Jay crusher speed conveyor Drop Operation Clinker In process 133,975 tpy Partially enclosed Functional 70% Uncontrolled 0.003 lb/ton 0.01345 0.3 0.27022 0.06029 0.27022
Finish Plant FP28 El Jay crusher speed conveyor Conveyor Clinker In process 133,975 tpy Dust cover Functional 70% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 0.3 No calculated value 0.01151 0.01151
Finish Plant FP29 Drop point, El Jay crusher speed conveyor to El Jay crusher Drop Operation Clinker In process 133,975 tpy Enclosed Functional 90% Uncontrolled 0.003 lb/ton 0.01345 0.1 0.09007 0.02010 0.09007
Finish Plant FP30 El Jay crusher General Clinker In process 133,975 tpy Baghouse Not functional 90% Uncontrolled 2.50E-02 lb/ton No calculated value 0.1 No calculated value 0.16747 0.16747
Finish Plant FP31 Drop point, El Jay crusher to El Jay discharge conveyor Drop Operation Clinker In process 133,975 tpy Enclosed Functional 90% Uncontrolled 0.003 lb/ton 0.01345 0.1 0.09007 0.02010 0.09007
Finish Plant FP32 El Jay discharge conveyor Conveyor Clinker In process 133,975 tpy None None 0% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 1 No calculated value 0.00804 0.00804
Finish Plant FP33 Drop point, El Jay discharge conveyor to #2 return conveyor Drop Operation Clinker In process 133,975 tpy Enclosed Functional 80% Uncontrolled 0.003 lb/ton 0.01345 0.2 0.18015 0.04019 0.18015
Finish Plant FP34 #2 return conveyor Conveyor Clinker In process 133,975 tpy Dust cover Functional 70% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 0.3 No calculated value 0.01398 0.01398
Finish Plant FP35 Drop point, #2 return conveyor to #2 conveyor Drop Operation Clinker In process 133,975 tpy Enclosed Functional 80% Uncontrolled 0.003 lb/ton 0.01345 0.2 0.18015 0.04019 0.18015
Finish Plant FP36 Drop point, triple deck finish mill screen to fines to silo conveyor Drop Operation Block mix In process 28,000 tpy Enclosed Functional 90% Uncontrolled 0.003 lb/ton 0.00373 0.1 0.00522 0.00420 0.00522
Finish Plant FP37 Fines to silo conveyor Conveyor Block mix In process 28,000 tpy Dust cover Functional 70% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 0.3 No calculated value 0.00840 0.00840
Finish Plant (FP37) Baghouse Not functional 0% (Additional control) (Additional control) (Additional control) #N/A (Additional control)
Finish Plant FP38 Drop point, fines to silo conveyor to enclosed fines storage pile Drop Operation 4x0 In process 85,000 tpy Chute Functional 94% Uncontrolled 0.003 lb/ton 0.00373 0.06 0.00951 0.00765 0.00951
Finish Plant FP39 Enclosed fines storage pile Storage Pile 4x0 In process 85,000 tpy Roof Functional 20% 5.85111 0.2 0.03001 #N/A 0.03001
Finish Plant (FP39) Concrete enclosure at bottom Functional 75% (Additional control) (Additional control) (Additional control) #N/A (Additional control)
Finish Plant (FP39) Tarps Functional (Additional control) (Additional control) (Additional control) #N/A (Additional control)
Finish Plant FP40 Open fines storage pile Storage Pile 4x0 In process 85,000 tpy Enclosed Functional 20% 5.85111 0.2 0.00981 #N/A 0.00981
Finish Plant (FP40) Concrete wall to south Functional 50% (Additional control) (Additional control) (Additional control) #N/A (Additional control)
Finish Plant (FP40) Wind screen Functional 50% (Additional control) (Additional control) (Additional control) #N/A (Additional control)
Finish Plant FP41 Baghouse dust silo 1 Storage Pile Block mix In process 85,000 tpy Enclosed Functional 97% Controlled, fabric filter 9.90E-03 lb/ton 7.82955 0.03 0.00153 0.01262 0.00153
Finish Plant FP42 Drop point, baghouse dust silo 1 to shipping belt Drop Operation Block mix In process 85,000 tpy Enclosed Functional 99% 0.003 lb/ton 0.00373 0.01 0.00158 0.00128 0.00158
Finish Plant FP43 Baghouse dust silo 2 Storage Pile Block mix In process 85,000 tpy Enclosed Functional 97% Controlled, fabric filter 9.90E-03 lb/ton 7.82955 0.03 0.00153 0.01262 0.00153
Finish Plant FP44 Drop point, baghouse dust silo 2 to shipping belt Drop Operation Block mix In process 85,000 tpy Enclosed Functional 99% 0.003 lb/ton 0.00373 0.01 0.00158 0.00128 0.00158
Finish Plant FP45 Shipping belt Conveyor Block mix In process 27,094 tpy Partially underground Functional 90% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 0.1 No calculated value 0.00102 0.00102
Finish Plant (FP45) Dust cover Functional (Additional control) (Additional control) (Additional control) #N/A (Additional control)
Finish Plant FP46 Drop point, shipping belt to stationary belt Drop Operation Block mix In process 27,094 tpy Enclosed Functional 90% Uncontrolled 0.003 lb/ton 0.00373 0.1 0.00505 0.00406 0.00505
Finish Plant FP47 Stationary belt Conveyor Block mix In process 27,094 tpy Dust cover Functional 70% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 0.3 No calculated value 0.00369 0.00369
Finish Plant (FP47) Baghouse; Improved maintenance Functional; Functional (Additional control) (Additional control) (Additional control) #N/A (Additional control)
Finish Plant FP48 Drop point, stationary belt to radial stacker Drop Operation Block mix In process 27,094 tpy Enclosed Functional 90% Uncontrolled 0.003 lb/ton 0.00373 0.1 0.00505 0.00406 0.00505
Finish Plant FP49 Radial stacker Conveyor Block mix In process 27,094 tpy Dust cover; Spray head adjustment Functional; Partially Functional 70% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 0.3 No calculated value 0.00301 0.00301
Finish Plant FP50 Drop point, radial stacker to block mix short term storage pile 1 Drop Operation Block mix In process 27,094 tpy Baghouse Functional 90% Uncontrolled 0.003 lb/ton 0.00373 0.0125 0.00063 0.00051 0.00063
Finish Plant (FP50) Water suppression Functional 50% (Additional control) (Additional control) (Additional control) #N/A (Additional control)
Finish Plant (FP50) Adjustable discharge height Functional 75% (Additional control) (Additional control) (Additional control) #N/A (Additional control)
Finish Plant FP51 Block mix short term storage pile 1 Storage Pile Block mix In process 15,133 tpy Low pile height/bldg Functional 20% 7.82955 0.8 0.07249 #N/A 0.07249
Finish Plant FP52 Block mix short term storage pile 2 Storage Pile Block mix In process 14,764 tpy Low pile height/bldg Functional 20% 7.82955 0.8 0.07249 #N/A 0.07249
Finish Plant FP53 Block mix short term storage pile 3 Storage Pile Block mix In process 2,147 tpy Low pile height/small pile/bldg Functional 50% 7.82955 0.5 0.03096 #N/A 0.03096
Finish Plant FP54 Block mix short term storage pile 4 Storage Pile Block mix In process 13,421 tpy Low pile height/bldg Functional 20% 7.82955 0.8 0.11829 #N/A 0.11829
Finish Plant FP55 Block mix short term storage pile 5 Storage Pile Block mix In process 33,788 tpy Low pile height Functional 20% 7.82955 0.8 0.27841 #N/A 0.27841
Finish Plant FP56 Block mix short term storage pile 6 Storage Pile Block mix In process 2,550 tpy Low pile height/small pile Functional 50% 7.82955 0.5 0.05963 #N/A 0.05963
Finish Plant FP57 3/4" long term storage pile 5 Storage Pile 3/4" Post process 37,531 tpy Low pile height Functional 20% 1.13655 0.8 0.01717 #N/A 0.01717
Finish Plant FP58 Loading 3/4" onto trucks Drop Operation 3/4" Post process 69,000 tpy Loader Operator Protocol Functional 0% Uncontrolled 3.00E-03 lb/ton 0.00080 1 0.02763 0.10350 0.02763
Finish Plant FP59 Loading 3/8" onto trucks Drop Operation 3/8" Post process 46,000 tpy Loader Operator Protocol Functional 0% Uncontrolled 3.00E-03 lb/ton 0.00080 1 0.01842 0.06900 0.01842
Finish Plant FP60 Loading clinker onto trucks Drop Operation Clinker Post process 233,000 tpy Loader Operator Protocol Functional 0% Uncontrolled 3.00E-03 lb/ton 0.00141 1 0.16458 0.34950 0.16458
Finish Plant FP61 Loading block mix onto piles Drop Operation Block mix Post process 92,000 tpy Loader Operator Protocol Functional 0% Uncontrolled 3.00E-03 lb/ton 0.00080 1 0.03684 0.13800 0.03684
Finish Plant FP62 Loading block mix onto trucks Drop Operation Block mix Post process 92,000 tpy Loader Operator Protocol Functional 0% Uncontrolled 3.00E-03 lb/ton 0.00080 1 0.03684 0.13800 0.03684
Fines Processing FN1 8 X 0 long term storage pile Storage Pile Block mix Post process 27,094 tpy Enclosed Functional 85% 7.82955 0.15 0.02218 #N/A 0.02218
Fines Processing FN2 4 X 0 fines feed pile Storage Pile 4x0 In process 66,839 tpy Low pile height Functional 20% 5.85111 0.8 0.01975 #N/A 0.01975
Fines Processing FN3 Loading of block mix into Cedarapids feed hopper (surge bin) Drop Operation 4x0 In process 66,839 tpy None None 0% Uncontrolled 3.00E-03 lb/ton 0.00373 1 0.12459 0.10026 0.12459
Fines Processing FN4 Cedarapids feed hopper (surge bin) General 4x0 In process 66,839 tpy None None 0% Uncontrolled 3.00E-03 lb/ton No calculated value 1 No calculated value 0.10026 0.10026
Fines Processing FN5 Drop point, Cedarapids feed hopper to feeder belt Drop Operation 4x0 In process 66,839 tpy None None 0% Uncontrolled 0.003 lb/ton 0.00373 1 0.12459 0.10026 0.12459
Fines Processing FN6 Feeder belt Conveyor 4x0 In process 66,839 tpy None None 0% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 1 No calculated value 0.01702 0.01702
Fines Processing FN7 Drop point, feeder belt to screen feed belt Drop Operation 4x0 In process 66,839 tpy None None 0% Uncontrolled 0.003 lb/ton 0.00373 1 0.12459 0.10026 0.12459
Fines Processing FN8 Screen feed belt Conveyor 4x0 In process 66,839 tpy None None 0% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 1 No calculated value 0.01154 0.01154
Fines Processing FN9 Drop point, screen feed belt to Astec 2618 fines screen Drop Operation 4x0 In process 66,839 tpy None None 0% Uncontrolled 0.003 lb/ton 0.00373 1 0.12459 0.10026 0.12459
Fines Processing FN10 Astec 2618 fines screen General 4x0 In process 66,839 tpy None None 0% Uncontrolled 0.002 lb/ton No calculated value 1 No calculated value 0.06684 0.06684
Fines Processing FN11 Drop point, fines screen to #4s belt Drop Operation 4x0 In process 66,839 tpy None None 0% Uncontrolled 0.003 lb/ton 0.00373 1 0.12459 0.10026 0.12459
Fines Processing FN12 #4s belt Conveyor 4x0 In process 66,839 tpy None None 0% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 1 No calculated value 0.01421 0.01421
Fines Processing FN13 Drop point, #4s belt to 4 mesh reject pile Drop Operation 4x0 In process 66,839 tpy None None 0% Uncontrolled 0.003 lb/ton 0.00373 1 0.12459 0.10026 0.12459
Fines Processing FN14 4 mesh reject pile Storage Pile 4x0 In process 27,094 tpy Low pile height Functional 20% 5.85111 0.8 0.01975 #N/A 0.01975
Fines Processing FN15 Drop point, fines screen to fines #8s belt Drop Operation 8x0 In process 27,094 tpy None None 0% Uncontrolled 0.003 lb/ton 0.00373 1 0.05050 0.04064 0.05050
Fines Processing FN16 #8s belt Conveyor 8x0 In process 27,094 tpy None None 0% Uncontrolled 0.003 lb/ton per 300 ft No calculated value 1 No calculated value 0.00580 0.00580
Fines Processing FN17 Drop point, #8s belt to fines 8 X 0 pile Drop Operation 8x0 In process 27,094 tpy None None 0% Uncontrolled 0.003 lb/ton 0.00373 1 0.05050 0.04064 0.05050
Fines Processing FN18 8 X 0 pile Storage Pile 8x0 In process 27,094 tpy Low pile height Functional 20% 7.53489 0.8 0.02543 #N/A 0.02543
Fines Processing FN19 3/4" long term storage pile 6 Storage Pile 3/4" Post process 9,847 tpy Low pile height Functional 20% 1.13655 0.8 0.00384 #N/A 0.00384
Fines Processing FN20 Loading screened fines onto trucks (8 X 0, 4 X 0, 4 mesh reject) Drop Operation Block mix Post process 27,094 tpy Loader Operator Protocol Functional 0% Uncontrolled 3.00E-03 lb/ton 0.00080 1 0.01085 0.04064 0.01085
Block Mix BM1 Block mix long term storage pile 1 Storage Pile Block mix Post process 8,376 tpy None None 0% 7.82955 1 0.25272 #N/A 0.25272
Block Mix BM2 Block mix long term storage pile 2 Storage Pile Block mix Post process 8,376 tpy Low pile height Functional 20% 7.82955 0.8 0.01598 #N/A 0.01598
Block Mix BM3 Block mix long term storage pile 3 Storage Pile Block mix Post process 8,376 tpy Low pile height Functional 20% 7.82955 0.8 0.01862 #N/A 0.01862
Block Mix BM4 Block mix long term storage pile 4 Storage Pile Block mix Post process 11,341 tpy Low pile height Functional 20% 7.82955 0.8 0.20980 #N/A 0.20980
Block Mix BM5 Loading block mix into portable screen Drop Operation Block mix Post process 89,118 tpy Loader Operator Protocol Functional 0% Uncontrolled 3.00E-03 lb/ton 0.00080 1 0.03568 0.13368 0.03568
Block Mix BM6 Astec 710T General Block mix Post process 44,559 tpy None None 0% Uncontrolled 0.002 lb/ton No calculated value 1 No calculated value 0.04456 0.04456
Block Mix BM7 Reade screen General Block mix Post process 44,559 tpy None None 0% Uncontrolled 0.002 lb/ton No calculated value 1 No calculated value 0.04456 0.04456
Block Mix BM8 Loading onto temporary block mix pile Drop Operation Block mix Post process 89,118 tpy Loader Operator Protocol Functional 0% Uncontrolled 3.00E-03 lb/ton 0.00080 1 0.03568 0.13368 0.03568
Block Mix BM9 Temporary block mix pile for customer pickup Storage Pile Block mix Post process 89,118 tpy Low pile height Functional 20% 7.82955 0.8 0.04084 #N/A 0.04084
Block Mix BM10 Loading block mix onto trucks Drop Operation Block mix Post process 89,118 tpy Loader Operator Protocol Functional 0% Uncontrolled 3.00E-03 lb/ton 0.00080 1 0.03568 0.13368 0.03568
Block Mix BM11 Loading onto block mix pile Drop Operation Block mix Post process 89,118 tpy None None 0% Uncontrolled 3.00E-03 lb/ton 0.00080 1 0.03568 0.13368 0.03568
Island IS1 3/4" long term storage pile 1 Storage Pile 3/4" Post process 2,840 tpy Low pile height Functional 20% 1.13655 0.8 0.00719 #N/A 0.00719
Island IS2 3/4" long term storage pile 2 Storage Pile 3/4" Post process 70,138 tpy Low pile height Functional 20% 1.13655 0.8 0.01052 #N/A 0.01052
Island IS3 3/4" long term storage pile 3 Storage Pile 3/4" Post process 4,014 tpy Low pile height Functional 20% 1.13655 0.8 0.02381 #N/A 0.02381
Island IS4 3/4" long term storage pile 4 Storage Pile 3/4" Post process 10,528 tpy Low pile height Functional 20% 1.13655 0.8 0.04041 #N/A 0.04041
Island IS5 3/8" long term storage pile Storage Pile 3/8" Post process 45,642 tpy Low pile height Functional 20% 1.24178 0.8 0.01876 #N/A 0.01876
Island IS6 Block mix long term storage pile 5 Storage Pile Block mix Post process 2,147 tpy Low pile height Functional 20% 7.82955 0.8 0.02643 #N/A 0.02643
Island IS7 Loading onto 3/4" pile Drop Operation Block mix Post process 69,000 tpy None None 0% Uncontrolled 3.00E-03 lb/ton 0.00080 1 0.02763 0.10350 0.02763
Island IS8 Loading 3/4" onto trucks Drop Operation Block mix Post process 69,000 tpy Loader Operator Protocol Functional 0% Uncontrolled 3.00E-03 lb/ton 0.00080 1 0.02763 0.10350 0.02763
Island IS9 Loading onto 3/8" pile Drop Operation Block mix Post process 46,000 tpy None None 0% Uncontrolled 3.00E-03 lb/ton 0.00080 1 0.01842 0.06900 0.01842
Island IS10 Loading 3/8" onto trucks Drop Operation Block mix Post process 46,000 tpy Loader Operator Protocol Functional 0% Uncontrolled 3.00E-03 lb/ton 0.00080 1 0.01842 0.06900 0.01842
Boneyard BY1 Boneyard shale pile 1 Storage Pile Shale fines Post process 9,446 tpy None None 0% 0.16838 1 0.00410 #N/A 0.00410
Boneyard BY2 Boneyard shale pile 2 Storage Pile Shale fines Post process 9,446 tpy None None 0% 0.16838 1 0.00410 #N/A 0.00410
Boneyard BY3 Loading shale fines onto boneyard shale piles Drop Operation Shale fines Post process 9,446 tpy None None 0% Uncontrolled 3.00E-03 lb/ton 0.00073 1 0.00346 0.01417 0.00346
Boneyard BY4 Loading boneyard shale piles onto trucks Drop Operation Shale fines Post process 9,446 tpy Loader Operator Protocol Functional 0% Uncontrolled 3.00E-03 lb/ton 0.00073 1 0.00346 0.01417 0.00346
Overburden Storage OS1 Bulldozing Bulldozing Overburden Post process 206,265 tpy None None 0% Uncontrolled 3.00E-03 lb/ton 6.55695 1 2.88506 0.30940 2.88506
Overburden Storage OS2 Receiving overburden from quarry Drop Operation Overburden Post process 206,265 tpy None None 0% Uncontrolled 2.00E-03 lb/ton 0.00008 1 0.00793 0.20627 0.00793
Overburden Storage OS3 Wind erosion in overburden storage area Overburden Erosion Overburden Post process -- -- None None 0% Uncontrolled 3.80E-01 ton/acre-year No calculated value 1 No calculated value 1.90000 1.90000
Road RD1 Transport of stone from quarry to primary Unpaved Road Shale fines In process 15,504 mi Water Functional 50% Uncontrolled 6.2 lb/mi 0.56834 0.5 2.20290 48062.78750 2.20290
Road RD2 Transfer of overburden from quarry to overburden storage area Unpaved Road Shale fines In process 15,875 mi Water Functional 50% Uncontrolled 6.2 lb/mi 0.56834 0.5 2.25566 49214.02652 2.25566
Road RD3 Transport of shales fines to boneyard Unpaved Road Shale fines In process 1,043 mi Water Functional 50% Uncontrolled 6.2 lb/mi 0.56834 0.5 0.14819 3233.12856 0.14819
Road RD4 Transport of product off-site by truck Unpaved Road Shale fines Post process 7,992 mi Water Functional 50% Uncontrolled 6.2 lb/mi 0.55304 0.5 1.10499 24775.34091 1.10499
Road RD5 Travel of LGF delivery trucks Unpaved Road Shale fines #N/A 550 mi Water Functional 50% Uncontrolled 6.2 lb/mi 0.55304 0.5 0.07598 1703.67898 0.07598
Road RD6 Maintenance traffic Unpaved Road Shale fines #N/A 2,914 mi Water Functional 50% Uncontrolled 6.2 lb/mi 0.29637 0.5 0.21589 9032.71307 0.21589
Road RD7 Passenger vehicle traffic Paved Road Shale fines #N/A 5,952 mi Water Functional 50% 0.96935 0.5 1.44230 #N/A 1.44230
Road RD8 Transport of shale fines to overburden storage area Unpaved Road Shale fines #N/A 1,427 mi Water Functional 50% Uncontrolled 6.2 lb/mi 0.56834 0.5 0.20276 4423.84091 0.20276
Road RD9 Water truck movement Unpaved Road Shale fines #N/A 3,686 mi Water Functional 50% Uncontrolled 6.2 lb/mi 0.35795 0.5 0.32983 11425.92129 0.32983
Road RD10 On-site product movement via front end loader Unpaved Road Shale fines #N/A 4,493 mi Water Functional 50% Uncontrolled 6.2 lb/mi 0.32171 0.5 0.36139 13929.45076 0.36139
24
APPENDIX D
SITE-SPECIFIC VARIABLES
25
Site‐wide Variables & Assumptions
a
Values obtained from AP‐42.
b
Values obtained from historical daily weather data for Albany International Airport for the years 2004 through 2013.
26
Overburden Characteristics
Silt
Content,
Sample Number Sample %
12580 SAND, fine/medium; some Silt/Clay; some fine Gravel 32.80%
12212 SILT/CLAY; little fine/medium Sand; little Fine Gravel 74.90%
12205 SILT/CLAY; and fine Sand; little fine Gravel 48.30%
12175 SAND, fine/medium; some Silt/Clay; some fine Gravel 31.80%
11707 SILT/CLAY; trace fine Sand; trace fine Gravel 95.10%
11706 SILT/CLAY; and fine/medium Sand; little fine Gravel 46.50%
11705 SILT/CLAY; trace fine Sand 98.50%
Average 61.13%
All values taken from Gifford Engineering's Interim Stablity Report on the Overburden Spoil
Storage Berms dated October 30, 2012.
27
Production Rates & Hours (select examples)
2012 Operating 2013 Operating Average
Average Hours Hours Operating Hours Fraction of Year
Area 2012 (ton/year) 2013 (ton/year) (ton/year) (hours/year) (hours/year) (hours/year) Operational
Quarry: 288,759 272,707 280,733 2,365 3,081 2,723 0.311
Kiln 1: 127,993 107,146 117,570 8,069 7,583 7,826 0.893
Kiln 2: 109,115 103,801 106,458 7,925 7,649 7,787 0.889
28
Product Characteristics
Moisture content (in Moisture content (post
a b c
Product Silt content, % process) , % process), % Density, ton/yd3
Raw shale 0.25% 2.00% 2.00%
Shale fines 0.20% 8.00% 8.00%
Clinker 3.30% 1.00% 5.00%
3/4" 1.35% 2.50% 7.50%
3/8" 1.48% 2.50% 7.50%
Block mix 9.30% 2.50% 7.50%
3/16" 1.35% 2.50% 7.50%
4x0 6.95% 2.50% 7.50%
8x0 8.95% 2.50% 7.50%
Overburden 61.13% 40.00% 40.00%
Kiln baghouse dust 100.00% 0.00% 30.00% 0.42
Kiln rear chamber seal dust 14.65% 0.00% 30.00% 1.20
Kiln clinker cooler multiclone dust 32.90% 0.00% 30.00% 0.93
Block mix baghouse dust 100.00% 2.50% 2.50%
Muck pile baghouse dust 100.00% 30.00% 30.00%
Finish plant baghouse dust 100.00% 2.50% 2.50%
a
Although material passing through a 200 sieve can contain both silt and clay, we assumed that all material passing through a 200 sieve is silt as a
conservative estimate of emissions.
b
The "in process" moisture content for the end products (3/4", 3/8", block mix, 3/16", 4x0, and 8x0) is 2.5%. The average moisture content for
these materials is between 0% and 5%, so an average value of 2.5% has been used in calculations.
c
The "post process" moisture content for the end products (3/4", 3/8", block mix, 3/16", 4x0, and 8x0) is 7.5%. The average moisture content for
these materials is between 5% and 10%, so an average value of 7.5% has been used in calculations.
29
Mean Vehicle Weightsa
Vehicle Type Mean Weight, tons
Quarry haul truck 42.5
Customer delivery truck 40
LGF delivery truck 40
Maintenance truck 10
Passenger vehicle 2
Front end loader 12
Water truckb 15.2
a
All vehicle weights listed here are mean weights (mean
of empty and full vehicles, if applicable).
b
Assume the water trucks can hold an average of 2,500
gal of water.
30
Southern Overburden Storage Area Clay Yardage
3
Year Overburden Stripped, yd Overburden Stripped, tons
2008 187,903.0 240,731.9
2009 339,389.0 434,808.2
2010 108,705.0 139,267.4
2011 150,580.0 192,915.6
2012 146,638.0 187,865.3
2013 61,940.0 79,354.4
Average* 165,859.2 212,490.5
* Excludes 2014 data
31
APPENDIX E
PHOTOGRAPH LOG
32
FUGITIVE DUST
EMISSION POINTS
PHOTOGRAPH LOG
NORLITE, LLC
A DIVISION OF TRADEBE ENVIRONMENTAL SERVICES, LLC
COHOES, NEW YORK
33
QUARRY AREA (QA)
EMISSION POINTS
PHOTOGRAPHS
34
Quarry Photograph 1, facing west:
Drilling (QA1, not pictured) and blasting (QA2, not pictured) operations occur in
the quarry to extract stone from the earth. Facing west, below is a quarried stone
pile (QA3) in the quarry, as a result of those efforts.
35
Quarry Photograph 2, facing west:
Stone is loaded (QA4) into a truck in the quarry. Stripped overburden (QA5, not
pictured) is also loaded (QA6, not pictured), into trucks in the quarry.
Stone loaded
into a truck
(QA4)
36
PRIMARY AREA (PR)
EMISSION POINTS
PHOTOGRAPHS
37
Primary Photograph 1, facing southwest:
Primary operations begin with loading (PR1, not pictured) and unloading (PR3, not
pictured) material onto and from the shot rock pile (PR2, not pictured). Shale from
the quarry is also loaded (PR4, not pictured) onto the shale stockpile (PR5, not
pictured) by front end loaders. A view of stone from the shale stockpile (PR5) being
unloaded (PR6) into the primary jaw crusher (PR7), primary jaw crusher (PR8), and
related drop points (PR9 and PR10).
Drop point –
transfer of raw
shale to primary
crusher (PR7,
Drop point enclosed)
from primary
crusher (PR9)
to crusher belt
(PR10,
enclosed) Shale stockpile
(PR5)
38
Primary Photograph 2, looking west:
A view of the primary jaw crusher (PR8) and where material drops (PR9) onto the
crusher belt (PR10) and drops (PR11) from the crusher belt to the screen belt
(PR12, enclosed).
Primary jaw
crusher (PR8)
Crusher belt
Transfer drop point (PR10)
from crusher belt to
screen belt (PR12)
(enclosed)
39
Primary Photograph 3, looking southwest:
A view of the partially enclosed screen belt (PR12) and where material drops (PR13) into the
double deck screen (PR14). The screen separates material onto two separate conveyor belts
(one to the kiln feed pile (PR21) and the other to the shale fines storage pile (PR25)). Within
the screen, some material is dropped (PR15, unseen) into the primary cone crusher (PR16,
unseen), to further crush material. This material drops (PR17, unseen) from the primary cone
crusher back to the primary crush screen for sorting. Some material, destined for the kiln
feed pile, drops (PR18) from the screen to the shale conveyor belt (PR19).
40
Primary Photograph 4, looking south:
A view of the shale conveyor belt (PR19) and the transfer of material dropping
(PR20) onto the shale kiln feed pile (PR21).
41
Primary Photograph 5, looking northwest:
A view of the second conveyor belt, the shale fines conveyor (PR23), transporting
material (PR24) from the double deck screen (PR15) to the shale fines pile (PR25).
There is also a loader that is used to load the shale fines to trucks (PR26).
42
KILN FEED AREA (KF)
EMISSION POINTS
PHOTOGRAPHS
43
Kiln Feed Area Photograph 1, looking southwest:
Underground and below the shale kiln feed pile (PR21), material drops (KF1, not
pictured) onto the #4 conveyor belt (KF3), which starts underground and extends
aboveground to transfer (KF4) material to the #5 conveyor belt (KF6). The #5
conveyor belt transports material to a drop point that deposits the material into the
kiln feed storage structure. A loader (not pictured) also transfers (KF2) material to
the #4 conveyor belt.
#5 conveyor belt
(KF5) to shale
storage structure #4 conveyor belt (KF3)
(KF7) (partially underground)
44
Kiln Feed Area Photograph 2, looking northeast:
A full view the transfer (KF4) from #4 conveyor belt (KF3) to the #5 conveyor belt
(KF5), which transfers (KF6) to the shale kiln feed storage structure (KF7) through
an enclosed chute. The shale storage structure is partially enclosed with a roof and
a back wall.
# 4 conveyor belt
(KF3)
45
Kiln Feed Area Photograph 3, looking east:
A close-up view of #5 conveyor belt (KF5) dropping (KF6) material through an
enclosed chute onto the shale kiln feed storage pile (KF7). The shale storage
structure is partially enclosed with a roof and a back wall.
Transfer drop point (KF6) Shale storage
from #5 conveyor belt to structure drop chute
shale storage structure (enclosed)
Shale storage
structure
northern wall
Kiln feed
storage pile
Shale storage structure roof
(KF7)
46
Kiln Feed Area Photograph 4, underground and looking northwest:
The shale kiln feed storage pile (KF7) drops (KF8) material onto the kiln 1 feeder
belt (KF9), which then drops (KF10) onto the kiln1 lower belt (KF11). The kiln 1
lower belt extends outside from underground and transfers material to the kiln 1 top
belt (out of frame).
47
Kiln Feed Area Photograph 5, looking north:
The kiln 1 lower belt (KF11) drops (KF12) material onto the kiln 1 top belt (KF13).
The kiln 1 top belt drops (KF14) material into the kiln 1 feed (KF15).
48
Kiln Feed Area Photograph 6 looking northwest:
The kiln 1 feed (KF15, enclosed), feeds material through the kiln 1 rear chamber
system (KF16, enclosed) and the kiln 1 front seal (KF17, enclosed).
49
Kiln Feed Area Photograph 7: Underground and looking northwest, the shale kiln
feed storage pile (KF7) drops (KF18) material onto the Kiln 2 feeder belt (KF19),
which then drops (KF20) onto the Kiln 2 lower belt (KF21). The Kiln 2 lower belt
extends from underground to the outside.
50
Kiln Feed Area Photograph 8, looking southeast:
The Kiln 2 lower belt (KF21) drops (KF22) material onto the kiln 2 middle belt
(KF23), which drops (KF24) material onto the kiln 2 top belt (KF25). The top belt
drops (KF26) material into kiln 2 feed (KF27, enclosed), which goes directly into
kiln 2 rear chamber system (rim seal) (KF28). Material goes through, internally, to
the kiln 2 front seal (KF29, enclosed and not pictured).
51
Kiln Feed Area Photograph 9, looking northwest:
The kiln rim seal, which has a chute that can be opened for cleaning (KF30).
Off Photo
52
Kiln Feed Area Photograph 10, looking west: The kiln rim seal chute is opened
(KF31) for cleaning.
53
KILN AREA (KL) EMISSION
POINTS PHOTOGRAPHS
54
Kiln Area Photographs 1 and 2:
Underground and looking west, material from Kiln 1 drops (KL1, out of frame) to the Kiln 1
clinker cooler (KL2, unseen – in building). Looking north, material then drops (KL3) below
to the Kiln 1 clinker belt (KL4), which advances outside from underground.
Fugitive dust
source IDs KL1
(Kiln 1 material
drop) and KL2
(Kiln 1 clinker
cooler) originate
inside of this
building.
Material drops
The kiln 1 clinker (KL3) from kiln 1
belt (KL4), clinker cooler
partially
underground
55
Kiln Area Photograph 3:
Looking west, material from kiln 1 clinker belt (KL4) drops (KL5) to the kiln 1
clinker pile (KL6). Material from the kiln 2 clinker pile (KL12, not pictured) is also
transferred (KL13) to the kiln 1 clinker pile.
56
Kiln Area Photographs 4 and 5:
Looking west, material from kiln 2 drops (KL7, unseen – in building) to the kiln 2
clinker cooler (KL8, unseen – in building). Material then drops (KL9) below to the
Kiln 2 clinker belt (KL10), which advances outside from underground.
57
Kiln Area Photograph 6:
Looking west, material from kiln 2 clinker belt (KL10) drops (KL11) to the kiln 2 clinker pile
(KL12). Material in the kiln 2 clinker pile is transferred (KL13) to combine with the kiln 1
clinker pile (KL6). Material from the kiln 2 clinker pile (KL12) is also transferred (KL13) to
the kiln 1 clinker pile.
Material being
loaded for transfer
(KL13) to the Kiln
1 clinker pile
58
Kiln Area Photograph 7, looking north: This is the muck pile (KL14), from where
material is loaded (KL15, not pictured) and unloaded (KL16, not pictured).
59
FINISHING PLANT AREA (FP)
EMISSION POINTS
PHOTOGRAPHS
60
Finishing Plant Area Photograph 1, looking west: The material in the kiln 1 clinker
pile (KL6) is dropped (FP1, underground and not pictured) onto the #1 conveyor
(FP2), which begins underground and extends above ground.
#1 conveyor
(FP2)
Kiln 1 clinker
pile (KL6)
61
Finishing Plant Area Photograph 2, looking northwest:
The material on the #1 conveyor (FP2) drops (FP3) into the grizzly (FP4), which is a
small screen that sits on the lightweight aggregate feed platform. Material drops (FP5)
from the grizzly onto the grizzly reject pile (FP6).
Grizzly (FP4)
#1 conveyor (FP2)
62
Finishing Plant Area Photograph 3, looking north:
The accepted material from the grizzly drops (FP7) onto the #2 conveyor (FP8),
which then drops (FP9) the material to the triple deck finish mill screen (FP10).
#2 conveyor (FP8)
63
Finishing Plant Area Photograph 4, looking northwest:
The material in the triple deck finish mill screen (FP10) drops (FP11) material onto the 3/4”
discharge conveyor (FP12). Material from the 3/4” discharge conveyor (FP12) then drops
(FP13, out of frame) onto the 3/4” to stockpile conveyor (FP14, out of frame).
64
Finishing Plant Area Photograph 5, looking east:
Material from the 3/4” discharge conveyor (FP12) drops (FP13) onto the 3/4” to
stockpile conveyor (FP14). Material on the 3/4” to stockpile conveyor then drops
(FP15) onto the 3/4” short term storage pile (FP16).
65
Finishing Plant Area Photograph 6, looking east: The material in the triple deck finish mill
screen (FP10) drops (FP17, internal and not pictured) material onto the 3/8” discharge
conveyor (FP18). Material from the 3/8” discharge conveyor drops (FP19) onto the 3/8” to
stockpile conveyor (FP20). Material on the 3/8” to stockpile conveyor drops (FP21) onto the
3/8” short term storage pile (FP22).
3/8” stockpile
conveyor (FP20)
Drop point (FP17)
onto 3/8” discharge
conveyor (FP18)
Drop point (FP21)
from 3/8” stockpile
conveyor to 3/8”
short term storage
pile (FP22)
3/8” discharge
conveyor (FP18) 3/8” short term
storage pile (FP22)
66
Finishing Plant Area Photograph 7, looking east:
The material in the triple deck finish mill screen (FP10) drops (FP23, enclosed and not pictured)
material onto the oversize discharge conveyor (FP24). Material from the oversize discharge
conveyor drops (FP25) into the oversize hopper (FP26). The material in the oversize discharge
hopper (FP26) drops (FP27) onto the El Jay crusher speed conveyor (FP28). From here, material
drops (FP29) into the El Jay crusher (FP30) where the oversized material is crushed down into
Triple deck finish smaller sizes.
mill screen (FP10,
internal) Drop point (FP25,
enclosed with chute)
Drop point (FP23, Oversize hopper (FP26)
from FP24 to FP26.
not seen) from FP10
to FP24.
Oversize discharge
conveyor (FP24)
67
Finishing Plant Area Photograph 8, looking northeast:
After material is re-crushed in the El Jay crusher (FP30), it is dropped (FP31) onto the El Jay
discharge conveyor (FP32), which transfers (FP33) material to the #2 return conveyor (FP34).
The #2 return conveyor returns (FP35) material to the #2 conveyor (FP8), which brings the
material back (FP9) to the triple deck finish mill screen (FP10) for re-sorting.
Triple deck finish
mill screen (FP10, El Jay crusher (FP30)
#2 conveyor (FP8) internal)
Drop point
(FP31, obscured
from view) from
FP30 to FP32
68
Finishing Plant Area Photograph 9, looking north:
The material in the triple deck finish mill screen (FP10) drops (FP36, enclosed and not
pictured) material onto the fines to silo conveyor (FP37). Material from the fines to silo
conveyor drops (FP38) down an enclosed chute into the enclosed fines storage pile (FP39).
Drop point
(FP38) from
FP37 to FP39
Fines to silo
conveyor (FP37)
Drop point
(FP36, enclosed)
from FP10 to
FP37
Enclosed fines
storage pile (FP39)
69
Finishing Plant Area Photograph 10, looking north:
A view of the open fines storage pile (FP40), which is to the immediate north of the
enclosed fines storage pile (FP39). Included in this photo is a view of the baghouse
dust silo 1 (FP41) and baghouse dust silo 2 (FP43).
70
Finishing Plant Area Photograph 11, looking north: Material drops (FP42, underground, not
viewed) material from Baghouse dust silo 1 (FP41) onto the shipping belt (FP45, mostly
obscured from view). Material is also dropped (FP44) from Baghouse dust silo 2 (FP43) onto
the shipping belt. Material is then transferred (FP46) onto the stationary belt (FP47), which
transfers (FP48) the material to the radial stacker (FP49). The radial stacker drops (FP50)
material onto the Block mix short term storage pile 1 (FP51).
Drop point (FP48) from Stationary belt Drop point (FP46) from
FP47 to FP49 (FP47) FP45 to FP47
71
Finishing Plant Area Photograph 12, looking north: The radial stacker (FP49)
transfers (FP50) material to block mix short term storage piles 1 through 6 (FP51
through FP56). Below is an example of what these short term storage piles may
look like at any given time.
72
Finishing Plant Area Photograph 13: Looking west, 3/4” long term storage pile 5
(FP57).
73
Finishing Plant Area Photograph 14: Looking northwest, a front-end loader is loading
(FP61) block mix on block mix short term storage pile 2 (FP52). A front-end loader
would similarly be used to load (FP58) 3/4” onto truck, load (FP59) 3/8” onto trucks,
load (FP60) clinker onto trucks, and load (FP62) block mix onto trucks.
Loading (FP61) of
block mix onto piles
74
FINES PROCESSING AREA
(FN) EMISSION POINTS
PHOTOGRAPHS
75
Fines Processing Area Photograph 1: Looking east, the 8x0 long term storage pile
(FN1), which is partially enclosed. The 8x0 pile (FN18, partially obscured) sits
outside and to the direct south of the 8x0 long term enclosure. The 4x0 fines feed
pile (FN2, not pictured) and the 4 mesh reject pile (FN14, not pictured) are also
stockpiles in the same row of stockpiles to the south of this enclosure in the fines
processing area. The 3/4” long term storage pile 6 (FN19, not pictured) sits to the
north of the pictured enclosure.
8x0 pile,
partially
obscured
(FN18)
76
Fines Processing Area Photograph 2, looking southwest: Block mix is loaded (FN3,
not pictured) into the Cedarapids feed hopper (FN4), which then drops (FN5)
material onto the feeder belt (FN6). The feeder belt transfers (FN7) the material
onto the screen feed belt (FN8).
Drop point
(FN7) from
FN6 to FN8
77
Fines Processing Area Photograph 3: Looking west, material is carried on the
screen feed belt (FN8) and dropped (FN9) from the screen feed belt to the Astec
2618 fines screen (FN10).
Drop point
(FN9, partially
Screen feed belt (FN8)
obscured) from
FN8 to FN10
78
Fines Processing Area Photograph 4, looking northeast: Material is separated though
the Astec fines screen (FN10) and is dropped (FN9) from the screen feed belt to the
Astec 2618 fines screen (FN10). Material that has not passed through the No. 4
sieve screen is transferred (FN11) to the #4s belt (FN12). Material that does not pass
through the No. 8 sieve screen is transferred (FN15, not pictured) to the #8s belt
(FN16, mostly obscured).
Astec 2618
fines screen
#8s belt (FN16, mostly (FN10)
obscured)
Drop point
(FN11) from
FN10 to FN12
79
Fines Processing Area Photograph 5, looking northwest: A portable conveyor, the
#8s belt (FN17), is used to drop (FN18) material onto the 8x0 pile (FN18), which
sits to the south of the 8x0 long term storage pile (FN1). Similarly, the #4s belt
drops (FN12, not pictured) material onto the 4 mesh reject pile (FN14, not
pictured), which sits to the south of the 8x0 pile. Partially obscured in the
background, there is a front-end loader, which is used to load (FN20) screened fines
onto a truck, which is also in the background
Front-end loader, Drop point
which loads (FN20) (FN16) from
screened fines onto #8s belt
FN17 to FN18
trucks (FN17)
8x0 pile
(FN18)
80
BLOCK MIX AREA (BM)
EMISSION POINTS
PHOTOGRAPHS
81
Block Mix Area Photograph 1, looking southeast: Material is dropped (BM11) onto
the block mix long term storage piles 1 through 4 (BM1 through BM4) by way of
multiple, movable conveyor belts, which sit in the block mix area.
82
Block Mix Area Photograph 2, looking west: The block mix is loaded (BM5, not
pictured) into a portable screen, such as the Astec 710T (BM6) or the Reade screen
(BM7).
Astec 710T
portable screen
Reade screen (BM6)
(BM7)
83
Block Mix Area Photographs 3 & 4: Looking southeast, the block mix is loaded (BM8, not in
picture) onto the temporary block mix pile (BM9) for customer pickup. the block mix is
loaded (BM10) onto trucks and loaded (BM11) onto a block mix pile.
Temporary block
mix pile (BM9) for
customer pickup
84
ISLAND AREA (IS) EMISSIONS
POINT PHOTOGRAPHS
85
Island Area Photograph 1, looking northeast: An example of the 3/4” long term storage piles 1
through 4 (IS1 through IS4), which vary in size depending on customer demand. A 3/8” long
term storage pile (IS5, not pictured) and the block mix long term storage pile 5 (IS6, not
pictured) are also located in the island area of the facility. Material is loaded (IS7) onto the
3/4” pile (IS1 through IS4) or loaded (IS9) onto the 3/8” pile (IS5). The loading (IS8) of 3/4”
material onto trucks and the loading (IS10) of 3/8” material onto trucks also occurs in the
island area, but is not pictured.
86
BONEYARD AREA (BY)
EMISSION POINTS
PHOTOGRAPHS
87
Boneyard Area Photograph 1, looking southwest: A view of the boneyard shale
piles (BY1 and BY2), which vary in size.
88
APPENDIX F
DECEMBER 2013 STOCKPILE INVENTORY
89
90
91
92
APPENDIX G
ENGINEERING DRAWINGS OF KILN REAR CHAMBER SYSTEM AND RIM SEAL
CHUTES
93
94
95
96
97
98
99
APPENDIX H
FINES AND KILN SILO STUDY
100
FUGITIVE DUST EMISSIONS
CALCULATIONS
FOR LIGHTWEIGHT AGGREGATE FINES
STOCKPILES AND KILN FEED STOCKPILE
Prepared for:
Norlite, LLC
A Division of Tradebe Environmental Services, LLC
May 8, 2014
Prepared by:
Page 1 of 14
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INTRODUCTION
The Tradebe Environmental Services, LLC (Tradebe) Norlite facility, located in the City of Cohoes,
Albany County, New York, was inspected by the New York State Department of Environmental
Conservation (NYSDEC) in early 2012 and received a Notice of Violation (NOV) letter on May 9, 2013.
As part of this NOV letter, NYSDEC is requesting upgrades to the facility’s Fugitive Dust Plan (Plan)
because they have expressed concern regarding the Plan. Specifically, NYSDEC is concerned that two
existing material silos were removed for what Norlite identified as safety considerations and is requesting
information regarding the need for replacement of the former lightweight fines and kiln feed silos. The
current aggregate stockpiles in question, which are the subject of this study and report, are: a
substantially-enclosed fines stockpile in the former fines silo footprint (enclosed fines), an open fines
stockpile (open fines) that is located just to the north of the enclosed fines, and a substantially-enclosed
shale feed stockpile (kiln feed). The following report details SPEC’s efforts to evaluate the existing
material storage areas and estimates potential fugitive dust emissions from each source.
BACKGROUND INFORMATION
Tradebe approached SPEC to seek third-party evaluation of potential fugitive dust emissions at Norlite.
To do this, SPEC reviewed the adequacy and accuracy of the existing Plan. The existing Plan includes
data for fugitive dust sources and control methods for the Norlite facility from 1990 and 1995 and
estimates for proposed updates and changes to control methods and fugitive dust sources in 1990 and
1995. SPEC conducted an in-depth review of the former lightweight fines and shale feed silos to provide
a third-party estimate of whether or not replacement silos are needed. Specific information regarding the
former kiln feed and lightweight fines silos, as outlined in the existing Plan, is outlined below.
The original lightweight fine aggregate material silo was referenced in the existing Plan multiple times on
the following pages: 3-6, 3-10, 3-14, 4-4, 5-2, 5-4, 5-10, 8-1, and 8-23 (Appendix A). This silo was also
mentioned in Table 8-1 of the existing Plan and in two letters from SCI-TECH, INC. to Timothy Lachell
of Norlite, dated December 14, 2001, and December 31, 2002. All of these references to the original silo
are merely mentions of there being a silo present, that it is a potential fugitive dust source, and suggested
improvements to the silo. Most of the references to the silo are about the screens for the silo and not the
silo itself. The silo is identified as housing fine aggregates.
Upon review of these references in terms of dust control, SPEC asserts that the silo was never taken into
account in the 1990 calculations as a control device used to mitigate dust emissions as it was never
explicitly mentioned. Further, the existing Plan Source ID 40 (“Fines Silo Screens”) has the following
description: “TSP emissions are generated from the screening of fines transferred to the fines silos. Two
Screens serve the three silos. The emissions are controlled by an enclosure.” When fugitive dust
calculations were completed in 1990 for the Source ID pages, a screen house existed on top of the silo,
serving as a control method for fugitive dust emissions from the conveyor belt/screen atop the silos. It is
this enclosure that the Source ID description mentions at the time of the 1990 calculation and not the silo
itself. The screen house was removed sometime between 1990 and 1993 due to changes in the material
handling process. There is confusion over the word “enclosure” referring to the fines silo itself, when
what is specifically referenced is the screen enclosure atop the silos. The silos themselves were never
calculated to be emission control devices.
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There is little mention of a kiln feed silo in the existing Plan. The few references in the existing plan are
in Tables 3-1, 3-2, 4-1, and 5-2, referring to “Silo Conveyor to Kiln Feed Silo” as a fugitive dust source,
but there is no description and no other substantial information about the kiln feed silo itself in the
existing Plan. Along these lines, no credit is ever applied to the kiln feed silo as an emissions control
device.
An aerial photograph showing the three (3) pile areas important to this report is included below as Photo
1.
Photo 1. Overhead map of the Norlite facility, showing the spatial locations of the three (3) areas in question in relation to each
other and in relation to the facility as a whole.
With the removal of the lightweight fines silos, the enclosed fines product is currently contained in a
structure made of square concrete blocks roughly eight (8) feet high and approximately thirty feet (30)
long on all sides. There are two (2) tiers of metal bracing above the concrete base covered by heavy tarps.
The roof of the original silo is still in place and helps to enclose the lightweight fines. A guarded material
chute drops in from above, through the roof and down into the fines enclosure. The enclosed chute sits
just above the stockpile within the structure, creating a short material transfer point. Below are a photo of
the fines stockpile structure and a diagram of the chute (Photo 2 and Figure 1).
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Photo 2. The enclosed fines structure, including chute coming in from above structure, tarp surrounding structure, and other
structure details.
Figure 1. Diagram showing the specs of the chute for the enclosed fines material structure (provided in Norlite’s existing Plan).
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The second material storage area is the open fines pile located on the northern side of the enclosed fines
structure. The open fines stockpile sits in a low profile and is situated in a topographic depression
adjacent to the enclosed fines structure. The open fines are substantially blocked by a three (3) to four (4)
foot high concrete retaining wall that is adjacent to the structure and is also blocked from wind erosion by
the enclosed fines structure itself. There is also a banded wind screen on the west side of the open fines
stockpile. Below are photos of the open fines storage area (Photos 3, 4, and 5).
Photo 3. View of open fines area from western side, showing the wind screen.
Photo 4. Open fines area, showing concrete wall on eastern side of pile which acts as a barrier against wind erosion.
Page 5 of 14
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Photo 5. Open fines area, showing wind screen on western side of area.
With the removal of the former kiln feed silo, the kiln feed pile has a concrete wind wall on the north end
of the pile and is covered overhead by a newly constructed metal overhang. There is an enclosed material
chute that drops down from the conveyor above, through the roof, and ends just above the kiln feed
stockpile. Material is transferred from the bottom of the pile (surge pile) directly into a conveyor system
that delivers material into the kiln, giving the pile a concave shape. The kiln feed pile has a pile height
sensor that hangs down from the metal overhang of the enclosure and limits pile height. When the
material in the pile touches the sensor, an alarm sounds to alert personnel to stop feeding the kiln feed
pile. Below are photos of the kiln feed pile (Photos 6 and 7).
Photo 6. Kiln feed pile, showing concrete wind wall in back, metal overhang, and chute above pile.
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106
.
Photo 7. Close-up on back wall, chute, and height sensor that hangs above kiln feed pile. Note the limited accumulation of dust
on the wall and roof structure.
To calculate potential fugitive dust emissions, SPEC used equations from AP-42 Compilation of Air
Pollutant Emission Factors1 (Fourth and Fifth Editions, called referred to as AP-42 for the remainder of
this report) which specifically calculate emission factors from wind erosion and material drop operations.
These equations are the industry standard for calculating emissions in the aggregate industry. The
calculated emission factors were then used in AP-42’s general emissions equation in order to calculate the
total fugitive dust emissions from each source. Storage pile wind erosion calculations will be discussed
first, followed by drop point calculations.
The following is EPA AP-42’s general emission rate equation and takes into account activity rate, an
emission factor, and emission reductions from control methods.
ER ER
E A EF 1 1 1 2 ... (Equation 1)
100 100
E emissions (lb/yr)
A activity rate (units depend on the units of the emissions factor)
EF emission factor (varies)
ER emission reduction efficiency (%)
1
AP-42 Compilation of Air Pollutant Emission Factors, Fourth and Fifth Editions, United States Environmental
Protection Agency
Page 7 of 14
107
Note: Emissions reduction efficiencies can be compounded for multiple emissions reduction methods
(ER1, ER2, etc.), serving as a multiplying variable in the series.
The units on the activity rate depend on the units on the emission factor. As can be seen below, the units
of the emission factor for wind erosion are lb/day/acre. Therefore, the activity rate has units of day-
acre/year. The emission factor units for the drop point are lb/ton, so the activity rate units are ton/year.
Although AP-42 provides emission factors for numerous products and processes, they are generalized
factors based on studies that the EPA has conducted and may not be suitable for all processes. AP-42
provides many equations that can be used to calculate these emission factors, which typically provide
more accuracy than the factors that are provided by AP-42 because they use site- or process-specific
values to calculate the emission factors.
The following equation, taken from the fourth edition of AP-42, can be used to calculate the emission
factor for wind erosion on product stockpiles. This equation takes into account material silt content as
well as information regarding the site’s climate.
s 365 p f
EF 1.7 (Equation 2)
1.5 235 15
EF total suspended particulate emission factor (lb/day/acre)
s silt content of aggregate (%)
p number of days with 0.01 in of precipitation per year
f percentage of time that the unobstructed wind speed exceeds 12 mph at the mean pile height
This equation takes into account material silt content and climate factors in order to obtain more accurate
results.
The emission factor for the drop operations onto the storage piles can be calculated using the AP-42
equation for drop operations. This equation is applicable to both batch drop operations, such as product
addition onto the open storage pile, and continuous drop operations, such as product addition onto the kiln
feed pile and the enclosed fine pile.
1.3
U
5
EF k (0.0032) 1.4 (Equation 3)
M
2
EF emission factor (lb/ton)
k particle size multiplier (dimensionless)
U mean wind speed (mph)
M material moisture content (%)
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This equation for drop operations takes into account mean wind speed for the site as well as the product
material moisture content. The particle size multiplier k is a dimensionless factor that is applied in order
to calculate emissions of different particulate matter.
The emission factor values obtained in Equations 2 and 3 were then applied to Equation 1 in order to
calculate the annual emissions from each of the three (3) emission sources.
During SPEC’s site visit on October 21, 2013, SPEC personnel observed the controls currently in place
and used these observations to determine which emission reduction efficiency values should be used for
each pile’s calculations. EPA-450/3-77-010Technical Guidance for Control of Industrial Process Fugitive
Particulate Emissions2 (EPA-450/3-77-010) and EPA-450/2-92-004 Fugitive Dust Background Document
and Technical Information Document for Best Available Control Measures3 (EPA-450/2-92-004) were
used as guidelines for assigning emission reduction efficiency values. Field observations were conducted
during dry, moderately high wind conditions.
All three (3) piles are subject to wind erosion and have material dropped onto them. The enclosed fines
storage pile and the kiln feed pile have emissions from the material drop operations onto them. The Open
fines storage pile does not have a drop point emission value to it due to the nature of the pile formation:
the pile forms as a result of the enclosed fines storage pile overflowing onto it rather than a conveyor or
front end loader manually adding material to it.
The enclosed fines storage pile was assigned emission reduction efficiencies of 20% for the roof and 75%
for the concrete enclosure for wind erosion calculations. For drop point calculations, the enclosed fines
storage pile is assigned emission reduction efficiencies of 75% for its enclosure and 75% for the
elongated drop chute, both observed in Photo 2 above.
The open fines pile does not have a defined enclosure and has limited built-in containment based on its
location. For wind erosion calculations, SPEC assigned emission reduction efficiencies of 50% for the
enclosed fines storage pile’s concrete wall that blocks wind to the open fines pile, 50% for wind reduction
due to the wind screen to the west of the pile, and 20% for the stockpile’s low height, which decreases the
potential for erosion. These control features for wind-borne erosion can be observed in Photos 3, 4, and 5
above. For drop point calculations, the concrete wall and wind screen were both given emission reduction
efficiency values of 50% each.
Based on field observations, SPEC assigned the kiln feed pile emission reduction efficiencies of 50% for
the roof, 75% for the concrete wind wall, and 20% for low pile height. Similar to the enclosed fines
storage pile, the kiln feed pile has an enclosed chute that drops material onto the pile. The storage pile’s
height is controlled by a height sensor that alerts personnel of high pile levels. Because the kiln feed pile
is located at the lower end of a steep incline, there is also built-in topographical shielding from wind. For
drop point calculations, SPEC assigned the following emission reduction efficiencies: 75% for the
concrete wall on the north side, 50% for the metal overhang above the storage pile, and 75% for the
2
EPA-450/3-77-010 Technical Guidance for Control of Industrial Process Fugitive Particulate Emissions, US EPA
March 1977
3
EPA-450/2-92-004 Fugitive Dust Background Document and Technical Information Document for Best Available
Control Measures, US EPA September 1992
Page 9 of 14
109
enclosed chute. All of these control features can be observed in Photos 6 and 7 above. These assigned
control efficiencies are consistent with EPA AP-42 and EPA-450/3-77-010. Relevant efficiency values
from these two documents are compiled in the following table.
Material silt content and material moisture content was determined from sieve analysis data provided by
Norlite to SPEC. Although silt is typically defined as material that passes through the No. 200 sieve,
SPEC used a higher value in order to establish a conservative estimate of fugitive dust emissions. The
medians of the percentages of material passing through the No. 100 sieve and No. 200 sieve were used for
calculations.
SPEC obtained the values for p and f for Equation 2 through analysis of daily local weather data for
Albany International Airport in Albany, NY. This weather data collection site is 5.2 miles from the
Norlite site. Typical airport anemometer heights are between 20 feet to 50 feet high4. This gives us an
overestimation of the average wind speeds at the height of the storage piles, leading to conservative
fugitive dust emission numbers. The equation from the fourth edition of AP-42 was used instead of the
equation found in the fifth edition due to the availability of applicable accurate site-specific data. Storage
piles were assumed to be present 365 days per year for wind erosion calculations.
Rather than using one of the listed aerodynamic particle size multipliers from AP-42 (Table 3 below),
SPEC has used k=1 in order to account for larger total suspended particles (TSP) in the equation for drop
point emissions (Equation 3).
Calculations
The following table summarizes the results of the wind erosion calculations using Equations 1 and 2. For
all three (3) storage piles, the following numbers were used: p = 139.4 days for number of days annually
with at least 0.01 in of precipitation, f = 11.6% for percentage of time with winds above 12 mph, and 365
days for the number of days annually that each pile is present.
4
Wind Resource Assessment Handbook: Fundamentals for Conducting a Successful Monitoring Program, AWS
Scientific, Inc., prepared for National Renewable Energy Laboratory, April 1997
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110
These calculations are updates to the calculations performed by SCI-TECH, INC. in the 1990s due to the
availability of newer fugitive dust emission factor estimation equations. Thus, although the SCI-TECH,
INC. report calculation numbers were accurate at the time, they are no longer an accurate representation
of the fugitive dust emissions at the Norlite site.
The following table summarizes the results of the drop point calculations using Equations 1 and 3. For all
three (3) storage piles, the following numbers were used: k = 1 for particle size multiplier and U = 7.15
mph for average wind speed.
By adding the values from the wind erosion calculations and the drop point calculations, SPEC has
estimated the annual emissions from each of these emission sources. These results are summarized in
Table 5.
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111
CONCLUSION
SPEC asserts that the current sum of 0.0728 tons of annual emissions potential is typical. Based on this
analysis, SPEC does not see the need for the reconstruction of the lightweight aggregate fines or kiln feed
silos.
Based on the emissions rates detailed in this report, SPEC does not recommend the installation of a new
silo. SPEC has no recommendations for improvements to the kiln feed enclosure. The kiln feed area is
well contained by its roof, its concrete wall, its surge pile, and its pile height restriction. Similar to the
kiln feed area, SPEC has no recommendations for improvements to the open lightweight fines pile that is
north of the enclosed fines structure aside from continued good housekeeping practices. The open fines
area is adequately contained by the banded wind screen, the concrete retaining wall that blocks wind,
maintenance of a low height profile, and its position in a topographic depression. The area also benefits
from the enclosed fines enclosure to the south, as the open fines area is effectively screened on three sides
from wind erosion.
Although the potential fugitive dust emissions are low, SPEC has several recommendations for the
enclosed fines structure. Though a new silo is not recommended, SPEC proposes the following alternative
cost-effective solutions for improving fugitive dust emissions from the enclosed fines enclosure.
Improvements to the lightweight fines enclosure: Currently, the enclosure consists of concrete
blocks with tarps for two tiers and is open from the upper tarp to the roof. SPEC suggests that
the bottom tier of tarp be removed and sheet metal be installed in its place. If sheet metal is
not an option, SPEC recommends wind screen bands, similar to the banded wind screen, to be
installed in place of the lower tarp. This will reduce dust from both wind erosion and from
product accumulating on the tarp itself. The fabric of the lower tarp tends to accumulate and
concentrate fine material that then becomes fugitive dust. It is believed that sheet metal siding
will not accumulate the fine fraction and will adequately provide for wind screening above
the concrete blocks.
Addition of misters: SPEC suggests the addition of water misters. Spraying the air around the
material will reduce the amount of fugitive dust that leaves the area surrounding the storage
pile. It is SPEC’s understanding that the material cannot be directly wetted because of
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112
customers’ moisture constraints. Misters will only add minimal moisture content to the fines
and should not exceed maximum moisture content limits.
Addition of a height sensor above enclosed fines piles within the silo: The kiln feed storage
pile has a sensor hanging above the pile, highlighted in Photo 7 above. This sensor’s purpose
is to detect when the aggregate pile has reached the maximum height for operational
efficiency. When the aggregate reaches the sensor, it triggers a signal to stop the feed onto the
pile. Installation of a similar device in the fines enclosure will prevent material from
overstepping the concrete block walls.
Housekeeping: Fugitive dust may also be reduced by additional pile housekeeping and
improved housekeeping methods. Housekeeping improvements include:
o More frequent clearing of fines that overstep the concrete block walls
o Repair or replace any damaged parts of the elongated chute
Adding wind speed alarms to enclosed fines pile : Much like the height sensor suggested
above, a wind alarm would also provide an additional method of monitoring the potential for
fugitive dust emissions. An anemometer would serve as a sensor to wind conditions around
the facility, potentially hanging above a pile like the height alarm sensors do. According to
page 6 of a letter to Timothy Lachell from SCI-TECH dated December 14, 2001, this
instrument has already been installed near the eastern property boundary tree line. If relocated
to the fines structure, this alarm would notify Norlite personnel to observe the area or areas at
risk and use judgment to determine if the pile needs additional misting, needs additional
cover, if material loading activities should be suspended, etc.
Calculations estimating reduction of fugitive dust emissions from the enclosed fines pile
SPEC calculated an estimated reduction of fugitive dust emissions if a few suggested improvements were
implemented. If the enclosed fines structure were improved by adding the sheet metal as part of the
containment in place of the lower tarp, the emissions reduction efficiency would increase. SPEC assumes
this could increase the emission reduction of the enclosure from 75% to 90%. This improvement would
impact the emissions from both wind erosion and the drop point. If misters were employed around the
enclosed fines pile, water suppression could be added as an additional control method for the drop point
with an efficiency of 50%. The results of these improvements are summarized in the following two tables.
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113
Table 9. Drop Point Potential Emissions with Improved Controls
Pile Activity M Emission ER1 ER2 ER3 Emissions Emissions
Rate (material factor (lb/yr) (ton/yr)
(ton/yr) moisture (lb/ton)
content)
Enclosed 85,000 2.05% 0.0049 90% 75% 50% 5.23 0.0026
fines
The total emissions from these three storage piles after improvements have been made to the enclosed
fines storage pile are summarized in Table 9.
REFERENCES
1. AP-42 Compilation of Air Pollutant Emission Factors, Fourth and Fifth Editions, United States
Environmental Protection Agency
2. EPA-450/3-77-010 Technical Guidance for Control of Industrial Process Fugitive Particulate
Emissions, US EPA March 1977
3. EPA-450/2-92-004 Fugitive Dust Background Document and Technical Information Document
for Best Available Control Measures, US EPA September 1992
4. New Source Review (NSR) Emission calculations, Texas Commission on Environmental Quality,
Air Permits Division, May 2008.
5. Wind Resource Assessment Handbook: Fundamentals for Conducting a Successful Monitoring
Program, AWS Scientific, Inc., prepared for National Renewable Energy Laboratory, April 1997
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APPENDIX I
TEXAS COMMISSION ON ENVIRONMENTAL QUALITY, AIR PERMITS DIVISION,
NEW SOURCE REVIEW (NSR) EMISSION CALCULATIONS (2008)
115
Texas Commission on Environmental Quality
This information is maintained by the Chemical NSR Section and is subject to change.
Last update was made May 2008. These emission calculations represent current NSR
guidelines and are provided for informational purposes only. The emission calculations
are subject to change based on TCEQ case by case evaluation. Please contact the
appropriate Chemical NSR Section management if there are questions related to the
emission calculations.
The emissions resulting from the storage and transfer of petroleum coke can be calculated by
using the AP-42 emission factors and equations for aggregate handling and storage piles.
Drop Operations
Either adding aggregate material to a storage pile or removing it usually involves
dropping the material onto a receiving surface. Truck dumping on the pile or loading out
from the pile to a truck with a front-end loader are examples of batch drop operations.
Adding material to the pile by a conveyor stacker is an example of a continuous drop
operation.
1.3
⎛ U
⎞
⎜ ⎟
E
=
k(0.0032) ⎝
⎠
1.4
5
⎛ M
⎞
⎜ ⎟
⎝
2
⎠
116
Where: E = emissions factor (lb/ton)
k = particle size multiplier (dimensionless)
U = mean wind speed (miles/hr)
M = material moisture content (%)
The particle size multiplier in the equation, k, varies with aerodynamic particle size
range, as follows:
Company A is capable of loading a maximum of 200 tons per hour and a total of 300,000 tons per
year of petroleum coke. The mean wind speed at the facility is 10 miles per hour while the
moisture content in the coke is 8 percent. PM10 emissions resulting from the drop operations
would be:
1.3
⎛ U
⎞
⎜ ⎟
E
=
k(0.0032) ⎝
⎠
1.4
5
⎛ M
⎞
⎜ ⎟
⎝
2
⎠
1.3
⎛ 10
⎞
⎜ ⎟
E = 0.35(0.0032)
⎝
⎠1.4
5
⎛ 8
⎞
⎜ ⎟
⎝
2
⎠
E
= 0.0004 lb PM 10 / ton coke
HourlyEmissions = 0.08lb PM 10 / hr
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Conveyors
The transfer (drop) of material from one conveyor belt to a different conveyor belt should
be treated as a drop point and potential emissions should be calculated using the
methodology in the preceding example. However, drop of material from the conveyor
belt directly onto the storage pile is not considered a drop point. Emissions from
dropping material from the conveyor onto the pile are accounted for in calculation of
emissions from wind erosion that follows.
Fugitive emissions can be expected from the conveying and transferring of material due
to wind, belt vibration, scrapers or brushes, etc. For an estimation of fugitive emissions
along conveyors, a conservative assumption of one drop per 1,000 feet of conveyor
length is made.
Example
Company B uses a 2,000 foot conveyor to transport petroleum coke to its storage pile.
The conveyor is capable of transporting 25 tons per hour to the pile and, moves 4,000
tons of coke annually. Mean wind speed at this facility is 12 miles per hour and the
moisture content of the coke is 10 percent. The PM10 emissions resulting from this
conveyor would be:
1.3
⎛ U
⎞
⎜ ⎟
⎛ length of conveyor ⎞
E
=
k(0.0032) ⎝
⎠
1.4
5
⎜⎜ ⎟⎟
⎛ M
⎞ ⎝ 1,000 ft ⎠
⎜ ⎟
⎝
2
⎠
1.3
⎛ 12
⎞
⎜ ⎟
⎛ 2,000 ft ⎞
E
=
0.35(0.0032)
⎝
⎠
1.4
5
⎜⎜ ⎟⎟
⎛ 10
⎞ ⎝ 1,000 ft ⎠
⎜ ⎟
⎝
2
⎠
E
= 0.0007 lb PM 10 / ton coke
HourlyEmissions = 0.02lb PM 10 / hr
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Annual Emissions = 0.0014 TPY PM10
Example
Company C has a petroleum coke stockpile that covers 4 acres. There is activity at the site 300
days per year and the coke pile is routinely sprayed with water. PM10 emissions due to wind
erosion would be:
13.2(300 )(4)(0.3)
E=
2000
E = 2.38 TPY PM 10
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APPENDIX J
LOADER OPERATOR PROCEDURES
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