WMA Energy Savings 

and Emission Reduction

Preliminary Report on NCHRP 09-

Brian D. Prowell, Ph.D., P.E. 

Advanced Materials Services, LLC

Bob Frank

Compliance Monitoring Service
=

+

‐20

‐10

0

102030405060

45 50 53 54 74 90 103 

Fuel Savings,%

TemperatureReduction, Degree F

Fuel Usage

Production Temperature belowboiling point of water

Emulsion Technology

24% Average Reduction 

15 Projects

6 Technologies 
Boeing 787 Dreamline

$3,400,000 investment = 20% less 
‐20

‐10

0

102030405060

45 50 53 54 74 90 103 108 112

Fuel Savings,%

TemperatureReduction, Degree F

Fuel Usage

Production Temperature below

boiling point of water

Emulsion Technology

‐30‐20‐10

0

10203040506070

Reduction 45 50 53 54 7in CO

2 Emissions,

%

TemperatureRe

CO2 Emissi
NCHRP 9-47A Emission Te

Dry Freeze

Dry No Freeze Wet No Freeze

Wet Freeze

Rapid River, MI

Griffith, IN

N
Rapid River, MI

AdveraTM WMA Evot

Bituma PF Drum

Astroflame & Used Oil 
Rapid River, MI Fuel Savin

Mix Temp 0

F

Agg % 

Moisture

DTH/ton

Tank

DTH/to

Stack

HMA 300 3.6 0.271 0.285 

WMA - A 269 4.1 0.187 0.248 WMA - B 269 3.9 0.225 0.237 

DTH = decatherm = 1,000,000 BTU
Griffith, IN

Gencor Ultrafoam GX2

“Green Machine”

Wax

Astec Dbl Barrel

Ecostar & Nat Gas 
Griffith, IN Fuel Savings

Mix Temp 0

F

Agg % 

Moisture

DTH/ton

NG Meter

DTH

Sta

Historic HMA 0.28HMA 300 3.2 0.226 0.1WMA - C 277 3.5 0.224 0.2WMA - D 256 3.8 0.212 0.1WMA - E 268 3.8 0.201 0.1

DT = decatherm = 1,000,000 BTUHMA 0.28 DT/ton prior to tuning; 19% savings
Griffith, IN 

Electrical Usage

Mix Avg. Production 

Temperature, F

Drum, amps 

HMA 300 37 WMA - C 277 39 WMA - D 256 40 WMA – E 268 40 
New York, NY

Cecabase RT

Surfactant

SonneWarmix

Synthetic Wax

BituTech PER

Organic technology

McCarter Batch Tower 

with Dillman Duo Drum

Ecostar IIB & Nat Gas 
New York, NY Fuel Saving

Mix Temp 0

F

Agg % 

Moisture

DTH/ton

NG Meter

DTH/t

Stac

HMA 332 3.1 0.260 0.29

WMA – F 240 3.4 0.236 0.23WMA – G 252 2.4 0.216 0.19WMA - H 253 3.6 0.211 0.21

DT = decatherm = 1,000,000 BTU
200

130

WMA
0

5

10152025303540

0 20 40 60 80 

% Fuel Savings

WMA Delta F

13 WMA TECHNOLOGI
Stack Emissions Sites

Rapid River, MI Griffith, IN Ne
46.0 46.0

39.7

23.5

26.0

24.2

18.6

35.9

28.4

05

101520253035404550

HMA WMA A WMA B HMA WMA C WMA D WMA E HMA WMA F 

Michigan Indiana New 

lb/ton

CO2
0.023 0.013

0.056

0.393

0.461

0.785

0.257

0.033 0.014 

0

0.10.20.30.40.50.60.70.80.9

1

HMA WMA A WMA B HMA WMA C WMA D WMA E HMA WMA F 

Michigan Indiana New 

lb/ton

CO
0.035

0.018 0.019

0.036

0.057

0.040

0.048

0.013

0.016

0

0.010.020.030.040.050.060.07

HMA WMA A WMA B HMA WMA C WMA D WMA E HMA WMA F 

Michigan Indiana New 

lb/ton

VOC
0.035

0.018 0.019

0.036

0.057

0.040

0.048

0.013

0.016

0.021

0.019

0

0.010.020.030.040.050.060.07

HMA WMA A WMA B HMA WMA C WMA D WMA E HMA WMA F WMA G WMA H

Michigan Indiana New York

lb/ton

VOC
0.064

0.058

0.064

0.023 0.022 0.021

0.015

0.031

0.024

0

0.010.020.030.040.050.060.07

HMA WMA A WMA B HMA WMA C WMA D WMA E HMA WMA F 

Michigan Indiana New 

lb/ton

NOx

EPA Emission Factor, Oil, 0.055 lbs/ton
0.019

0.009 0.008

0.000

0.005

0.000

0.002

0.003

0.001 

0.0000.0050.0100.0150.0200.025

HMA WMA A WMA B HMA WMA C WMA D WMA E HMA WMA F 

Michigan Indiana New 

lb/ton

SO2

EPA Emission Factor

Waste Oil

0.058 lbs/ton

EPA Emission Factor

Natural Gas

0

10203040506070

0 0.001 0.002 0.003 0.004 0.005 0.006 

Observed Frequency,%

FormaldehydeEmissions,lbs/ton

ENInN

Formaldehyde Frequency Distribu
Unintended Consequenc

FTIR Formaldehyde Test
CONCLUSIONS

• WMA reduces fuel consumption and plant emissions.• Quantifying actual reduction is difficult due to impact 

factors – i.e. aggregate moisture.

– 3% savings/10 

oF is a good average. 

• Accurate stack emission testing requires experienced 

with reference method analyzers.

• Emissions should be reported in mass/unit production 

comparisons to be meaningful.

• Emission reductions should mirror magnitude of fuel • Look for inconsistencies in your data and expect the • Implement Best Practices, including burner tuning, be

WMA energy and emission evaluation.
WMA Energy Savings 

and Emission Reduction

Preliminary Report on NCHRP 09-

Bob Frank

Compliance Monitoring Service

Refrank2@gmail.com

609.335.3341