WMA Energy Savingsand Emission ReductionsPreliminary Report on NCHRP 09-47ABrian D. Prowell, Ph.D., P.E.Advanced Materials Services, LLCBob FrankCompliance Monitoring Service=++‐20‐10010203040506045 50 53 54 74 90 103 108 112

Fuel Savings, %TemperatureReduction,DegreeFFuelUsageProductionTemperaturebelowboiling pointofwaterEmulsionTechnology24% Average Reduction15 Projects6 TechnologiesBoeing 787 Dreamliner$3,400,000 investment = 20% less fuel‐20‐10010203040506045 50 53 54 74 90 103 108 112

Fue l Savings, %TemperatureReduction,DegreeFFuelUsageProductionTemperaturebelowboiling pointofwaterEmulsionTechnology‐30‐20‐1001020304050607045 50 53 54 74 90 103 108 112

Reduction in CO 2 Emissions, %TemperatureReduction,DegreeFCO2EmissionsNCHRP 9-47A Emission Test SitesDry FreezeWet No FreezeDry No FreezeWet FreezeRapid River, MIGriffith, INNew York, NYRapid River, MIEvothermTM 3GAdveraTM WMABituma PF DrumAstroflame & Used OilRapid River, MI Fuel SavingsMix Temp0FAgg %MoistureDTH/tonTankDTH/tonStack%SavingsHMA 300 3.60.2710.285 NAWMA - A 269 4.10.1870.248 13%WMA - B 269 3.90.2250.237 17%DTH = decatherm = 1,000,000 BTUGriffith, INGencor Ultrafoam GX2“Green Machine”Evotherm DATWaxAstec Dbl BarrelEcostar & Nat GasGriffith, IN Fuel SavingsMix Temp0FAgg %MoistureDTH/tonNG MeterDTH/tonStackSavingsHistoric HMA 0.28HMA 300 3.2 0.2260.19119%WMA - C 277 3.5 0.2240.2120.9%WMA - D 256 3.8 0.2120.1966.2%WMA - E 268 3.8 0.2010.15111.1DT = decatherm = 1,000,000 BTUHMA 0.28 DT/ton prior to tuning; 19% savingsGriffith, INElectrical UsageMix Avg. ProductionTemperature, FDrum, amps Drag Slat,ampsHMA 300 37 81WMA - C 277 39 87WMA - D 256 40 91WMA – E 268 40 89New York, NYCecabase RTSurfactantSonneWarmixSynthetic WaxBituTech PEROrganic technologyMcCarter Batch Towerwith Dillman Duo DrumEcostar IIB & Nat GasNew York, NY Fuel SavingsMix Temp0FAgg %MoistureDTH/tonNG MeterDTH/tonStackSavingsHMA 332 3.10.2600.299 NAWMA – F 240 3.40.2360.235 20.9WMA – G 252 2.40.2160.198 32.0WMA - H 253 3.60.2110.210 29.2DT = decatherm = 1,000,000 BTU200140100130WMA05101520253035400 20 40 60 80 100 120

% Fuel SavingsWMADeltaF13 WMA TECHNOLOGIESStack Emissions SitesRapid River, MIGriffith, INNew York, NY46.0 46.039.723.526.024.218.635.928.424.425.405101520253035404550HMA WMAA WMAB HMA WMAC WMAD WMAE HMA WMAF WMAG WMAHMichigan Indiana NewYork

lb/tonCO20.0230.0130.0560.3930.4610.7850.2570.0330.0140.016 0.01600.10.20.30.40.50.60.70.80.91HMA WMAA WMAB HMA WMAC WMAD WMAE HMA WMAF WMAG WMAHMichigan Indiana NewYork

lb/tonCO0.0350.0180.0190.0360.0570.0400.0480.0130.0160.0210.01900.010.020.030.040.050.060.07HMA WMAA WMAB HMA WMAC WMAD WMAE HMA WMAF WMAG WMAHMichigan Indiana NewYork

lb/tonVOC0.0350.0180.0190.0360.0570.0400.0480.0130.0160.0210.01900.010.020.030.040.050.060.07HMA WMAA WMAB HMA WMAC WMAD WMAE HMA WMAF WMAG WMAHMichigan Indiana NewYork

lb/tonVOC0.0640.0580.0640.0230.0220.0210.0150.0310.0240.0190.02200.010.020.030.040.050.060.07HMA WMAA WMAB HMA WMAC WMAD WMAE HMA WMAF WMAG WMAHMichigan Indiana NewYork

lb/tonNOxEPAEmissionFactor,Oil,0.055lbs/ton0.0190.0090.0080.0000.0050.0000.0020.0030.0010.000 0.0000.0000.0050.0100.0150.0200.025HMA WMAA WMAB HMA WMAC WMAD WMAE HMA WMAF WMAG WMAHMichiganIndianaNewYork

lb/tonSO2EPAEmissionFactorWasteOil0.058lbs/tonEPA EmissionFactorNaturalGas0102030405060700 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008

Observed Frequency, %FormaldehydeEmissions,lbs/tonEPAAP‐42NCHRPHMAIndustryHMANCHRPWMAFormaldehyde Frequency DistributionUnintended Consequence ofFTIR Formaldehyde TestingCONCLUSIONS•WMA reduces fuel consumption and plant emissions.•Quantifying actual reduction is difficult due to impact of otherfactors – i.e. aggregate moisture.– 3% savings/10oF is a good average.•Accurate stack emission testing requires experienced contractorswith reference method analyzers.•Emissions should be reported in mass/unit production forcomparisons to be meaningful.•Emission reductions should mirror magnitude of fuel savings.•Look for inconsistencies in your data and expect the unexpected.•Implement Best Practices, including burner tuning, before anyWMA energy and emission evaluation.WMA Energy Savingsand Emission ReductionsPreliminary Report on NCHRP 09-47ABob FrankCompliance Monitoring ServiceRefrank2@gmail.com609.335.3341