Gila River Indian Community (GRIC) TIP Development Source Specific Emission Limitations & Standards Technical Support Document

Section 

### V71.Rule 

### E -Nonmetallic Mineral Mining andProcessing 

### (I) Nonmetallic Mineral Mining and Processing (2) Concrete Batch Plants (3) Hot Mix Asphalt Plants (4) VermiculiteandPerlite Processing


### 1.0 Introduction & Source Description
Nonmetallic mineral mining and processing is a general source category including one or more ofthe following components:

r Sand and gravel mining and processing (including crushed stone processing) Concretebatching Hot mix asphalt production Vermiculite/perlite processing
Because of commonraw materials, processing equipment, emission mechanisms, and control techniques, a single emission standard is proposed for nonmetallic mineral mining and processing with subsections to address specific processes as identified above. Several facilities cwentlylocated and operating on GRIC land comprise this sourcecategory, All subcategories are cwently represented and expected to be potential candidatesfor expansion andor future new source siting.
1.1 Sand and Gravel ~rocessin~',~~~ Deposits of sand and gravel are generally found in near surface alluvial deposits and in subterranean and sub aqueous beds. Such deposits are common on GRICLand, Sand and gravel are typicallymined in a moist or wet conditionby open pit excavationor by dredging. Open pit excavation is carried out with power shovels, draglines, fiont-end loaders, and bucket wheel excavators. Mining by dredging involves mounting the equipment onboats or barges and removing the sand and gravel fiom the bottom ofthe body of water by suction or bucket-type dredges. After mhing, the materials are tramported to the processing plant by suctionpump, earthmover,truck, belt conveyors, or othermeans. Sandand gravel may be used for fill, bedding, sub base, and base course withoutprocessing, but all current GRIC facilitiesinclude fbrtherprocessing for concrete and or asphaltproduction. The processing of sand and gravel for a specific market involves the use of different combinationsof washers, screens, and classifiers to segregate particle sizes; crushersto reduce oversized material; and storage and loading facilities. A process flowdiagram for construction sand and gravel processing is included in Appendix A ofthis document.

NMMProc TSD 614-02Created on 6118t2002 9:39:00 AM 1After being transportedto the processing plant, the wet sand and gravel raw feed is stockpiled or emptied directly into a hopper, which typically is covered with a "grizzly" ofparallel bars to screen out large cobbles and boulders. From the hopper, the material is transported to fixed or vibrating scalping screens by gravity, belt conveyors, hydraulicpump, or bucket elevators. The scalping screens separate the oversize material from the smaller, marketable sizes. Oversize material may be directed to a crusher for sizereduction, to produce crushed aggregate. Crushing generally is carried out in one or two stages, althoughthree-stage crushing may also be performed. Following crushing, the material is returned to the screening operation for sizing. The material that passes through the scalping screen is fed into a battery of sizing screens, which generally consists of either horizontal or sloped, and either single or multideck, vibrating screens. Rotating trommel screens with water sprays are also used to process and wash wet sand and gravel. Screening separatesthe sand and gravel into different size ranges. Water 

### is sprayed onto the material throughoutthe screening process. AfZer screening,the sized gravel istransported to stockpiles, storage bins, or, in some cases, to crushers by belt conveyors, bucket elevators, or screw conveyors. The sand is freed from clay and organic impuritiesby log washers or rotary scrubbers. 

### Mer scrubbing, the sand typically is sized by water classification.

### Wet and dry screening is rarely used to size the sand. After classification,the sand is dewatered using screws, separatorycones, or hydroseparators. After processing, the sand is transported to storagebins or stockpiles by belt conveyors, bucket elevators, or screw conveyors. 1.2 Concrete

# atc chin^^'

Concrete is composed essentiallyof water, cement, sand (fine aggregate) and coarse aggregate. Coarse aggregate may consist of gravel, crushed stone or iron blast furnace slag. Some specialty aggregateproducts could be eitherheavyweight aggregate (ofbarite, magnetite, limonite, ilmenite, iron or steel) or lightweight aggregate (with sintered clay, shale, slate, diatomaceous shale, perlite, vermiculite, slag, pumice, cinders, or sinteredfly ash). Concretebatching plants store, convey, measure and discharge these constituents into trucks for transport to a job site. 

### In some cases, concrete is prepared at a building construction site or for the manufacture of concrete products such aspipes and prefabricated constructionparts. A generalized process diagram for concretebatching is included in Appendix A of this document.
The raw materials can be deliveredto a plant by rail or truck, but in the case ofexisting sources on GFUC land, they are collocated with nonmetallic sand/gravelmining and processing facilities. The cement istransferred to elevated storage silospneumatically or by bucket elevator. The sand and coarse aggregate are transferredto elevated bins by front-end loader, clamshell crane, belt conveyor, or bucket elevator. From these elevated bins, the constituents 

### are fed by gravity or screw conveyor to weigh hoppers, which combinethe proper amounts of each material.
Truck mixed (transit mixed) concrete is the process practiced at one ofthe existing GRIC concrete batch plants. At these plants, sand, aggregate, cement and water 

### are all gravity fed from the weigh hopper into the mixer trucks. The concrete is mixed on the way to the site where the concrete isto be poured. Central mix facilities (including shrinkmixed) constitute another concrete production process in use on GFUC lands. With these, concrete is mixed and then

NMMProc TSD 6-14-02 Createdon 6/18/2002 9:39:00AM 2transferredto either an open bed dump truck or an agitator truck for transport to thejob site. 

### Shrink mixed concrete is concrete that is partially mixed at the central mix plant and then completelymixed in a truck mixer on the way to thejob site. Dry hatching, with concrete mixed and hauled to the construction site in dry form, is seldom, if ever, used.
1.3 Hot Mix ~s~hall?'
Hot 

### mix asphalt 

### (HMA) paving materials are a mixture ofwell graded, high quality aggregate (which can include reclaimed asphaltpavement w]), and liquid asphalt cement, which is heated and mixed in measured quantitiesto produce 

### HMA. Aggregate and 

### RAP (if

### used) constitute over 92 percent by weight ofthe total mixture. 

### side hm the amount and grade of asphalt cement used, mix characteristicsare determinedby the relative amounts and types of aggregate and 

### RAP used. A certainpercentage of fine aggregate (less than 74 micrometers [pm] in physical diameter) is required for the production of good quality

### NMA. Hot 

### mix asphalt paving materials can be manufactured by: (1) batch mix plants, (2) continuousmix 

### (mix outside 

### drum) plants, 

### (3) parallel flow 

### drum mix plants, and (4) counterflow 

### drummix plants. This order of listing generallyreflectsthe chronologicalorder of development and use within the 

### HMA industry. 

### An 

### HMAplant 

### can be constructedas a permanentplant, a skid-mounted (easily relocated) plant, or aportableplant. All plants can have 

### RAP processing capabilities. Virtually allplants being manufactured today have 

### RAP processing capability. A generalized process diagram for hot 

### mix asphalt is included in Appendix A ofthis document
1.4 Vermiculite and Perlite ~rocessin~~~~
Vermiculite - Vermiculite is the geologicalname given to a group ofhydrated laminar minerals that are aluminum-iron-magnesium silicates and &at resemble mica 

### in appearance. The chemical formula for vermiculite is (Mg,CaJC,Fe ) (Sifl,Fe ) 

### 0 (ON) 4H 

### 0. When subjectedto heat, vermiculite has the unusual property of exfoliating, or expanding, due to the interlaminar generation of 

### steam. Uses of unexpanded vermiculite include muds for oil-well drilling and fillersin fire-resistantwallboard. Vermiculiteore is mined using open-pit methods. Beneficiation includes screening, flotation, drying in rotary or fluid bed dryers, and expansion by exposureto high heat. 

### All mined vermiculite is 

### dried and sized at the mine site prior to exfoliation. A generalizedprocess diagram for vermiculiteprocessing is included in Appendix A ofthis document.
Crude ore hm open-pit mines 

### is brought to the 

### mill by truck and is loaded onto outdoor stockpiles. 

### Primary processing consists of screening the raw material to remove the waste rock greater than 518 inch and relmaing the 

### raw ore to stockpiles. Blending is accomplished as material is removed &om stockpiles and conveyed to the mill feed bin. The blended ore is fed to the mill, where it is separated into hctions by wet screening and then concentrated by gravity. All concentrates are collected, dewatered, and dried in either a fluidized bed or rotary dryer. Drying reduces the moisture content ofthe vermiculite concentratefkom approximately 15to 20 percent to approximately 2 to 6percent. At most facilities, the dryer products are transported by bucket elevators to vibrating screens, where the material is classified. The dryer exhaust

NMMProc TSD 6-14-02 Createdon 6/18/2002 9:39:00AM 3generally is ducted to a cyclone for recoveriug the finer grades ofvermiculite concentrate. The classified concentratethen is stored in bins or silos for later shipment or exfoliation. The rotary dryer is the more common dryer type used in the industry, although fluidizedbed dryers also are used. Drying temperatures are 250 to 900 

### F, and he1oil is the most commonly used hel. Natural gas and propane also are used to he1dryers.
After being transported to the exfoliationplant, the vermiculite concentrate is stored. The ore concentrate then is conveyed by bucket elevator or other means and is dropped continuously through a gas- or oil-fired vertical furnace. Exfoliation occurs after a residence time of less 

### than 8 seconds in the furnace, and immediate removal of the expanded material fiom the fimace prevents damage to the structure of the vermiculite particle. Flame temperatures ofmore than 1000 F are used for exfoliation. Proper exfoliationrequires both a high rate of heat transfer and a rapid generation of steam within the vermiculiteparticles. The expanded product falls 

### through the hce and is 

### air conveyed to a classifier system, which collects the vermiculiteproduct and removes excessive fines. The furnace exhaust generally is ducted through a product recovery cyclone, followed by an emission control device. At some facilities, the exfoliated material is ground in a pulverizer prior to being classified. Finally, the material is packaged and stored for shipment
Perlite - Perlite is a glassy volcanic rock with a pearl-like luster. It usually exhibitsnumerous concentric cracks that cause it to resemble an onion skin. A typical perlite sample is composed of 71 to 75 percent silicon dioxide, 12.5 to 18.0percent alumina, 4 to 5 percent potassium oxide, 1 to 4 percent sodium and calcium oxides, and trace amounts of metal oxides. Crude perlite ore is mined, crushed, dried in a rotary dryer, ground, screened, and shippedto expansionplants. Horizontal rotary or vertical stationary expansion furnaces are used to expand the processed perlite ore. Crude perlite ismined using open-pit methods and then is moved to the plant site where it is stockpiled. A generalized process diagram for perlite processing is included in Appendix A ofthis document
The kt processing step is to reduce the diameter ofthe ore to approximately 0.6 inch in a primary jaw crusher. The crude ore is then passed through a rotary dryer, which reduces the moisture content from between 4 and 10 percent to less than 1 percent After drying, secondary grinding takes place in a closed-circuit systemusing screens, 

### airclassifiers, hammer mills, and rod mills. Oversized material produced from the secondary circuit is returned to the primary crusher. Large quantities of fines, produced throughoutthe processing stages, areremoved by air classification at designated stages. The desired size processed perlite ore is stored uatil it is shipped to 

### an expansionplant. At the expansionplants, theprocessed ore is eitherpreheated or fed directly to the hrnace. Preheating the material to approximately 800 F reduces the amount of finesproduced in the expansion process, which increasesusable output and controls the uniformity ofproduct density.


### In the furnace, the perlite ore reaches a temperature of 1400 to 1800 F, at which point it begins to softento a plastic statewhere the entrappedcombined water is released as steam. This causes the hot perlite particles to expand 4 to 20 times their original size. A suction fan draws the expanded

NMMProc TSD 6-14-02 Created on 6/18t2002 9:39:00AM 4particles out ofthe furnace and transports them pneumatically to a cyclone classifier system to be collected. The air-suspendedperlite particles are also cooled as they are transported to the collection equipment. The cyclone classifier system collects the expanded perlite, removes the excessive fines, and discharges gases to a baghouse or wet scrubber for 

### air pollution control. The grades of expanded perlite produced can also be adjusted by changing the heating cycle, altering the cutoff points for size collection, and blending various crude ore sizes. All processed products are graded for specificuses and are usually stored before being shipped. Most production rates 

### are less than 2 tomdhr, and expansion bace temperatures range fiom 1600 to 1 800 F. Natural gas is typically used for fuel, althoughNo. 2 fuel oil and propane are occasionally used.
2.0 GRIC Source Profile Four sources currently located and operating on GRIC land comprisethe nonmetallic minerals mining and processing source category. Those sources are: United Metro #4 1 United Metro #48 Rock Solid Thermo-Rock Inc.
United Metro # 4 1 This facility includes 

### a sand and gravel mining operation, two concretebatch plants, and a hot 

### mix asphaltplant. The facility is subject to NSPS Subpart000 (Nonmetallic Mineral Processing) and NSPS Subpart

### I (Hot 

### Mix Asphalt). Appendix A ofthis document includes site visit notes providing further details on this facility as well 

### as a generalized process flow diagram.
United Metro #48
This facility is another sand and gravel mining and processing operation with a concrete batch plant. United Metro No. 48 does not operate a hot 

### mix asphalt plant. The facility is subject to NSPS Subpart 

### 000 (Nonmetallic Mineral Processing).
Rock Solid
Rock Solid is a concrete batch plant without associated mineral mining and processing stages. Aggregate and other raw materials are deliveredto the site and loaded to hoppers prior to weighing, mixing, and truck loading. Concrete is loaded to trucks in dry form and water is added directly to the concrete trucks on site prior to departure. Rock Solidplans to move and expand its operations on GRIC land.
Thermo-Rock Lnc. Thermo-Rock, Inc, is a vermiculate and perlite processing facility. Operationsinclude vermiculite and perlite expansion fbmaces, potting soil manufacture, and fire retardant

NMMF'roc TSD 6-14-02 Createdon 6118D0029:39:00 AM 5production. One ofthe facility fimaces is subjectto NSPS Subpart

### UUU (Calciners and Dryers in Mineral Industries). Two other facility furnacespredate the NSPS applicability date.
3.0 Technical Review 

## - Emission Units, Pollutants, and Control Technologies
3.1 Emissions and Controls
Sand and Gravel Miningl~rocessin~'~
Emissions from the production of sand and gravel consistprimarily ofparticulate matter 

### (PM) and particulate matter less than 10 micrometers (PM- 1 0) 

### in aerodynamic diameter, which are emittedby many operations at sand and gravel processing plants, such 

### as conveying, screening, crushing, and storing operations. Generally, these materials are wet or moist when handled, and process emissions can be negligible. 

### A substantial portion ofthese emissionsmay consist of heavy particles that settle out 

### withinthe plant. Other potentially significant sources of PM and PM-10 emissions are 

### haul roads. Emissions from dryers include PM and PM-10, 

### as well 

### as typical combustion products including CO, COz 

### ,and Na. 

### In addition, dryersmay be sources of volatile organic compounds (WC) or 

### sulfuroxides (S&) emissions, depending on the 

### type of %el used to fire the dryer.
With the exception of drying, emissionsfiom sand and gravel operations primarily are in the form of fugitive dust, and control techniques applicableto fugitive dust sources are appropriate. Some successful control techniquesused for haul roads are dust suppressant application,paving, route modifications, and soil stabilization; for conveyors, covering and wet suppression;for storage piles, wet suppression,windbreaks, enclosure, and soil stabilizers;for conveyor and batch transfer points, wet suppression and various methodsto reduce freefall distances (e. g., telescopic chutes, stone ladders, and hinged boom stacker conveyors); and for screening and other size classification, covering and wet suppression. Wet suppressiontechniques include application of water, chemicals and/or foam, usually at crusher or conveyor feed and/or discharge points. Such spray systems at transfer points and on material handling operationshave been estimatedto reduce emissions 70 to 95 percent. Spray systems can alsoreduce loading and wind erosion emissions from storage piles ofvarious materials 80

### to 90 percent. Control efficiencies depend upon local climatic conditions, source properties and duration of control effectiveness. Wet suppression has a carryover effect downstream ofthe point of applicationof water or other wetting agents, 

### as long 

### as the surface moisture content is high enoughto cause the fines to adhere to the largerrock particles.
In addition to figitive dust control techniques, some facilitiesuse add-on control devicesto ' reduce emissions ofPM and PM-10 from sand and gravel processing operations. Controls in use include cyclones, wet scrubbers, venturi scrubbers, and fabric filters. These types of controls are rarely used at construction sand and gravel plants, but are more common at industrial sand and gravel processing facilities.

NMMProc TSD 6-14-02 Created on 6/18/20029:39:00 AMConcrete Batch plants4 Particulate matter, consisting primarily of cement dust but including some aggregate and sand dust emissions, is the only pollutant of concern fiom concrete batch operations. All but one of the emission points are fugitive in nature. The only point source is the transfer of cement to the silo, and this is usually vented to a fabric filter or "sock." FugiGve sources include the transfer of sand and aggregate, truck loading, mixer loading, vehicle traffic, and wind erosion fiom sand and aggregate storagepiles. The amount of fugitive emissions generated during the transfer of sand and aggregate depends primarily on the surface moisture content of these materials. The extent of fugitive emission control varies widely from plant to plant. Types of controlsused may include water sprays, enclosures, hoods, curtains, shrouds, movable and telescoping chutes, and the like. A major source of potential emissions, the movement of heavy trucks over unpaved or dusty surfaces in and around the plant, can be controlledby good maintenance and wetting ofthe road surface.
Hot 

### Mix ~s~halt'
As with most sources in the mineral products industry, batch 

### mix HMA plants have two major categories of emissions: ducted sources (those vented to the atmosphere through some type of stack, vent, or pipe), and fugitive sources (those not confined to ducts and vents but emitted directly fiom the source to the ambient air). Ducted emissions are usually collected and transportedby an industrial ventilation system having one or more fans or air movers, eventually to be emitted to the atmosphere through some type of stack. Fugitive emissions redtfiom process and open sources and consist of a combination of gaseouspollutants and PM.
The most significantducted source of emissions fiom batch 

### mix HMA plants is the rotary 

### drum dryer. Emissions fiom the drum consist ofwater (as steam evaporated fiom the aggregate);PM; products of combustion (carbon dioxide [Ca], nitrogen oxides [N&], and 

### sulfiu oxides [SOx]); carbon monoxide (CO); and small amounts of organic compounds of various species (including volatile organic compounds [VOC], methane [Ca], and hazardous air pollutants [HAP]). The organic compound emissionsresult fiom incomplete combustionofthe fuel and fiom heating and mixing of the liquid asphalt cement inside the dm. The CO emissions result from incomplete combustion ofthe fuel. Processing of RAP materials may increase organic compound emissions because of an increase in mixing zone temperature duringprocessing. Once the organic compoundscool after discharge hm the process stack, some condenseto form a fine organic aerosol or "blue smoke" plume. Because liquid asphalt cement, aggregate, and sometimesRAP, are mixed in a zone not in contact with the hot exhaust gas stream, counterflow dm 

### mix plants will likely have lower organic compound emissionsthan parallel flow drum mix plants. Other potential process sources include the hot-side conveying, classifling, and mixing equipment, which are vented to either the primary dust collector (along with the dryer gas) or to a separatedust collection system. The vents and enclosures that collect emissionsfrom these sources are commonly called "fugitiveair" or "scavenger" systems. The scavenger systemmay or may not have its own separate air mover device, depending on the particular facility. The

NMMProc TSD 6-14-02 Created on 6/18R002 9:39:00 AM 7emissionscaptured and transported by the scavenger system are mostly aggregatedust, but they may also contain gaseous organic compounds and a fine aerosol of condensed organic particles. This organic aerosol is created by the condensation of gas into particles during cooling of organic vapors volatilized 

### from the asphalt cement in the mixer (pug mill). The amount of organic aerosol produced dependsto a large extent on the temperature of the asphalt cement and aggregate enteringthe pug mill. Organic vapor and its associated aerosol are also emitted directly to the atmosphere as process fugitivesduring truck loadout, fiom the bed ofthe truck itselfduring transportto thejob site, and hm the asphalt storage tank. Both the low molecular weight organic compounds and the higher weight organic aerosol

### may contain small amounts of 

### HAP. The ducted emissions fiom the heated asphalt storage 

### tanks may include gaseous and aerosol organic compounds and combustion products fiom the 

### tankheater.
There are also a number of fugitive dust sources associated 

### with batch 

### mix HMA plants, includingvehicular trafficgenerating fbgitive dust on paved and unpaved roads, aggregate materialhandling, and other aggregate processing operations. Fugitive dust may range fiom 0.1 pm to more than 300 pm in aerodynamic diameter. 

### On average, 5 percent ofcold aggregate feed is less than 74 pm (minus 200 mesh). Fugitive dust thatmay escape collectionbefore primary control generally consists of PM with 50 to 70 percent ofthe total mass less than 74 pm. Process fugitive emissionsassociated with batch plant hot screens, elevators and the mixer (pug mill) are not present 

### in the 

### drum 

### mix processes. However, there 

### are fugitive PM and VOC emissions fiom transport and handling of the 

### HMA 

### from the drum mixer to the storage silo and also fiom the load-out operationsto the delivery trucks. Since the 

### drumprocess is continuous, these plants have surge bins or storage silos. The fugitive dust sources associated with 

### drum mix plants are similarto those ofbatch mix plants with regard to truck traffic and to aggregate material feed and handling operations. Applicable 

### PM emission controls for 

### HMA plant dryers and vent lines include dry mechanical collectors, scrubbers, and fabric filters. Attempts to apply electrostaticprecipitatorshave met with little success. Practically all plants use primary dust collection equipment such as large diametercyclones, skimmers, or settlingchambers. These chambers are often used 

### as classifiers to return collectedmaterial to the hot elevator and to combine it withthe drier aggregate. To capture remainingPM, the primary collector effluent is ducted to a secondarycollection device. Most plants use either a fabric filter or a venturi scrubber for secondary emissions control. As with any combustionprocess, the design, operation, and maintenance ofthe burner provides opportunitiesto minimizeemissions of

### NOx 

### , COY and organic compounds.
A number ofprocess modifications or restrictions have been introducedto reduce blue smoke hm rotary 

### drum dryers, including installationofflame shields, rearrangement of 

### flightsinside the 

### drum, adjustments of the asphalt injection point, and other design changes.
Vermiculite ~rocessing~ The primary pollutants of concern in vermiculite processing are particulate matter (PM) and PM less than 10 micrometers (PM-10). Particulate matter is emitted fiom screening, drying, exfoliating, and materials handling and transfer operations. Emissions &omdryers and exfoliatingfurnaces, in addition to filterable and condensablePM and PM-10, include products

Nh4MF'roc TSD 6-14-02 Created on 6/18/2002 9:39:00 AM 8ofcombustion, such 

### as carbon monoxide (CO), carbon dioxide (C02),nitrogen oxides 

### (NOx), and sulfur oxides (SOx). Wet scrubbers are typically used to control dryer emissions. The majority of expansionbacesare ducted to fabric filters for emission control. However, wet scrubbers also are used to control the furnace emissions. Cyclones and fabric filters also are used to control emissions fiom screening, milling, and materials handling and transfer operations.
Perlite ~rocessin~'
The major pollutant of concern emitted fiom perlite processing facilitiesisparticulate matter 

### (PM). The dryers, expansion fusnaces, and handling operations can all be sources of PM emissions. Emissions of nitrogen oxides fiom perlite expansion and drying generally are negligible. When sulfur-containing fuels are used, sulfur dioxide (SO2)emissions may result from combustion sources, However, the most common 

### type of fie1 used in perlite expansion Eumaces and dryers is

### natural gas, which is not a significant source of SO2 emissions. To control PM emissions fiom both dryers and expansion furnaces, the majority ofperlite plants use baghouses, some use cyclones either alone or in conjunction 

### with baghouses, and a few use scrubbers. Frequently PM emissions fiom material handling processes and fiom the dryers are controlledby the same device. J~I most plants, fabric filters arepreceded by cyclones for product recovery. Wet scrubbers are also used 

### in a small number of perlite plants to control emissions fiom perlite milling and expansion sources. 3.2 Emission UnitPollutant Matrix
Emission units and pollutants associated with nonmetallic mineral mining and processing, as defined in this document, are presented in Table 3-1. This matrix is based on available EPA literatureon source category emissionsand emissionhtors.
Table 3-1. Emission UnitPollutant Matrix

NMMProc TSD 6-14-02 Created on 6/18f2002 9:39:00 AM 94.0 Regulatory Review


### 4.1 Tribal Programs/Rules PollutantJParameter Opacity, PWM-10, COY 

### N&, so*,

### voc, HAP VOC, HAP Opacity, PMIPM- 10 Opacity, PWM-10, COY NOx, SO*, VOC, HAP Opacity, PWM- 10 Opacity, PWM-10 Opacity, PWM-10, COY NOx, S02, VOC, HAP Opacity, PMIPM- 10 Opacity, PWM-10, SO*,HAP Opacity, PMIPM- 10 Source Subcategory Hot Mix Asphalt

Vermiculite Processing

Perlite Processing



### A review of U.S. tribal air quality programs was performed to define the baseline of existing tribal rules and source specific standards. This review was conducted jointly between RTP and the 

### GRIC. At 

### the time of this retriew, no tribal programs or rules were identified that specifically pertained to nonmetallic minerals mining and processing source categories. EmissionUnit1Process Dryer Hot Oil Heater Loadout Rotary Dryer
Concentrate Screening Concentrate Conveyor Transfer Exfoliation (VerticalFurnace) Product Grinding ExpansionFurnace Dryer

4.2 Federal Programs 

### and Regulations


### 4.2.1 New Source Performance Standards (NSPS)
ThreeNSP Standardswere identified as applicable to the nonmetallic mineral mining and processing industry as defined 

### inthis document. Those standards are: NSPS Subpart 000 

### - Standards of Performance forNonmetallic Mineral Processing Plants NSPS Subpart 

### I - Standards ofPerformance for Hot

### mix Asphalt Facilities NSPS Subpart

### UUU - Standards of Perfomance for Calciners and Dryers in Mineral Industries
Table 4- 

### 1presents a summary ofidentified NSPS provisions by Subpart and equipment/process unit.
Table 4- 1. NSPS Summary

NMMProc TSD 6-14-02 Createdon 6/18/2002 9:39:00AM 10 Subpart
000 EmissionLimitfstandard(Units)
0.05 g/dscm 7 % (unless scrubber controlled)
10 % Equipment/Process Unit Transfer point on belt conveyors or my other affected facility - stack emissions Transfer point on belt conveyors or any other affected facility -fugitive emissions Pollutant/ Parameter PM Visible Emissions Visible Emissions4.2.2 National Emission Standards for Hazardous 

### Air Pollutants (NESHAP)/MaximumAvailable Control Technology (MACT) Standards A single listed MACT development source category was identified as potentially applicable to the nonmetallic mineral mining and processing source category 

### as defined in this document. However, this source category, Asphalt Concrete Manufacturing, will be delisted per information obtained fiom the EPA Unified 

### Air Toxics (UATW) web site. No further analogous standards were identified 

### as a resource for GRIC standard development for this sourcecategory. No GRIC sourceswithin this category are major sources ofHAP (i.e., emissions 

### > 10tpy for a single 

### HAP or 

### >25 tpy for total combined 

### HAP).

Subpart

I
UZTU

4.2.3 Reasonably Available Control Technology/BestAvailable Control Technology/LowestAchievable Emission Rate (RACTBACT/LAER) Clearinghouse '~ected facilities include dryers; systems for screening, handling, storing and weighing hot aggregate;systemsfor loading trausfening, and storingmineral filler; systems for mixinghotmix asphalt; and the loading, transfer, and storage systems associated with emission control systems. Pollutant/ Parameter PM Visible Emissions Visible Emissions Visible Emissions
PM Opacity PM Opacity Equipment/ProcessUnit
Transferpoint on belt conveyors or any other affected Edcility -inside building, building vents Crusher (withoutcapture system) - Wtiveemissions Wet Screening ops and subsequent, screening ops, bucket elevators,belt conveyors Any affected facility'
Calcinersand dryers



### An EPA RACTBACTILAER Clearinghouse (RBLC) search for entries after 1990was conduced for the following source categories: EmissionLimitlstandard (Units)
0.05gldscm 0%
15 %
0%

0.04 grldscf 20 % 0.040grldscf/ 0.025 grldscf 10 % (unless scrubbercontrolled)

r 90.024: Nonmetallic Mineral Processing 90.006: Cement Manufacturing 90.003 :Asphalt Concrete Manufacturing 90.017: Calciners & Dryers and Mineral Processing Facilities
Tables 4-2 through 

### 4-5 (Attached to this document) present a summary of RBLC entriesrelevant to the nonmetallic mineral mining and processing source category as defined in this document.
4.2.4 Accidental Release Prevention [Sec. 112(r)]
No materials expected to be stored or processed at nonmetallic mineral mining and processing facilitiesare regulated under the EPA accidentalrelease prevention rule (40 CFR Part 68). Fuels,

NMMF'roc TSD 6-14-02 Created on 6/18/2002 9:39:00AM 11including liquefied petroleum gas (LPG), were removed fiom the list ofregulated materials under 112(r) in 1999.
4.2.5 Other
No other federal air quality regulatory programs or standards were identified as applicable or potentially applicableto the nonmetallic mineral mining and processing source category.
4.2.6 

### Summary of Identified Federal RulesPrograms 

### -Testing, Monitoring, Recordkeeping & Reporting Provisions
Presented in Table 4.6 is a summary of applicableFederal rule monitoring, source testing, recordkeeping and reporting requirements relevant to the nonmetallic mineral miningand processing source category 

### as defined in this document.
Table 4-6. Federal Rule Monitoring, Testing, Recordkeeping and Reporting 

## I Rule ( Subject 

## 1 Monitoring 62 Testing Provisions 

## I RecordkeepingReporting Provisions 1 NSPS

000 Equipment/Pollutant Affected hility Test methods 6om 40 CFR 60 

## I Replacement equipment: rated


# I I Written report of all compliancetest

Appendix A or specified in Subpart 000


## I results within 30 days - Wet scrubberPM 

### I Continuous monitoring devices - 

### I Daily -record measurements of capacity, swface area of screens, width of conveyor belts, capacity of storage bins

Control pressure drop and sc&bing liquid drop and liquid flow. 

# I flow Semiannualreport of deviations 

## I +- 30% of last-performancetest Compliance 

### I EPA Method 5 or 17 

### 1 Written report ofall compliancetest deterkination: PM 

## I 

## I results within 30 days Compliance 

### 1 EPA Method 9, distanceto source = 

### I Written report of all comvliance test determination: 15ft. Minimize fugitive interference. results within 30 days

a Opacity Water mist not includedAlternate Compliance determination: Opacity 6om storage bin baghouse Compliance determination: Opacity fiom fugitive method provided in 60.675(e) EPA Method 9, duration of 1hour 

### I Written report of all compliancetest (10 6-minute averages) results wit& 30 days

emissions Compliance ( EPA Method 22,75 minute duration 

### I Written report of all compliance test EPA Method 9, durationmay be reduced to 1hour if certain conditions are met

determination: Opacity fiom processes enclosed in building Written report ofall compliancetest results within 30 days

results 

### within 30 days -

NMMTroc TSD 6-14-02 Created on 6/18/2002 9:39:00AM 12NMMProcTSD 6-14-02 Createdon 6/18/2002 9:39:00 AM 13 RecordkeepingReporting Provisions Monitoring & Testing Provisions
Test methods fiom 40 CFR 60 Appendix A or specified in SubpartI EPA Method 9

EPG Method 5, sampling time and volume at least 60 mb, 31.8 d~cf. Facility shall monitor dry control device exhaust with continuous emissions monitoring system, or
For the sources listedbelow with a dry control device: Certiiied visible emissions observer 

### - measure and record tbree 6-minute averages ofthe opacity ofvisible emissions each day of operationin accordance with Method 9 of appendix A of part 60. Sources: ball clay vibrating grate dryer bentonite rotary dryer diatomiteflasb dryer

3 diatomite rotary calciner feldspar rotary dryer fire clay rotary dryer industrial sand fluid bed dryer
r kaolin rotary calciner perlite rotary dryer roofing granules fluid bed dryer roofing granules rotary dryer talc rotary calciner titanium dioxide spray dryer titanium dioxide fluid bed dryer vermiculitefluidbed dryer vermiculite rotary dryer
Sources exempt fiom monitoring provisions (ifequipped with dry control device): ball clay rotary dryer diatomite rotary dryer feldsparfluidbed dryer fuller's earth rotary dryer gypsumrotary dryer
r gypsum flash calciner gypsum kettle calciner industrial sand rotary dryer kaolin rotary dryer kaolin multiple hearth furnace perlite expansion furnace talc flash dryer

, talcrotary dryer Rule
NSPS 1

NSPS UlTU Subject Equipment/Pollutant Affected facility Compliance determination: Opacity Compliance determination: PM Dry control device: PM andopacity monitoring4.3 State/RegionaVLocal Regulations
To define State, regional, and local air quality rules applicableto the source categoriespresent or expectedto potentially site on 

### GRIC land, all U.S. State 

### air quality rules and selectregionaVlocal district rules were screened using Internetresources. This screening identified sets of air quality rules with source specific regulationsmatching the matrix of GRIC source categories. The summary results of this study are contained in a separate electronic file titled STATEMATRTX.xls. From this research, specific rule provisions applicableto the nonmetallic mineral mining and processing source category, including emissionlimitations, standards, RecordkeepinglReportingProvisions

Determine and record once each day an arithmetic average over a 2-hour period of botb the change in pressure ofthe gas stream across the scrubber and the flowrate ofthe scrubbing liquid. Submit written reports semiannually ofexceedauces of control device operating parametersreed to be monitored.
Exceedances: (1) All 6-minuteperiods during which the average opacity l?om dty control devices is greater than 10 percent; or (2) Any daily 2-hour average ofthe wet scrubberpressure dropthat is less than 90 percent ofthe average value recorded during the most recent performance test that demonstrated compliance with the particulate matter standard; or (3) Each daily wet scrubberliquid flow rate recorded that is less than 80 percent or greaterthan 120 percent of the average value recorded during the most recent performance test that demonstrated compliance with the particulate matter standard.

NMMProc TSD 6-14-02 Created on 6/18/2002 9:39:00 AM 14 Monitoring & Testing Provisions

= titanium dioxide direct or indirect rotary dryer or a vermiculite expansion furnace Wet scrubber controlled sources: Install,calibrate, maintain, and operate continuous monitoring devices for scrubber pressure drop and liquid flow to scrubber Scrubbermonitoring device accuracy spec: 5% based on manufacturer certification Initial performance test of a wet scrubber: Use the monitoring devices to determinethe average change in pressure ofthe gas stream across the scrubber and the average flow rate of the scrubber liquid during each of the particulatematter nms. The arithmetic averages of the three runs shallbe used as the baseline average values.

EPA Method 5, sampling time and volume for each test run at least 2 hours and 1.70 dscfin. EPA Method 9 Rule Subject EquipmentJPollutant

Wet scrubber control: PMIOpacity Parameter monitoring

Compliance detemhtion: PM Compliance determination: Opacitymonitoring, recordkeeping and reporting were documentedto form a baseline of analogous StateRegionalrules.
4.3.1 Summary of Identified Rules -Emission Limitations & Standards 

### This section presents a summary of existing StateRegional air quality rules applicable to the nonmetallic

### mineral mining and processing source category as defined 

### in this document. Five StateRegionalprogram standardswere identified 

### as relevant and ofpotential value in developing the 

### GRIC emission limits and standards forthis source category. The identified rule provisions, including applicability, emission limits/standards, monitoring, recordkeeping and reporting are summarized in Table 4-7.
Table 4-7. 

### Summary StateIRegionalRule Emission Limits and Standards

NMMProcTSD 6-14-02 Createdon 6/18/20029:39:00AM 15

State Rule
Arizona Rule 722

Arizona Rule 723

Arizona Rule 708

Maricopa County Rule 316 Applicability Existing Gravel and Crushed Stone Processing Plants

Existing Concrete Batch Plants

Existing Asphalt Concrete Plants

Liquid Fuel Solid Fuel Nonmetallic Mineral Processing Plants Pollutant/ Parameter PM Emissions

PM Control

PM: Fugitive Dust

PM Emissions



### s(sod s (so21 PM: Stack Emissions Opacity: Stack Emissions Opacity; Emission Limit/Standard (Units)
For process rates <30 tph: Max. allowable PM emissions (E) =4.1 OPO.~' For processrates >30 tph: Max. allowable PM emissions @) =55.0p0." -40, Where: P =Process weight rate (tph) Spray bar pollution controls in accordance with EPA "Control ofAir emissionsFrom Process Operationsin the Rock Crushing Inch~~try" (EPA 34011-79-002). Placement of spray bars and nozzles as required by Director Shallbe controlled in accordance with R18-2-604 through 607 NOTE: Rules 604-607 include gend requirements for fugitivedust sources including open areas, dry washes, and riverbeds, Roadways and streets;Materialhandling; and Storage Piles. Requirementsare limitedto "reasonable precautions" including chemical or wet suppression, covering, etc. For process rates <30 tph: Max. allowable PM emissions (E) =4.1 OPO.~' For processrates >30 tph: Max. allowable PM emissions (E) =55.0p0." -40, Where: P =Process weight rate (tph)
Total process weight of all similar units employing a similarprocess type shall be used in determining max. allowable PM emissions Shall not exceed 0.9 % S by weight Shall not exceed 0.5 % S by weight Stack emissions shall not exceed 0.02 grldscf
Stack emissions shallnot exceed 7 %opacity
Emissions fiom any crusher shallnot exceed 15 % opacity