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COMPREHENSIVE INDUSTRY DOCUMENT ON HOT MIX PLANTS

Technical Report · October 2018

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 COMPREHENSIVE INDUSTRY DOCUMENT SERIES
COINDS/2018-19

COMPREHENSIVE INDUSTRY DOCUMENT

ON
HOT MIX PLANTS

Central Pollution Control Board

Ministry of Environment, Forest & Climate Change
Delhi-110032
Website: [Link], Email: cpcb@[Link]

October, 2018
 Project Team

Dr. Dal Singh Kharat

Ms. Deepa Choudhary

Mr. Ouiman Sauel

Mr. Yogendra Prakash

Mr. K.D. Bhardwaj

Contacts:
Central Pollution Control Board
Ministry of Environment, Forests & Climate Change
East Arjun Nagar
Shahdara
Delhi-110032, India
Website: [Link], Email: cpcb@[Link]

@Copy right 2018 Central Pollution Control Board, Delhi

i.
ii
 Nomenclatures

APCD Air pollution control device

BC Bituminous concrete
BM Bituminous macadam
CNG Compressed natural gas
CPCB Central Pollution Control Board
CO2 Carbon dioxide
DG Diesel generator
DBC Dense bituminous macadam
FO Furnace oil
HMP Hot mix plant
ID Induced draft
KGPT Kilogram per tonne
KLPD Kiloliter per day
KVA Kilovolt ampere
LDO Light diesel oil
LPH Litre per hour
LPT Litre per tonne
NOx Oxides of nitrogen
NPC National Productivity Council
PAH Polycyclic aromatic hydrocarbon
PNG Piped natural gas
PM Particulate matter
SDBC Semi dense bituminous carpet
SO2 Sulphur dioxide
TPH Tonne per hour
VG Viscosity grade
VOC Volatile organic compound
mg/Nm3 Milligram per normal cubic meter
µg/m3 Microgram per cubic meter
ng/m3 Nanogram per cubic meter

iii.
 List of Tables
Page No.
Table 2.1 Classification of hot mix plants 3

Table 2.2 Operating temperature 4

Table 4.1: Pollution sources and identified parameters 18

Table 5.1 Details of hot mix plants selected for field studies 20

Table 5.2 Stack emission results of batch hot mix plants 26

Table 5.3 Tack emission load for batch hot mix plants 27

Table 5.4 Stack emission results of drum hot mix plants 28

Table 5.5 Tack emission load for drum hot mix plants 29

Table 5.6 Ambient air quality monitoring results 30

Table 6.1 Measures for control of particulate 38

List of Figures

Figure 3.1 Cold aggregate storage 7

Figure 3.2 Open to bins (hopers) 7

Figure 3.3 Bitumen storage tanks 8

Figure 3.4 General process flow diagram for batch hot mix plants 10

Figure 3.5 A typical batch hot mix plant 11

Figure 3.6 General process flow diagram for drum hot mix plants 13

Figure 3.7 A typical drum hot mix plant 14

Figure 4.1 Fugitive emissions from hoppers 15

Figure 4.2 Emissions frm stack 16

Figure 6.1 Multiclone and venture scrubber system 34

Figure 6.2 Beg filter assembly 35

iv.
 Contents
Page No.
Project Team i.
Foreword ii.
Nomenclature iii.
List of Tables iv,
List of Figures iv.
Contents v.

Chapter 1 Introduction 1
1.1 Background 1
1.2 Methodology 1

Chapter 2 Industry Profile 3

2.1 Classification of Hot Mix Plants 3
2.1.1 Based on technology 3
2.1.2 Based on the mobility 4
2.1.3 Scale of operation 4
2.2 Operating Temperature 4
2.3 Future Growth 5
2.4 Status of Pollution Control 5

Chapter 3 Production Process 6

3.1 Basic Process Description 6
3.2 Cold Aggregate Storage 6
3.3 Bitumen Storage Tank 6
3.4 Batch Hot Mix Plant 9
3.5 Drum Hot Mix Plant 12

Chapter 4 Pollution Generation 15

4.1 Air Pollution 15
4.1.1 Fugitive emissions 15
4.1.2 Stack emissions 16
4.1.3 Storage tank emissions 16
4.2 Wastewater Generation 17
4.3 Solid Waste Generation 17
4.3.1 Scrubber water tank 17
4.3.2 Pollution control equipments 17
4.3.3 Bitumen mix waste 17
4.4 Noise 17
4.5 Odour 18
4.6 Pollution Characteristics 18

Chapter 5 Field Studies 19

5.1 Selection of Hot Mix Plants 19
5.2 Stack Monitoring 23
v.
 5.2.1 Batch hot mix plant 23
5.2.2 Drum hot mix plant 24
5.3 Ambient Air Quality Monitoring 25

Chapter 6 Pollution Control Guidelines 33

6.1 Stack Emissions 33
6.1.1 Cyclone 33
6.1.2 Multicyclone 33
6.1.3 Dust separator 33
6.1.4 Scrubber 33
6.1.5 Bag filter 34
6.2 Fugitive Emissions 35
6.2.1 Internal roads 35
6.2.2 Aggregate stockpiles 35
6.3 Volatile Organic Compounds 36
6.4 Sulfur Dioxide 36
6.5 Oxides of Nitrogen 36
6.6 Wastewater Management 36
6.7 Solid Waste Disposal 37
6.8 Wastes as Raw Material 37
6.9 Monitoring Programme 37

vi.
 Chapter 1

Introduction

1.1 Background
Hot mix plants are used for mixing of stone aggregates with bitumen (asphalt) and the
mix is mainly used for construction of roads. A hot mix plant usually comprises of
aggregate bins, feeder, weighting system, drying drum, bitumen and fuel storage tanks,
air pollution control devices, hot mix storage silo and loading facility. These plants are
installed near construction site and highways, and operate for such time till the
construction work continues. Hence, many hot mix plants are not of permanent nature.
Due to the temporary and seasonal nature of the plants, the precise numbers and
locations of the plats are not available. However, efforts have been made to collect
information about the hot mix plants from State Pollution Control Boards/Pollution
Control Committees and some highways construction companies.
Preparation of hot bitumen mix in hot mix plants (HMPs) emits emissions containing
particulate as well as gaseous air pollutants. The primary emission sources in HMP are
dryers and mixers, which emit particulate matter (PM) and a variety of gaseous
pollutants like sulphur dioxide, oxides of nitrogen, carbon monoxide, PAH, volatile
organic compounds etc. Other emission sources found at HMPs include material
handling and transfer activities, asphalt storage tanks and yard emissions, which cause
fugitive emissions. Emissions also result from vehicular traffic on paved or unpaved
internal roads, aggregate storage and vehicle exhaust.
Seized with the pollution problems, the Central Pollution Control Board (CPCB)
conducted a scientific study through the National Productivity Council (NPC). This report
includes findings of the study and the pollution control guidelines.
1.2 Methodology
Data/information was generated from literature survey, questionnaire survey, preliminary
and field studies. The concern organization such as SPCB/PCCs and some highway
authorities were also contacted. Based on data, 15 hot mix plants were identified for
detailed field studies. While selecting these hot mix plants, different types, size, fuel
used, technology adopted, mobility, location and provision of pollution control devices
were considered. At the selected 15 hot mix plants, stack emission, fugitive emissions
and ambient air quality monitoring were conducted. The stack emission monitoring was
conducted for particulate matter, sulphur dioxide, oxides of nitrogen, carbon monoxide,
PAH, VOCs, benzene, toluene and xylene. The ambient air quality was monitored in
respect of sulphur dioxide, oxides of nitrogen, PM10, PM2.5, benzene, benzo(o)pyrene
and carbon monoxide at 10 m distance from source of emission in upwind and

1
downwind directions to examine the effect of hot mixing activities on the ambient air
quality. Based on data, a profile of the sector and complication of best practices were
made. The pollution control guidelines are given based on gravity of environmental
concerns, availability of treatment technologies and cost aspect.

2
 Chapter 2
Industry Profile

The hot mix plant is an assembly of mechanical, electrical and electronic equipments
where aggregates are heated, dried, blended and mixed with binder to produce hot mix
asphalt confirming to the specified requirements.
2.1 Classification of Hot Mix Plants
Hot mix plants can mainly be classified based on the technology adopted in the plant
and scale of operation as well as the mobility of the plant. The criteria of classification is
given in Table 2.1

Table 2.1: Classification of hot mix plants

[Link]. Criteria Classification
1 Technology -Batch hot mix plants
-Drum hot mix plants:
(a) Parallel flow drum hot mix plants; and
(b) Counter flow drum hot mix plants
2 Mobility -Permanent hot mix plants
-Skid mounted or Portable hot mix plants
3 Scale of operation -Small (≤ 60 tph)
-Medium (>60 to ≤100 tph)
-Large (>100 tph)

2.1.1 Based on Technology

(i) Batch hot mix plants
In batch mix plants, the aggregates are dried in the drum and the dried aggregates are
lifted upwards and screened as per their size and mix design. The aggregates of
predetermined sizes and in the desired ratio are brought as a batch where in the
bitumen is added and mixed well. The prepared batch of mix is transferred to silo or
loaded directly on waiting truck.
(ii) Drum hot mix plants
Parallel flow drum mix plants: In parallel flow drum mix plants, aggregate is introduced
into the drum from the burner end. As the drum rotates, the aggregates as well as the
hot gases from the burner move towards the other end of the drum in parallel. Liquid
asphalt is introduced in the mixing zone midway down the drum in a lower temperature
zone, along with any filler.

3
Counter flow drum mix plants: In counter flow drum mix plants, aggregates are
introduced into the drum at one end and travels down to the burner end. The aggregate
travels down and the hot combustion gases pass up the drum in the opposite direction
or counter flow. The liquid asphalt is introduced behind the burner flame so as to avoid
direct contact with the hot gases and flame.
2.1.2 Based on the Mobility
Permanent type hot mix plants: These hot mix plants are stationed at one place and are
generally high capacity plants.
Skid mounted or Portable hot mix plants: These types of hot mix plants can easily be
shifted from one place to another depending on the requirement. These hot mix plants
are usually small capacity plants.
2.1.3 Scale of operation
The production capacity is another criteria for classification of hot mix plants such as
small (≤ 60 tph), medium (>60 to ≤100 tph) and the large hot mix plants (>100 tph). It is
noticed that there is no hard and fast rule to classify the plants. Depending upon the
purpose and convenience, the agencies use appropriate terminology and classification.
2.2 Operating Temperatures
The bituminous mixes are prepared in a hot mix plant that is capable of yielding a mix of
proper and uniform quality with thoroughly coated aggregate with bitumen. The
operating temperatures for the mixing, laying and rolling are given in Table 2.2.
However, the exact temperature depends upon the type and layer of application, and is
to be adopted as per the recommendations of the manufacturer. In order to ensure
uniform quality of mix, the plant is calibrated from time to time. A good design of
bituminous mix is expected to give strong, durable and resistive to fatigue.
Table 2.2: Operating temperature
Bitumen Bitumen Aggregate Temperature Laying Rolling
viscosity temperature temperature of mix temperature temperature
°C °C °C °C °C
VG-40 160-170 160-175 160-170 150 100
VG-30 150-165 150-170 150-165 140 90
VG-20 145-165 145-170 145-165 135 85
VG-10 140-160 140-165 140-160 130 80

4
2.3 Future Growth
India has the second largest road network in the world spanning a total of 4.69 million
km road length and the road transports over 60% of all goods and 85% of the total
passenger traffic. The current world production of bitumen is approximately 102 million
metric tonnes. India’s share in the world production is 4.6% and is in the top ten
countries in this regard. The bitumin is mainly used for paving, roofing and secondary
uses.
2.4 Status of Pollution Control
Air pollution is the major environmental issue in hot mix plants. Dust and gaseous
emissions like NOx, SO2, and VOCs are emitted through stack. Fugitive dust emissions
are generated during aggregate handling and charging. Majority of hot mix plant have
pollution control systems. Batch type hot mix plants are equipped with dual cyclone
followed by bag filters and the drum type hot mix plants have employed multiclone
followed by venturi scrubber as air pollution control devices.
Water is used for sprinkling inside the plant to suppress the dust emission. Water used
in scrubber is recycled back and hence, no issue of water pollution. Dust settled in
scrubber settling tank is removed from time to time and reused or disposed in low lying
areas.

5
 Chapter 3
Production Process

This chapter explains the basic processes involved in the production of bitumen hot mix.
The concept for bitumen mix plants has remained more or less same over the last two
decades. Hot mix plants existing in India are of two types based on the technology i.e.
drum hot mix plants and batch hot mix plants. Currently batch mix plants, in which
mixing is carried out in a special mixer unit (often referred to as the pug mill). In drum
mix plants, the mixing process takes place in the dryer drum. Some plant operations are
common to both the type of plants.

3.1 Basic Process Description

The bitumen mixing process consists of heating and drying of stone aggregates and
then are mixed with filler (sand, clay, dust, cement or fly ash) and bitumen. The process
can be accomplished either in a batch mix plant or in a drum mix plant. The aggregate
and filler material constitute typically 95% (by weight) of the total mixture and 5%
bitumen. The mix is then transferred directly to waiting delivery trucks or to silos for short
term (surge) storage before loading into the trucks for transportation to the paving site.
Supporting processes of the hot mix plants include aggregate storage piles and cold
feed bins, bitumen tanks and heaters, hot mix storage silos and air pollution control
equipments. Aggregate material may be trucked to the plant or the plant may be located
near an aggregate quary.
The complete plant operation is monitored from a control room. The degree of
automation and electronic control varies from plant to plant, depending on plant mobility
and age. Small plants can be operated through simple control mechanisms. A fully
computerized process control can monitor burner, fuel consumption, air flow rate,
finished mix discharge and storage selection.

3.2 Cold Aggregate Storage

Cold aggregate storage and feeding are common in batch and drum mix plants. The raw
aggregate are transported to the plant site and placed in storage piles that are located
near feeder bins (Figure 3.1) .
The cold aggregate feed is the first major operation of the plant. The cold feeder may be
charged by one or a combination of three methods:
(i) Open top bins with several compartments: Materials are usually fed by a front-
end loader (Figure 3.2);
(ii) Tunnels under stockpiles separated by bulkheads: Materials are stockpiled over
the tunnel by front-end loader; and
(iii) Bunker or large bins: Materials are usually fed by trucks, car unloaders, or bottom
dump freight cars.
6
Figure 3.1: Cold aggregate storage

Figure 3.2: Open top bins(hopers)

7
Front-end loaders manage the storage piles and transfer the aggregate to the
appropriate cold feed hoppers. Conveyor belts transport the aggregate from the feed
hoppers to the dryers or drum mixers.

The most common type of cold feeder used in a plant is the continuous belt conveyor.
The key element in the continuous belt feeder is how to control or regulate the flow of
material from each bin. Every manufacture has a different control method. Typical
control variations are: (a) Gate opening (fixed or adjustable); and (b) Belt (One speed or
adjustable speed).

The most common configuration is the adjustable gate and an adjustable belt speed.
Because a uniform flow of proper-sized aggregate is important to the hot mix asphalt
production, the technician is required to check before and during production to ensure
that the feeder system is functioning properly. The cold aggregate feeder is calibrated,
set and secured to ensure a uniform flow of aggregate. The feeder is calibrated for each
type and size of aggregate. Manufacturers often furnish approximate calibrations for
their equipment.

3.3 Bitumen Storage Tank

Bitumen viscosity varies with its temperature and therefore, it is controlled in terms of
bitumen temperature that is easily measurable. The temperature required to maintain
the appropriate viscosity of different grades of bitumen ranges between 150 to 180 oC.
The bitumen section mainly consists of bitumen tank(Figure 3.3), charging arrangement,
heating burner, hot oil system, pumping and metering units. The bitumen tank is fully
insulated to minimize heat losses and is equipped with manhole cover for inspection and
charging of bitumen, bitumen outlet connections, drain plug and the temperature meter.

Figure 3.3: Bitumen storage tanks

8
3.4 Batch Hot Mix Plant
Raw aggregate used for the production of asphalt is normally stockpiled near or at the
actual plant site. From the storage piles, the aggregates are hauled and placed in the
appropriate cold feed hopper. In the hopers, different sizes of aggregates are metered
on to a conveyer belt in specific portions depending on the type of asphalt mixture
required, and then transported to the intake of the rotary drum dryer. As the drum
rotates, the flights lift the material and let it fall down through the hot air stream in the
drum. At the same time, the aggregates slowly flow forward because the drum is placed
with a slight inclination. Usually, the counter flow process is followed (i.e. the gas flow
direction is opposite to the material flow). For the heating and drying of aggregates, gas,
coal or oil burner is placed at one end of the drum. The heat is mainly transferred by
convection.
After leaving the dryer, the hot aggregates (temperature 135-180°C) drop into a bucket
elevator and are conveyed to the top of the mixing tower. The aggregates are promptly
dropped into the weigh hopper of mixing tower. From the weigh hopper, the aggregates
go into a pug mill (mixer), where it is coated with bitumen that is pumped from a heated
storage tank in required proportion. At this stage, the specified amount of filler is added
to the mix. The finished asphalt mix is then transferred either directly to a waiting truck
for immediate delivery to the site or by a conveyer to heated asphalt storage silos.
Figure 3.4 and Figure 3.5 depict general process flow diagram of batch mix plants.
Water vapor and exhaust gases are sucked out at the cold end of the dryer drum and
mixing tower, and led out through a dual cyclone followed by bag filter. Finally, the
gases are let out to the atmosphere through a stack. The heavy particles collected from
dual cyclone are fed back to the drum. The fine dust collected in bag filters is collected
and reused or disposed to low lying area.

9
Figure 3.4: General process flow diagram of batch hot mix plants

10
Figure 3.5: A typical batch hot mix plant

11
3.5 Drum Hot Mix Plant
In a drum hot mix plant, the heating, drying and mixing of aggregates with filler and
bitumen takes place in single unit (drum). It simplifies the mixing process, since vibrating
screens, hot aggregate storage bins and the mixing tower are replaced by proportional
feed controls of the drum mixer. Drum hot mix plants are less flexible in changing
different mixes.
Basically, the aggregates are fed into the revolving drum and heated for drying by hot
gases in the drying zone of the drum. About midway, filler and liquid bitumen are
injected along the drum where the flights inside the rotating drum ensure that drying and
mixing is done properly before the finished mixed is discharged to a conveyer and finally
into a truck. Combustion gases and water vapour from the heating and drying process
are drawn out by an exhaust fan. The dust particles are collected in the multiclone
followed by venture scrubber.
Generally, drum mixers are designed with parallel flow of burner gases and the
aggregate flow whereas; the batch hot mix plants are designed for counter flow process
in most cases. Figures 3.6 and 3.7 depict process flow diagram of drum mix plants.

12
Figure 3.6: General process flow diagram of drum mix plants

13
Figure 3.7: A typical drum hot mix plant

14
 Chapter 4
Pollution Generation

The hot mix plant involves handling and processing of large quantities of aggregates.
The main pollutant emitted is particulate matter (PM). Fugitive or open sources of
emissions typically include traffic areas (internal road) and storage yards, stockpiles,
cold bins and aggregate transfer points. Stack emissions generate from the aggregate
heating, drying and mixing with bitumen.

4.1 Air Pollution

4.1.1 Fugitive emissions

Fugitive emissions from aggregate storage piles are generally caused by front-end
loader that transports the cold aggregates to the feed unit hoppers (Figures 3.4, 3.6 &
4.1). Other pre-dryer fugitive emission sources include transfer of the aggregates from
the hoppers to the dryer feed conveyor and subsequently, to the dryer entrance. Dust is
also emitted from the filler system, starting from the loading of silos and addition of the
filler into the mixer. In practice, the processing of the filler takes place in a closed system
from where emissions are law. Further, dust on the plant area may be whirled up by
traffic.

The paving of the internal roads will reduce airborne dust created by vehicle movement.
All internal roads and working areas should be kept clean and wet by sprinkling of water
to contain dust emission. Sprinkling water is also suggested near points of material
handling and transfer.

Figure 4.1: Fugitive emissions from hoppers

15
4.1.2 Stack emissions
Basically, the stack emission is related to the drying and heating process (Figures 3.4,
3.6 & 4.2). The source of stack emissions is the raw materials that are used for the
production of the bitumen and which are dried in the drum. These materials contain a
certain percentage of inherent fine particles that may be separated during the heating
process since the moisture is removed and also due to mechanical operation.

Figure 4.2: Emissions from stack

The emissions may include products of complete and incomplete combustion of fuel.
Products of complete combustion include oxides of nitrogen (NO x), if sulfur is present in
the fuel, sulfur dioxide (SO2) and carbon dioxide (CO2). Products of incomplete
combustion are carbon monoxide (CO) and VOCs. These incomplete combustion
emissions result from improper air and fuel ratio, poor mixing of fuel and air, inadequate
residence time and temperature.
In drum mix plants, emissions may result from the heating and mixing of liquid bitumen
inside the drum. The magnitude of these emissions is a function of the process
temperature and constituents of the bitumen being used. In batch mix plants, post-dryer
particulate matter emission sources include hot aggregate screens, hot bins, weigh
hoppers and mixing chamber. Uncontrolled particulate matter emissions from these
sources will be greater than emissions from pre-dryer sources primarily due to the lower
aggregate moisture content and also due to the larger number of transfer points.

16
4.1.3 Storage tank emissions
Storage tanks are used to store fuel oils and bitumen at hot mix plants which may be a
source of VOC emissions Bitumen storage tanks are usually less than 50000 L. When
bitumen is heated, organic fumes and VOCs may be emitted as emissions. However,
these emissions are not normally seen when heating bitumen, as the boiling point of
bitumen is much higher. Emissions from bitumen tanks are particularly low due to their
low vapour pressure.

4.2 Wastewater Generation

There is no wastewater generation in batch type hot mix plants as water is not used in
the process. The air pollution control systems used in these plants are dual cyclone
followed by bag filter that operate sans water. In drum hot mix plants, multiclone and wet
scrubber are used as particulate control equipment. The scrubber water is completely
recyclable with intermittent top-ups and there is no wastewater disposal (Figures 3.4 &
3.6).

4.3 Solid Waste Generation

4.3.1 Scrubber water tank
The particulate matter settled in the scrubber water tank is cleaned periodically. During
the cleaning of the water tank, the sludge is removed from the bottom and make-up
water is added when required. Quantity of sludge may vary from plant to plant based on
the capacity and operation of the plant. Most of the plant visited during field study
reported reusing the dried sludge as filler material (Figures 3.4 & 3.6).

4.3.2 Pollution control equipments

Dust collected from cyclone and bag house is reused or disposed off into low lying areas
of the plant premises or outside (Figures 3.4 & 3.6). The fine dust sometimes gets
deposited at the bottom of the aggregate storage bins and belt conveyors. This is
collected for reuse or disposed.

4.3.3 Bitumen mix waste

Bitumen mix waste may sometimes generate due to ‘bad-batch’ and during loading or
unloading into the trucks. Normally, bad-batch occurs due to sudden break down of
electric supply also. This bitumen mix waste is used for filling up low lying lands or as
sub grade material in the road construction.

4.4 Noise
The main sources of noise include electric motors, DG Set, Dryer drum, burner hot
bucket elevator and pneumatic system. Other associated noise sources are traffic noise
from loaders and lorries for supplying raw materials and collecting bitumen mixes.

17
4.5 Odour
The bitumen is possible source of odour in hot mix plants. Odour generation may be
expected during the loading of the bitumen tanks which is accomplished by expelling
gas from the bitumen tank or by pressure release from the bitumen lorries. Basicaly, the
odour is related to the bitumen crude source and temperature.
It is to be noted that the noise and odour sources are non continuous and may affect
internal environment only to some extent.

4.6 Pollution Characteristics

The source specific parameters of environmental concern in a hot mix plant have been
identified on the basis of literature survey and preliminary visits to units. The emissions
arising out of hot mix plant contain gaseous compounds and particulates. A summary of
pollution sources and identified parameters are given in Table 4.1.

Table 4.1: Pollution sources and identified parameters

S. No. Source Monitoring location relevant parameters

1. Stack emissions Stack Temperature, flue gas low,
PM, CO, CO2,SO2, NOx,
VOCs (benzene, toluene and
xylene) and PAH
(Benzo(o)pyrene)
2. Fugitive At 10 m from source Ambient air quality parameters
emissions (PM10, PM2.5, SO2, NOx, CO,
benzene, benzo(o)pyrene)
3. Solid waste Air pollution control The solids collected from the
devices and sludge cyclone, bag filters and the
sludge is dust particles only,
which can be reused or
disposed into low laying area.

18
 Chapter 5
Field Studies
5.1 Selection of Hot Mix Plants
Based on data generated through preliminary field visits and questionnaire responses,
the following aspects were considered important in selecting the hot mix plants for
detailed study:
 Type of hot mix plant (batch type/drum type)
 Scale of operation
 Level of mechanization and technology used
 Fuel used
 Location
 Pollution control systems
The hot mix plants were short listed for detailed study considering the type of the plants.
Based on technology of the hot mix plants in India. There are only two types of the plant
i.e. (a) Batch hot mix plants; and (b) Drum hot mix plants. To cover representative units
in different scales of production, three scales namely small, medium and large units
were considered for the present study.
Type of fuel used is another criterion. The selection process is intended to cover
different fuels used in hot mix plant e.g. coal, light diesel oil, furnace oil, diesel, natural
gas etc. In addition, both old and new units were selected to cover the technology
variation and its environmental impact. Based on the mobility, the hot mix plants
expected to remain/stationed at one location or portable in nature was also considered.
The provision of air pollution control devices like cyclone, dual cyclone, multiclone, bag
filter and wet scrubber were considered with a view to assess the efficiency of the
control systems while carrying out detailed study in different zones i.e. South, West,
East, North and Central in the country.
On the basis of criteria mentioned above, 15 hot mix plants were selected. The list of
units and their codified form along with parameters on which they were selected is given
Table 5.1. The Table also enlists details relating to year of establishment, capacity, raw
materials, products, fuel and fuel consumption, control mechanism, air pollution control
measures etc.

19
 Table 5.1: Details of hot mix plants selected for detailed field studies
North
Location South zone West zone East zone Central zone
zone

Unit Code HMP-1 HMP-2 HMP-3 HMP-4 HMP-5 HMP-6 HMP-7 HMP-8 HMP-9 HMP-10 HMP-11 HMP-12 HMP-13 HMP-14 HMP-15

Type of HMP Drum Drum Drum Batch Batch Batch Batch Drum Batch Drum Batch Batch Batch Batch Drum

Speed
Make of HMP Atlas Apollo Apollo Apollo Apollo Apollo Apollo Local Marini Linnhoff Amman Apollo Linnhoff Atlas
craft

Year of installation at
2009 2007 2014 2010 2013 2011 2013 2010 2013 2010 2015 2015 2015 2015 2016
the existing location

Condition of the
plant at time of New Old New New New New New Old New Old New New New New New
installation

Rated capacity
60 90 90 128 128 128 128 35 200 60 160 100 160 160 90
(TPH)

Average production
50 70 80 125 100-110 100 100 30 170-175 50-55 120-130 80 110-120 90 70
(TPH)

DG set capacity No DG No DG 500 & 500, 550 & 500,

125 125 180 320 600 62.5 125 250 125
(KVA) Set Set 250 62.5 40 62.5

20
 Table 5.1: Details of hot mix plants selected for detailed field studies Contd…
North
Location South zone West zone East zone Central zone
zone

Unit Code HMP-1 HMP-2 HMP-3 HMP-4 HMP-5 HMP-6 HMP-7 HMP-8 HMP-9 HMP-10 HMP-11 HMP-12 HMP-13 HMP-14 HMP-15

Stone Stone
Stone Stone Stone Stone Stone Stone Stone
Stone Stone Stone Stone Stone aggrega Stone aggrega
aggrega aggrega aggrega aggrega aggrega aggrega aggrega
aggrega aggrega aggrega aggrega aggrega tes, aggrega tes,
tes, tes, tes, tes, tes, tes, tes,
Major raw materials tes, tes, tes, tes, tes, Bitumen tes, Bitumen
Bitumen Bitumen Bitumen Bitumen Bitumen Bitumen Bitumen
Bitumen Bitumen Bitumen Bitumen Bitumen , Diesel, Bitumen , Diesel,
, FO, , FO, , FO, , FO, , FO, , FO, , FO,
, Diesel , Diesel , Diesel , Diesel , Diesel FO, , Diesel FO,
LDO Diesel Diesel Diesel Diesel Diesel Diesel
Coal Coal

SDBC,
BC, BM, BC, BM, BC, BC, BC, BC, DBM, BC, DBM, DBM, DBM, DBM, DBM, DBM,
Major products DBM,
DBM DBM DBM DBM DBM DBM BC DBM BC BC BC BC BC BC
BM

4 (FO),
Diesel consumption 0.3, Coal =
4.5 40 4.5-5
for drum burner 6-7.5 5 2.5 0.3 5 5.5 (FO) 5 (FO) 1.14 6 (FO) NA 15
(LDO) (LPH) (FO)
(LPT) 5.5 (FO) KGPT
(LDO)

10,000 Coal =
100
Diesel consumption cum/mo KGPH
0.5 0.5 0.14 Coal = 4
for bitumen heating 15-20 20 15-20 1.1–1.3 1 (LPT) nth 1 (LPT) NA Na 25-50
(LPT) (LDO) (LPT) KGPT
(LPH)
(PNG/C
NG)

21
 Table 5.1: Details of hot mix plants selected for detailed field studies Contd…
North
Location South zone West zone East zone Central zone
zone

Unit Code HMP-1 HMP-2 HMP-3 HMP-4 HMP-5 HMP-6 HMP-7 HMP-8 HMP-9 HMP-10 HMP-11 HMP-12 HMP-13 HMP-14 HMP-15

Diesel consumption 0.33 0.26 0.6

15 12 25 40-45 NA NA 30 0.6 LPT NA 40-45 40 12-15
for DG set (LPH) (LPH) (LPT) (LPT)

Borewell Borewell
Source of water Borewell & & Borewell Borewell Borewell Borewell Tankers Borewell Borewell Borewell Borewell Borewell Borewell Borewell
Tankers Tankers

Water consumption
for sprinkling inside 4 4.5 14 2-4 8 3 8 2.5 36 2 72 36 20 NA 5-8
plant (KLPD)

Water consumption
2.5 1-2 6 NA NA NA NA 2.5 NA 5.4 NA NA NA NA 10
for scrubber (KLPD)

Process control Automat Automat Automat Automat Automat Automat Automat Automat Automat Automat Automat Automat Automat Automat Automat
mechanism ic ic ic ic ic ic ic ic ic ic ic ic ic ic ic

Multiclo Multiclo Multiclo Dual Dual Dual Dual Multiclo Multiclo Dual Multiclo
ne & ne & ne & Cyclone Cyclone Cyclone Cyclone ne & Bag ne & Bag Bag Cyclone Bag ne &
APCDs
Scrubbe Scrubbe Scrubbe & Bag & Bag & Bag & Bag Scrubbe House Scrubbe House House & Bag House Scrubbe
r r r House House House House r r House r

Stack height (m) 6 8 10 12 12 12 12 8 18 8 18 18 12 18 6

22
It can be noticed from Table 5.1 that the detailed field studies are conducted in 15 hot
mix plants. Of these, 3 are in Southern zone (Karnataka), 5 are in Western zone
(Gujarat), 2 are in Eastern zone (West Bengal), one is in Northern zone (Haryana) and
remaining 4 are in Central zone (Madhya Pradesh). These units are codified from HMP-
1 to HMP-15.
5.2 Stack Monitoring
Monitoring and analysis was undertaken to assess pollution levels in stack emissions of
hot mix plants for relevant parameters namely, particulate matter, SO 2, NOx, PAH, VOC
(Benzene, Toluene, Xylene). The Ambient Air Quality was also measured at upstream
and downstream locations from the hot mix plants. The ambient air quality parameters
include particulate matter (PM10 and PM2.5), SO2, NOx, Benzene and Benz(o)pyrene.
5.2.1 Batch hot mix plant
Batch hot mix plants were found equipped with dual cyclone followed by bag filters.
These plants have capacity ranging from 100 to 200 tph. The results of stack emissions
are presented in Table 5.2.
The PM concentration for batch type of hot mix plants is in the range of 99 to182
mg/Nm3 with average of 128 mg/Nm3. The PM concentration is less than 150 mg/Nm3 in
all batch type plant except one Unit (HMP-7) that showed PM as182 mg/Nm3. This could
be attributed to low efficiency of the bag filter. The batch hot mix plants have adopted
bag filters or dual cyclone with bag filters that are capable of reducing the PM level in
stack emissions. With proper operation and maintenance of bag filter, it is possible to
reduce the PM level
CO levels were found to be in the range of 212 to 586 mg/Nm3 with average of 341
mg/Nm3. The variation in CO levels is due to use of different types of fuel and burner. It
may be noted that CO level is found higher at HMP-7, which is using PNG. An
incomplete combustion results in, among other pollutants; the formation of CO.
Abatement of CO emissions therefore requires improvement of the combustion process.
It has been suggested that the combustion process needs more attention for proper
combustion (air to fuel ratio and retention time) thereby reducing the CO emissions.
SO2 concentration is varying from 116 to 257 mg/Nm3 with average of 169 mg/Nm3. It is
important to mention that some units have reported that sometimes they use small
quantity of lime as a raw material to reduce emission. Lime helps in formation of alkaline
dust layer on the bag filter which absorbs SO2. In order to reduce the SO2 emissions, it is
desirable that lower sulphur content fuel such as LDO, diesel, and PNG should be used
for combustion requirement. The high sulphur content fuel such as furnace oil and
rubber process should be avoided.

23
NOx concentration varies from 77 to 209 mg/Nm3 with average concentration of 109
mg/Nm3. The formation of NO x is predominantly determined by burner and flame
characteristics (flame temperature, burner type and volume of excess air).
PAHs, VOCs, benzene, toluene, xylene were observed below 0.01 mg/Nm3 in all units.
Low temperature condition does not include formation of these pollutants from hot mix
plant operations.
Total load of the particulate matter, SO 2, and NOx on hourly and per day basis was
calculated and given in Table 5.3. It is to be noted that hot mix plants operate normally
between 4 to 8 hours per day (in day or night time) subject to the entry restrictions to
various cities. However, the total load has been calculated on 8 hour working basis. It is
also important to mention that the particulate matter load is about 5 kg per hour (40 kg
per day). The SO2 load is about 7 kg/hour and NOx load is about 5.3 kg/hour, which are
not high.
5.2.2 Drum hot mix plant
Drum hot mix plants have installed multiclone followed by venture scrubber. Stack
monitoring was conducted for identified parameters including particulate matter, SO 2
and NOx. The monitoring results are presented in Table 5.4. It can be noticed that
capacity of drum type hot mix plants vary from 35 to 90 tph. Two plants were of 60 tph, 3
plants have 90 tph capacities and one plant was of 35 tph.
PM concentration for drum type hot mix plants was found as low as 84 mg/Nm 3 in one
plant (HMP-10) and as high as 409 mg/Nm3 in other plant (HMP-3). Barring these
extreme values, the average of the remaining values is 282 mg/Nm 3. It is to be noted
that drum type hot mix plants are mostly small and medium scale units and provided
multiclone with scrubber. In view of this, it could be inferred that with proper operation
and maintenance of control measures, it is possible to achieve the desired PM
concentration by all the drum type hot mix plants.
CO levels are found to be in the range of 175 to 1411 mg/Nm3 with average of 685
mg/Nm3. SO2 concentration is varying from 115 to 217 mg/Nm3 with average
concentration of 182 mg/Nm3. SO2 emissions are influenced by the sulphur content of
the fuel (like high sulphur content in furnace oil). In order to reduce the SO 2 emissions, it
is desirable that lower sulphur content fuel such as LDO, diesel, and PNG should be
used for combustion requirement. The high sulphur content fuel such as furnace oil
should be avoided.
NOx concentration is varying from 79 to 215 mg/Nm3 with average concentration of 130
mg/Nm3. The formation of NO x is predominantly determined by burner and flame
characteristics (flame temperature, burner type and volume of excess air). PAHs, VOCs,
benzene, toluene, xylene were observed to be below 0.01 mg/Nm3 in all units.

24
Table 5.5 shows PM load per hour is 0.7 kg (5.7 kg per day on 8 hour working basis).
The SO2 load is 0.5 kg/hour and NOx is 0.4 kg per hour which are insignificant.
5.3 Ambient Air Quality Monitoring
Ambient air was monitored in upstream and downstream wind directions for various
parameters as as given in Table 4.1. The results of ambient air quality monitoring are
given in Table 5.6. PM10 and PM2.5 levels range from 55 to 385 µg/m3 and 22 to 184
µg/m3 respectively. The variation can be attributed mainly to sprinkling of water to
contain dust emission and scale of operation. It may be stressed that internal roads
should be paved. SO2 concentration is in the range of 4 to 26 µg/m3 that is insignificant.
It can be noticed that emission level of SO 2 and NOx are low and meets ambient air
quality standards. Further, the ambient quality monitoring results show no significant
effect of SO2 and NOx on ambient air quality.
The benzene concentrations were found less than 0.01 µg/Nm3 in all plant monitored.
Similarly, levels of benzo(o)pyrene were noticed below 0.01 ng/Nm3. CO concentrations
in ambient air were found between 0.09 to 0.287 mg/Nm3.

25
Table 5.2: Stack emission monitoring results of batch hot mix plants

Parameters Units HMP-4 HMP-5 HMP-6 HMP-7 HMP-9 HMP-11 HMP-12 HMP-13 HMP-14

1.1 x 1.0 x
Duct diameter m 0.98 0.98 0.98 0.98 0.95 1.86 1.18
0.92 0.92

Area of the duct m2 0.75 0.75 0.75 0.75 0.71 1.01 2.72 1.09 0.82

o
Flue gas temp. C 57 70 72 58 90 65 85 58 73

Velocity of the flue gas m/sec 7.36 7.80 7.80 8.41 10.90 13.60 16.67 11.40 14.30

Gas flow rate Nm3/hr 16694 17655 17645 19714 23482 39609 132497 39163 39848

Particulate matter (PM) mg/Nm3 124.5 102.4 112.2 182.2 98.7 130.9 125.7 130.2 143.2

Sulphure dioxide (SO2) mg/Nm3 116.20 122.50 136.70 256.70 213.70 151.40 225.10 157.40 139.40

Oxides of nitrogen (NOx) mg/Nm3 92.70 76.80 82.80 142.80 118.40 82.80 209.30 87.40 88.70

Carbon dioxide (CO2) % 5.80 5.90 5.70 5.12 5.70 5.10 5.20 5.20 5.30

Carbon monoxide (CO) mg/Nm3 285.90 235.20 285.51 585.61 436.70 325.50 425.20 212.10 275.60

Molecular weight of flue gas % 28.14 28.73 28.19 28.76 28.40 28.20 29.20 28.30 28.60

PAHs µg/Nm3 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

VOCs µg/Nm3 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

26
Parameters Units HMP-4 HMP-5 HMP-6 HMP-7 HMP-9 HMP-11 HMP-12 HMP-13 HMP-14

Benzene µg/Nm3 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

Toluene µg/Nm3 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

Xylene µg/Nm3 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

Table 5.3: Stack emission load for batch hot mix plant
Parameters Units HMP-4 HMP-5 HMP-6 HMP-7 HMP-9 HMP-11 HMP-12 HMP-13 HMP-14

Gas flow rate Nm3/hr 16694 17655 17645 19714 23482 39609 132497 39163 39848

mg/Nm3 124.5 102.4 112.2 182.2 98.7 130.9 125.7 130.2 143.2
Particulate matter
kg/hr 2.08 1.81 1.98 3.59 2.32 5.18 16.65 5.10 5.71
(PM)
kg/day 16.63 14.46 15.84 28.74 18.54 41.48 133.24 40.79 45.6

mg/Nm3 116.20 122.50 136.70 256.70 213.70 151.40 225.10 157.40 139.40

Sulphure dioxide (SO2) kg/hr 1.94 2.16 2.41 5.06 5.02 6.00 29.83 6.16 5.55

kg/Day 15.52 17.30 19.30 40.49 40.14 47.97 238.60 49.31 44.44

mg/Nm3 92.70 76.80 82.80 142.80 118.40 82.80 209.30 87.40 88.70
Oxides of nitrogen
kg/hr 1.55 1.36 1.46 2.82 2.78 3.28 27.73 3.42 3.53
(NOx)
kg/Day 12.38 10.85 11.69 22.52 22.24 26.24 221.85 27.38 28.28
27
Table 5.4: Sack Monitoring results for drum hot mix plants
Parameters Units HMP-1 HMP-2 HMP-3 HMP-8 HMP-10 HMP-15

Duct diameter m 0.2 x 0.17 0.2 x 0.18 0.2 x 0.17 0.2 x 0.17 0.45 x 0.45 0.51 x 0.53

Area of the duct m2 0.034 0.036 0.034 0.034 0.20 0.27

o
Flue gas temp. C 54 56 52 50 73 60

Velocity of the flue gas m/sec 10.8 10.4 12.33 10.20 10.80 10.40

Gas flow rate Nm3/hr 1160.6 1176 1328 1049 6524 8436

Particulate matter (PM) mg/Nm3 306.7 238.1 409.4 316.7 83.7 266.4

Sulphure dioxide (SO2) mg/Nm3 217.1 158.9 204.60 207.60 115.40 191.50

Oxides of nitrogen (NOx) mg/Nm3 128.6 214.9 132.70 118.70 78.60 108.40

Carbon dioxide (CO2) % 4.0 5.3 5.64 4.80 5.50 5.00

Carbon monoxide (CO) mg/Nm3 574.3 1411.2 1233.80 374.80 174.80 344.10

Molecular weight of flue gas % 29.0 29.2 29.26 28.70 29.10 28.70

PAHs µg/Nm3 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

VOCs µg/Nm3 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

Benzene µg/Nm3 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

Toluene µg/Nm3 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

28
 Parameters Units HMP-1 HMP-2 HMP-3 HMP-8 HMP-10 HMP-15

Xylene µg/Nm3 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

Table 5.5: Stack emission load for drum hot mix plant
Parameters Units HMP-1 HMP-2 HMP-3 HMP-8 HMP-10 HMP-15

Gas Flow Rate Nm3/hr 1160.6 1176 1328 1049 6524 8436

mg/Nm3 306.7 238.1 409.4 316.7 83.7 266.4

Particulate matter
kg/hr 0.36 0.28 0.54 0.33 0.55 2.25
(PM)
kg/day 2.85 2.24 4.35 2.66 4.37 17.98

mg/Nm3 217.1 158.9 204.60 207.60 115.40 191.50

Sulphure dioxide (SO2) kg/hr 0.25 0.19 0.27 0.22 0.75 1.62

kg/day 2.02 1.49 2.17 1.74 6.02 12.92

mg/Nm3 128.6 214.9 132.70 118.70 78.60 108.40

Oxides of nitrogen
kg/hr 0.15 0.25 0.18 0.12 0.51 0.91
(NOx)
kg/day 1.19 2.02 1.41 1.00 4.10 7.32

29
Table 5.6: Ambient air quality monitoring results
HMP-1 HMP-2 HMP-3 HMP-4 HMP-5

Parameters NAAQS Units

Down stream

Down stream

Down stream

Down stream

Down stream

Down stream

Down stream

Down stream

Down stream

Down stream
Up stream

Up stream

Up stream

Up stream

Up stream
Sulphure dioxide
80 µg/m3 4.0 8.5 8.8 4.9 5.1 5.3 5.6 6.6 7.1 8.7 9.5 9.7 9.2 10.6 10.3
(SO2)

Oxides of
80 µg/m3 5.2 9.9 10.4 5.8 6.1 6.4 7.9 8.2 8.9 10.3 13.4 13.1 11.7 13.1 12.8
nitrogen (NOx)

Particulate matter
100 µg/m3 55.0 102 113 61 63.0 66.0 81.0 87.0 91.0 165 176 178 316 334 325
(PM10)

Particulate matter
60 µg/m3 22.0 39 43 37.00 40.00 42.00 37.00 41.00 44.0 81 52 57 164 174 160.0
(PM2.5)

Benzene (C6H6) 5 µg/m3 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

Benzo (o) Pyrene

1 ng/m3 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01
in PM

Carbon monoxide
2 mg/m3 0.09 0.131 0.144 0.092 0.116 0.120 0.145 0.150 0.153 0.152 0.164 0.169 0.256 0.287 0.272
(CO)

30
Table 5.6: Ambient air quality monitoring results Cont….
HMP-6 HMP-7 HMP-8 HMP-9 HMP-10

Parameters NAAQS Units

Down stream

Down stream

Down stream

Down stream

Down stream

Down stream

Down stream

Down stream

Down stream

Down stream
Up Stream
Up stream

Up stream

Up stream

Up stream
Sulphure dioxide
80 µg/m3 7.9 9.9 10.2 8.1 9.8 10.3 10.2 13.2 12.3 12.6 13.1 14.1 15.2 18.2 17.1
(SO2)

Oxides of
80 µg/m3 11.3 15.6 15.8 10.2 14.3 14.5 16.6 18.4 17.4 15.2 16.2 17.3 18.6 21.7 19.3
nitrogen (NOx)

Particulate
100 µg/m3 278 294 308 254 285 294 295 331 341 312 385 312 223 314 287
matter (PM10)

Particulate
60 µg/m3 153 161 171 122 152 168 171 184 173 108 134 116 128 118 114
matter (PM2.5)

Benzene (C6H6) 5 µg/m3 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

Benzo (o)
1 ng/m3 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01
Pyrene in PM

Carbon
2 mg/m3 0.178 0.178 0.181 0.149 0.201 0.189 0.263 0.274 0.265 0.186 0.193 0.197 0.272 0.286 0.276
monoxide (CO)

31
Table 5.6: Ambient air quality monitoring results Cont….
HMP-11 HMP-12 HMP-13 HMP-14 HMP-15

Parameters NAAQS Units

Down stream

Down stream

Down stream

Down stream

Down stream

Down stream

Down stream

Down stream

Down stream

Down stream
Up Stream
Up stream

Up stream

Up stream

Up stream
Sulphure dioxide
80 µg/m3 18.4 22.1 20.8 20.2 23.1 25.8 17.8 19.4 20.2 16.8 18.1 18.5 15.1 17.6 16.8
(SO2)

Oxides of
80 µg/m3 24.2 26.8 24.4 24.4 28.7 29.2 21.3 23.7 24.6 19.7 22.0 21.4 17.9 18.8 19.2
nitrogen (NOx)

Particulate
100 µg/m3 328 318 282 328 285.1 248.3 342.5 228.7 270.5 160.8 223.4 198.7 157.8 203.1 216.1
matter (PM10)

Particulate
60 µg/m3 133 142 104 123 86.7 85.2 108.3 102.1 112.8 82.1 94.3 91.1 70.4 83.4 105.8
matter (PM2.5)

Benzene (C6H6) 5 µg/m3 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

Benzo (o)
1 ng/m3 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01
Pyrene in PM

Carbon
2 mg/m3 0.167 0.172 0.167 0.186 0.212 0.221 0.113 0.187 0.191 0.142 0.157 0.161 0.223 0.244 0.237
monoxide (CO)

32
 Chapter 6
Pollution Control Guidelines

This chapter deals with control technologies used in the hot mix plants and the
guidelines for abatement and control of pollution. Control efficiency for specific
equipment varies depending on the type of equipment and maintenance and repair
programme to up keep them.

6.1 Stack Emissions

Particulate matter (PM) in hot mix plants are generally controlled using primary and
secondary collection devices. The primary devices include cyclone, dual cyclone and
multicyclone to remove larger particulates. The secondary devices including fabric
filters and scrubbers remove fine particles. The particles separated by these devices
are collected and reused in the process as filler material or disposed.

6.1.1 Cyclone
The cyclone is a particulate control device that uses gravity, inertia and impaction to
remove particles from flue gas stream. Large diameter cyclones are often used to
remove the bulk of heavier particles from the flue gas before it enters a secondary or
final control system. A secondary collection device, which is more effective in
removing particulates than a primary collector, is used to capture remaining fine
particulates that escaped from the primary treatment device.

6.1.2 Multicyclone
It consists of numerous small diameter cyclones operating in parallel. Multicyclones
are less expensive to install and operate than the fabric filters, but are less effective
in removing small particulates (Figure 6.1). They are often used as precleaners to
remove the bulk of heavier particles from the flue gas before it enters the main
control device.

6.1.3 Dust Separator

Dust separators are used at hot mix plants as primary dust collection equipment.
They are fitted with baffles that arrest particles from the flue gases.

All the above primary control devices helps remove particulate matter and also
prevent the premature wear on in the bag filters that may occur, if the large
particulate was not removed from the air stream. They also facilitate reuse of the
large particulate in the process.

6.1.4 Scrubbers

Venturi scrubbers (sometimes also referred wet scrubbers) are used to remove
coarse and fine particulate matter Figure 6.1). Flue gas passes through a venturi tube
while low pressure water is added at the throat of venturi. The turbulence in the
venturi promotes intimate contact between the particles and the water. The
wetted particles and droplets are separated along with water stream. In addition to

33
controlling particulate emissions, the venturi scrubber is likely to remove some of
the process organic emissions from the exhaust gas. While the venturi scrubber
is reliable in controlling particulates, it requires considerable attention and daily
maintenance to maintain particulate removal efficiency. Use of wet scrubber
generates wastewater containing solids. The solids are settled as sludge that can be
dried and reused in the process as filler or disposed.

Figure 6.1: Multiclone and venturi scrubber system

6.1.5 Bag filter

Bag filters or fabric filters are used to remove particles through fabric filtering systems
(bags) as shown in Figure 6.2. The particles are caught on the surface of the bags,
while the cleaned flue gas passes through. To minimize pressure drop, the bag filters
are cleaned periodically as the dust layer builds up. Fabric filters can achieve the
highest particulate collection efficiency of all particulate control devices. Hot mix
plants use the bag filters for stack emissions control. The captured dust from these
devices should be recycled to the production process.

It was noticed from the field studies that bag filters give very high efficiency in
removing particulate matter. They are prevalent in batch hot mix plants. Use of bag
filter in drum hot mix plant was not found anywhere. It came to the notice that flue
gas temperature in drum hot mix plant is higher than that of batch hot mix plants. The
flue gases at higher temperature tend to damage the bag filter media and hence, its
application in drum hot mix plants particularly, the parallel flow plants, is not
practiced.

34
 Figure 6.2: Bag filter assembly

6.2 Fugitive Emissions

6.2.1 Internal road

The paving of the internal roads will reduce airborne dust caused by vehicle
movement. All internal roads and working areas should be kept clean and wet by
sprinkling of water to contain dust emission. Sprinkling water is also suggested near
points of material handling and transfer.

6.2.2 Aggregate stockpiles

There are many variables that affect the fugitive dust emissions from aggregate
stockpiles including moisture content of the material, proportion of fine particle and
age of pile. The older piles tend to lose surface particles. Watering of the stockpiles is
not generally advised because of the burden it may puts on the heating and drying
process. In addition, it may also lead to water pollution. All stockpile areas should be
kept neat and orderly. The heights should be kept to a reasonable minimum in order
to reduce wind erosion. Stockpiles should be positioned as close as possible to the
cold feed bins in order to minimize front-end loader travel between stockpiles and
bins.

35
6.3 Volatile Organic Compounds

Once the exhaust stream cools after discharge from the process, some VOCs
condense to form a fine liquid aerosol and may be separated from flue gas stream
while passing though the control devices. Process modifications or restrictions are
effected to reduce VOCs, including installation of flame shields, rearrangement of
flights inside the drum, adjustments of the asphalt injection point and other design
changes. Periodic burner tune-ups may reduce VOC emissions substantially. Fuel to
air ratio can be optimized to reduce emissions. The emissions from bitumen tank are
particularly low due to their low vapour pressure. For control of air emissions from
bitumen heating, temperature control is very important. At low temperature,
emissions of VOCs are not expected. In some cases, the tank emissions may be
routed back to combustion unit.

6.4 Sulfur Dioxide

Avoiding use of high sulphur content fuels such as furnace oil and rubber process oil
can substantially reduce SO2 emission. Fuel blending (A process of mixing higher
sulfur content fuels with lower sulfur fuels) can also be option to reduce the sulfur fed
for the combustion. Some units have reported that sometimes they use small quantity
of lime as a raw material. Alkaline aggregate i.e. limestone may adsorb sulfur
compounds from the exhaust gas. While exhaust stream passing through the bag
filters, SO2 may be reduced by limestone dust that coats the bag filters.
Consequently, limestone aggregate may maximise the removal of sulfur compounds.
A venturi scrubber may also adsorb sulfur compounds from the exhaust gas with re-
circulated water containing lime.

6.5 Oxides of Nitrogen

Combustion systems, such as low NOx burners that are used to reduce NOx
emissions in other industries, are not generally employed in the hot mix plants due to
economic and/or engineering considerations. Fuels lower in nitrogen content may
reduce some NOx emissions. Maintaining proper temperature for combustion may
also reduce NOx emission. However, low combustion temperature may increase CO
level.

6.6 Wastewater Management

There is no use water in production hot mix. Water is used only in the air pollution
control device i.e. wet scrubber. The wastewater after settling in the tank should be
recycled in the scrubber.

36
6.7 Solid Waste Disposal

Any process rejects or leftover of the hot mix should be recycled in the process. The
solid particles collected from particulate matter control devises should be used as
filler in the process. Sludge generated from scrubber water settling is also reported
be reused as filler in production of hot mix.

6.8 Wastes as Raw Material

The there is practice to use reclaimed asphalt pavement as raw material for hot mix
plants. The waste contains higher moisture compared to the aggregates. During
heating in the dryer drum of the plant, visible smoke may generate initially due to
formation of vapours. However, the use of reclaimed pavement is known to cause
less emission in terms of the particulate matter.

Waste plastic material has attracted attention of researchers to explore use of the
waste in bitumen mix for construction of roads. The literature survey has shown that
plastic wastes can reduce bitumen consumption to the tune of 10 to 15% without
affecting the quality of product. In this process, the bitumen is bonded with
aggregated by means of plastic, which acts as a binder.

Disposal of used tyres is a major environmental concern. The asphalt modified with
ground tyre rubber is reported to have several positive qualities. Adding ground tyre
rubber to the asphalt liquid reduces aging and oxidation of the binder, which
increases pavement life by lessening the brittleness and cracking.

During the survey, none of the hot mix plants that were selected for study was using
the plastic wastes or ground tyre rubber.

6.8 Monitoring Programme

The ambient air quality was monitored at 15 hot mix plants in up wind and down wind
direction at 10 m distance from source of emission as discussed in Chapter 5. The
results presented in Table 5.5 show that SO2 and NOx values are much below the
ambient air quality standards of 80 µg/m3. Benzene was observed less than 0.01
µg/m3 which is below the air quality standards of 5 µg/m3. The Benzo(o)pyrene was
also noticed below 0.01 ng/m3 against standard of 1 ng/m3. The carbon monoxide
concentration was noticed as 0.09-0.28 mg/m3 which is much below the standard of 2
mg/m3.

As far as PM10 and PM2.5 are concerned, the monitored values exceed the air quality
limit at both locations i.e. upwind and downwind directions, at all the 15 hot mix
plants. The higher concentrations of PM10 and PM2.5 at down wind direction than
upwind direction confirm contribution of particulates by hot mix plant. But the
accidences of PM10 and PM2.5 at up wind direction show contribution by sources
other than hot mix plants.

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 In view of the above, particulate matter is the relevant parameter to be monitored for
regulatory purposes. The measures for control of particulate matters are given in
Table 6.1.

Table 6.1 Measures for control of particulate matter

S. No. Source pollution Control measures

1. Stack emissions Cyclone, dual cyclone, multiclone, scrubber, bag

filters.
2. Wastewater Scrubber water should be completely recycled.
3. Waste from pollution The waste collected from cyclone, multiclone and
control measures bag filter is a dust that can be reused as filler in
process or disposed into low laying area.
4. Process waste Any process residue/waste should be reused in the
process.
5. Fugitive emissions The internal roads, working platform, loading and
unloading areas in premises should be paved and
kept clean all times. Dust emission from material
handling and transfer be contained with water
sprinkling or covering the points of dust emission.

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