Quantifying Combustion-Related Emissions from Asphalt Plants Through Thermal Energy and Exhaust-Gas Analysis

The production of hot mix asphalt (HMA) is energy-intensive, resulting in carbon dioxide (CO2) and greenhouse gas (GHG) emissions. The primary energy source (accounting for over 97%) and emissions source is the rotary drum employed for the drying and heating of the aggregates. Quantifying the CO2 emissions associated with combustion is of crucial importance in order to facilitate a more profound comprehension of the environmental impacts of HMA production. The objectives of this study are to develop a methodological framework for the quantification of combustion-related carbon dioxide emissions in the context of asphalt production. The proposed framework investigates three complementary approaches: (i) an energy-balance-based thermal energy (TE) model, (ii) recordings of fuel consumption and (iii) direct measurement of exhaust-gas composition. By applying these methods in parallel and cross-comparing their results batch by batch, the framework enables reliable verification of actual CO2 emissions from the module A3—production stage of asphalt manufacturing. In this stage, the predominant source of greenhouse gases is fuel combustion during aggregate drying and heating. A comprehensive set of data was collected from two HMA batch plants, each operating under distinct conditions. The parameters considered included fuel type, asphalt mixture type, asphalt production time, aggregate moisture content, mixing temperature, and production rate. The TE model demonstrated a robust linear correlation with measured energy consumption (R2 = 0.97), and fuel-based CO2 estimates exhibited minimal discrepancy compared to direct exhaust-gas measurements on average (mean difference 1.0%; t-test p = 0.674). However, systematic discrepancies were observed between the two plants (with overestimation of up to 20% at one plant (AP1) and underestimation of up to 12% at the other (AP2)). This demonstrates that energy-based CO2 estimation methods require plant-specific calibration against direct measurement before they can be reliably applied in life cycle assessment (LCA) and environmental product declaration (EPD) practice. Measured CO2 emission intensities ranged from 17.39 to 21.76 kg/t at AP1 and from 16.05 to 18.44 kg/t at AP2; the casing-losses factor of the TE model was calibrated to CL = 23% for the studied diesel-fired plants (mean deviation +0.4% from measured energy); and aggregate moisture content explained 74% of the variance in measured energy consumption (R2 = 0.743).