Instructions for Using this Worksheet

Emissions calculations can be done in a number of ways, depending on the type of processgenerating the emissions and what sort of data is available on the process and/or what it generates.

The following worksheets provide information on how to calculate emissions of volatile organic compounds (VOCs), particulate matter (PM), hazardous air pollutants (HAPs), and any resulting from fuel combustion. The following are summaries of the types of calculations explained on each worksheet.

Safety Data Sheets) for coatings or a mass balance approach assuming all VOC content in a product is emitted to the air except for what is collected and stored as waste. Some VOC emitting processes may have emission factors developed by EPA and those

AP-42 is organized by process or industry, so you may need to look in a few chapters to find appropriate factors. Follow the PM instructions on using an emission factor if you happen to have a VOC process with an EPA emission factor.

For those without an AP-42 emission factor, it may be necessary to perform some sort of mass balance onthe process to measure the amount of emissions generated. This would entail weighing items before and after processing or weighing material collected in any device connected to the exhaust to prevent emissions. DNR would probably prefer an actual stack test to develop an emission factor for the specific source.

determine the HAP emissions. Sometimes only trade associations have emissions data and make it available only to members.

be combusted by a source to create process steam, process heat, or building heat or to generate electricity. Only unusual fuels, like new refuse derived fuels or biofuels, might require a source to test to developemission factors, but once developed the emission factors are used the same way AP-42 values are.

VOCs - generally the key methods used to determine VOCs are either using MSDS (Material

can be found in EPA's AP-42 at: http://www.epa.gov/ttn/chief/ap42/index.html

PM - in general you will likely find emission factors for most PM sources in AP-42. See the web address above.

HAPs - usually you will have either MSDS information or an AP-42 emission factor available to

Fuel calculations - AP-42 has a wide range of emission factors for different types of fuels that might

VOC EMISSIONS CALCULATIONS (Coatings)

KeyCalculations:

Extra Calcs: **NOTE: If your MSDS or paint can doesn't have VOC in lb/gal you'll need to do these two calculations to get that value:

(VOC content in % by volume IS NOT THE SAME.)Example: Density = 12 lb/gal and VOC Content = 65% by wt; VOC Content = 12 lb/gal x 65%/100 = 7.8 lb VOC/gal

Example: SG = 0.84; Density = 0.84 * 8.34 = 7.00 lb/gal

Example: Solids Content = 35% by wt; VOC Content = (1 - {35/100}) x 100 = 65% by wt

plus the emissions from each of the previous 11 months and divide the total by 12. This gives you the annual rolling average.

Material Specific Gravity Density VOC Content VOC Content Amount Used VOC EmissionsCoatings Name or ID # (ratio) (lb/gal) (% by wt.) (lb/gal) (gal/month) (lb/mo)Example #1 Material #1 12.00 65.00 7.80 50.00 390.00Coating #1 0.00Coating #2 0.00Coating #3 0.00Coating #4 0.00Coating #5 0.00Coating #6 0.00Coating #7 0.00(Just insert more lines here for more coatings) 0.00

0.00

Thinners and Clean up Solvents 0.00Solvent #1 0.00Solvent #2 0.00Solvent #3 0.00(Just insert more lines here for more solvents) 0.00

Total VOCs for 390.00(write in month/year)

Amount Used (gal/mo) x VOC Content (lb/gal) = VOC EmissionsAdd together VOC Emissions from each coating and solvent = Total VOCs per month

Density of Coating * (VOC content in % by weight / 100) = VOC Content (lb/gal)

If MSDS doesn’t have Density of Coating then: Specific Gravity * 8.34 lb/gal = Density of Coating (lb/gal)

If MSDS only shows Solids Content in % by weight then: VOC content in % weight = (1 - {% solids/100})x100

ROLLING AVERAGES: Make a worksheet like this one for each calendar month. At the end of each month, add this month's emissions

=

VOC Content, As Applied This value is usually only necessary for calculations to demonstrate compliance with a coating limit.It is not used in actual emissions calculations over a certain time period.

VOC content of coating that is thinned prior to application:

Coating VOC 3.8 lb/gal Coating is thinned in 4:1 ratioThinner VOC 6.8 lb/gal

Add the total VOC emissions and divide by total gallons applied3.8 lb coating/gal x 4 gallons = 15.2 lbs VOC6.8 lb thinner/gal x 1 gallon = 6.8 lbs VOCTotal VOC = 22.0 pounds / 5 gallons applied

= 4.40 lb VOC/gal, as applied

If not all coating used, and thinned again later for additional application - repeat calculation as follows

Coating VOC (as calculated previously) 4.40 lb/gal Again thinned in 4:1 ratio, but only 1 gallon of previous 5 leftThinner VOC 6.8 lb/gal

Add the total VOC emissions and divide by total gallons applied4.40 lb coating/gal x 1 gal = 4.40 lbs VOC6.8 lb thinner/gal x 0.25 gal = 1.7 lbs VOCTotal VOC = 6.1 pounds / 1.25 gallons applied

= 4.88 lb VOC/gal, as applied

A similar calculation would be repeated for a multiple component coating that is also thinned.

Mass Balance if VOCs Not from Coatings

Storage - Drums labeled with waste mineral spirits from degreasing units.

Purchase 1 drum every 3 months, return 1 drum used solvent every 4 months.Mineral spirits: 6.7 pounds per gallon, 100% VOC content

Purchased: 55 gal/3 mo x 12 mo/yr = 220 gal/yrDisposed: 55 gal/4 mo x 12 mo/yr = 165 gal/yr

VOCs = 220.0 gal/yr - 165.0 gal/yr = 55.0 gal/yr x 6.7 lb VOC/gal = 368.5 pounds VOC/yr

PM EMISSIONS CALCULATIONS

Key Amount Used (ton material processed per hour) x Emission Factor (lb Pollutant/ton material) x (1-Control Efficiency)Calculations Emission Factors Usually Found in AP-42, EPA Document

http://www.epa.gov/ttn/chief/ap42/index.htmlMass Balance Allowed if NO Emission Factors - Must Be Well Documented

Dry Material Handling:Grain handling - EF Table 9.9.1-1, AP-42

Maximum Processing: 250 tons per hour

Receiving, railcar: 0.032 lb/ton Drying, column: 0.22 lb/tonCleaning w/cyclone: 0.075 lb/ton Shipping, railcar: 0.027 lb/ton

MTE = 250 TPH x (0.032 + 0.22 + 0.075 + 0.027) lb PM / ton = 88.5 lb PM/hr

Welding Emissions:

Emission Factor: Table 12.19-1, AP-42Amount of electrode used: 12,100 pounds carbon steel electrode GMAW used - ER70S-#. Emission factors vary by process used and electrode type.

PM10: 5.2 lb PM10/1000 lb electrode PM10 = (5.2 lb PM10 / 1000 lb electrode) * 12,100 lb electrode /yr = 62.92 pounds PM10/yr

Emission Factor: "Section 313 Reporting: Issue Paper - Clarification and Guidance for Metal Fabrication Industry", EPA, Jan 1990

GMAW - ER4043 Amount of electrode used: 1200 pounds aluminum electrode per yearPM10: 10.7 lb /1000 lb electrodePM10 = (10.7 lb PM10 / 1000 lb electrode) * 1200 lb electrode /yr = 12.8 pounds PM10/yr

Mass Balance if no Emission Factors:

Measure how much is collected over a month, during normal operations. (Making sure collector is clean before starting this measurement period.)Measure the period of time the unit is operated, and then weigh the amount of material collected during that period of time.

The final value is the amount in pounds over a certain number hours of operation. Minimum collection efficiency guaranteed by the manufacturer of the collection filters is 85%.

Then follow these equations to determine the particulate matter emissions:

Material collected: 100 pounds / 8 hours = 12.5 pounds per hour CE = 85%/100% or 0.85 as a fraction

That 8 hours operation for one month was fairly average. Assume 120 hours per year:

Max: 14.7 lb PM/hr x 120 hr/yr = 1764 lb PM/yrControlled: 2.2 lb/hr x 120 hr/yr = 264 lb PM/yr

PM From Painting OperationsOne thing usually missed is particulate matter calculations from the paints. You need the overspray collection efficiency (CE)of the waterwash wall and the transfer efficiency (TE) of the paint application system.Both can be obtained from equipment specs from the manufacturer

PM = amount of paint used in gal per year x (% solids in paint/100) lb/gal x (1-TE) x (1-CE)

Paint application: HVLP gun Coating A: 443 gallons/yr; 32% solids by weightTransfer efficiency: 70% Coating B: 534 gallons/yr; 43% solids by weightCollection efficiency: 85%

PM = {443 gal A/yr x (32% solids/100 ) + 534 gal B/yr x (43% solids/100)} x (1-0.7) x (1-0.85)

Uncontrolled emissions = material collected / (CE) = 12.5 lb/hr / (0.85) = 14.7 lb/hrControlled emissions = uncontrolled emissions (1-CE) = 14.7 lb/hr (1-0.85) = 2.2 lb/hr

= 371.4 gallons solids/yr x 0.3 x 0.15 = 16.71 pounds PM/yr from paints

HAP EMISSIONS CALCULATIONS(Coatings)

KeyCalculations:

Extra Calcs: **NOTE: You will need to find the HAP% by in the Hazardous Ingredient section of your MSDS for these initial calculations.

Example: Density = 12 lb/gal and HAP Content = 25% by wt; HAP Content = 12 lb/gal x 25%/100 = 3.0 lb HAP/gal

Example: SG = 0.84; Density = 0.84 * 8.34 = 7.00 lb/gal

plus the emissions of that HAP from each of the previous 11 months and divide the total by 12. This gives you the annual rolling average.Repeat the calculations for each HAP.

Material Specific Gravity Density HAP Content HAP Content Amount Used HAP Emissions HAP TOTALsHAPs Name or ID # (ratio) (lb/gal) (% by wt.) (lb/gal) (gal/month) (lb/mo) (lb/mo)Example HAP Example Mat'l 12.00 25.00 3.00 50.00 150.00HAP #1 Material #1 0.00

Material #2 0.00Material #3 0.00Material #4 0.00 0

HAP #2 0.00(Just insert more lines here for more materials that contain this HAP) 0.00HAP #3 0.00HAP #4 0.00HAP #5 0.00HAP #6 0.00HAP #7 0.00(Just add more HAPs here.) 0.00

0.000.000.00

Amount Used (gal/mo) x HAP Content (lb/gal) = HAP EmissionsAdd together HAP Emissions from each material = Total of each HAP per month

Density of Coating * (HAP content in % by weight / 100) = HAP Content (lb/gal)

If MSDS doesn’t have Density of Coating then: Specific Gravity * 8.34 lb/gal = Density of Coating (lb/gal)

ROLLING AVERAGES: Make a worksheet like this one for each calendar month. At the end of each month, add this month's emissions for one HAP

PM-based HAPs From Painting OperationsOne thing usually missed is particulate matter calculations from the paints. You need the overspray collection efficiency (CE)of the control device and the transfer efficiency (TE) of the paint application system.Both can be obtained from equipment specs from the manufacturer

PM-based HAP = amount of paint used in gal per year x (% HAP in paint/100) lb/gal x (1-TE) x (1-CE)

Paint application: HVLP gun Coating A: 443 gallons/yr; 3% carbon black by weightTransfer efficiency: 70%Collection efficiency: 85% from waterwash wall

HAP (Carbon black) = {443 gal A/yr x 7.26 lb/gal x (3% solids/100 ) x (1-0.7) x (1-0.85)

Mass Balance if HAPs Not from Coatings

Storage - Drums labeled with waste mineral spirits from degreasing units.

Purchase 1 drum every 3 months, return 1 drum used solvent every 4 months.Mineral spirits (Stoddard Solvent): 6.7 pounds per gallon, 100% HAP content

Purchased: 55 gal/3 mo x 12 mo/yr = 220 gal/yrDisposed: 55 gal/4 mo x 12 mo/yr = 165 gal/yr

Welding Emissions:

Emission Factor: Table 12.19-2, AP-42Amount of electrode used: 12,100 pounds carbon steel electrode per yearGMAW - ER70S-#. (Emission factors vary by process used and electrode type. Co and Cr and Cr(VI) are also listed for some electrodes.)

Manganese (Mn): 0.32 lb Mn/1000 lb electrode Mn = (0.32 lb Mn / 1000 lb electrode) * 12,100 lb electrode /yr = 3.87 pounds Mn/yr

Emission Factor: "Section 313 Reporting: Issue Paper - Clarification and Guidance for Metal Fabrication Industry", EPA, Jan 1990GMAW - ER4043 Amount of electrode used: 1200 pounds aluminum electrode per yearAluminum (Al): 4.9 lb Al/1000 lb electrodeAl = (4.9 lb Al / 1000 lb electrode) * 1200 lb electrode /yr = 5.88 pounds Al/yr

= 96.5 gallons solids/yr x 0.3 x 0.15 = 4.34 pounds CB/yr from paints

HAPs = 220.0 gal/yr - 165.0 gal/yr = 55.0 gal/yr x 6.7 lb HAP/gal = 368.5 pounds HAP/yr

FUEL EMISSIONS - ALL CRITERIA POLLUTANTS

Fuel Calculations:Max Fuel Volume/hr x EF lb pollutant/fuel volume

EF for NG: Tables 1.4-1 and -2, AP-42EF for Fuel Oil: Tables 1.3-1, -2, and -3, AP-42

TABLE 1: BOILER CRITERIA POLLUTANT EMISSIONS

B01: Natural Gas = 0.013 cf6/hr; Fuel Oil = 90 gal/hrB02: NG = 0.008 cf6/hr; FO = 60 gal/hr

Example: B01 NG = 0.013 cf6/hr x 3.0 lb PM/cf6 = 0.039 lb PM/hr

Pollutant NG EF B01 NG EF B02 FO EF B01 B0210-100 MMBTU Max. <10 MMBTU Max. Max. Max.

lb/hr lb/hr lb/hr lb/hrPM 3 0.039 3 0.024 2 0.18 0.12SO2 0.6 0.0078 0.6 0.0048 71.8 6.462 4.308NOx 140 1.82 100 0.8 20 1.8 1.2VOC 2.8 0.0364 5.3 0.0424 0.2 0.018 0.012CO 35 0.455 20 0.16 5 0.45 0.3

Worst Case Emissions are from Fuel Oil for each boiler, so MTE is based on those calculations:

TABLE 2: MTE BOILER CRITERIA POLLUTANT EMISSIONS

Pollutant B01 B02 Totals B01 B02 Totalslb/hr lb/hr lb/hr TPY TPY TPY

PM 0.18 0.12 0.3 0.788 0.526 1.314SO2 6.46 4.308 10.768 28.295 18.869 47.164NOx 1.82 1.2 3.02 7.972 5.256 13.228VOC 0.036 0.042 0.078 0.158 0.184 0.342CO 0.455 0.3 0.755 1.993 1.314 3.307

** Fuel HAPS are exempt from NR 445 when listed as group 1 virgin fossil fuels (natural gas, distillate/#2 fuel oil, propane)