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Emissions calculations can be done in a number of ways, depending on the type of process generating the emissions and
what sort of data is available on the process and/or what it generates. This worksheet is intended to assist you with
calculating your actual emissions for different air pollution permits, exemptions and rule applicability thresholds.
The following worksheets provide information on how to calculate emissions of volatile organic compounds (VOCs),
particulate matter (PM), hazardous air pollutants (HAPs), and criteria pollutants resulting from fuel combustion. The
following are summaries of the types of calculations explained on each worksheet.
VOCs:
The primary methods used to determine VOCs from solvent based materials rely on using a SDS (Safety Data Sheet) or a
Consumer Product Data Sheet (CPDS), both of which are available from the manufacturer. Then using data from the SDS
or CPDS, you calculate emissions assuming a mass balance approach where all VOC content in a product is emitted to the
air except for amounts collected and stored as waste.
Some VOC emitting processes may have emission factors developed by EPA and those can be found in EPA's AP-42 at:
http://www.epa.gov/ttn/chief/ap42/index.html. AP-42 is organized by process or industry, so you may need to look in a few
chapters to find emission factors that match or closely match your process. Follow the PM instructions on using an
emission factor if you happen to have a VOC process with an EPA emission factor.
PM:
You will likely find emission factors for most PM sources in AP-42. See the web address above.
For those without an AP-42 emission factor, it may be necessary to perform some sort of mass balance on the process to
measure the amount of emissions generated. This would entail weighing materials used both before and after processing
and weighing material collected in any device connected to the exhaust to prevent emissions. The difference between what
is input as raw materials, and what comes out as final product or waste is likely emitted into the air. However, it is preferred
if you have data from a site-specific stack test to develop an emission factor for the source.
HAPs:
Usually you will have either SDS information or an AP-42 emission factor available to determine the HAP emissions.
Sometimes only trade associations have emissions data and make it available only to members. Or you may find data in
industry or scientific journals derived from research testing.
Fuel (Boiler/Engine) calculations:
AP-42 has a wide range of emission factors for different types of fuels that might 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 site-specific stack test to develop emission factors, but once developed the emission factors are
used the same way as you would use AP-42 values.
compounds (VOCs),
uel combustion. The
by a source to create
new refuse derived fuels or
d the emission factors are
Extra Calcs:
**NOTE: If your SDS or paint container doesn't have VOC in lb/gal you'll need to do these two calculations to get that value:
Density of Coating * (VOC content in % by weight / 100) = VOC Content (lb/gal)
(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
If MSDS doesnt have Density of Coating then: Specific Gravity * 8.34 lb/gal = Density of Coating (lb/gal)
Example:
SG = 0.84; Density = 0.84 * 8.34 = 7.00 lb/gal
If MSDS only shows Solids Content in % by weight then: VOC content in % weight = (1 - {% solids/100})x100
Example:
Solids Content = 35% by wt; VOC Content = (1 - {35/100}) x 100 = 65% by wt
ROLLING AVERAGES: Make a worksheet like this one for each calendar month. At the end of each month, add this month's emissions
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
Coatings
Name or ID #
(ratio)
Example #1
Material #1
Coating #1
Coating #2
Coating #3
Coating #4
Coating #5
Coating #6
Coating #7
(Just insert more lines here for more coatings)
Density
(lb/gal)
VOC Content
VOC Content
Amount Used
VOC Emissions
(% by wt.)
(lb/gal)
(gal/month)
(lb/mo)
12.00
65.00
7.80
50.00
390.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Total VOCs for
=
(write in month/year)
390.00
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.
3.8 lb/gal
6.8 lb/gal
Add the total VOC emissions and divide by total gallons applied
3.8 lb coating/gal x 4 gallons = 15.2 lbs VOC
6.8 lb thinner/gal x 1 gallon = 6.8 lbs VOC
Total 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
Thinner VOC
6.8 lb/gal
Add the total VOC emissions and divide by total gallons applied
4.40 lb coating/gal x 1 gal = 4.40 lbs VOC
6.8 lb thinner/gal x 0.25 gal = 1.7 lbs VOC
Total 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.
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.html
Mass 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
Cleaning w/cyclone: 0.075 lb/ton
Welding Emissions:
Emission Factor: Table 12.19-1, AP-42
Amount 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
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 year
PM10: 10.7 lb /1000 lb electrode
PM10 = (10.7 lb PM10 / 1000 lb electrode) * 1200 lb electrode /yr
= 12.8 pounds PM10/yr
Paint application:
HVLP gun
Transfer efficiency (TE):
70%
Collection efficiency (CE): 85%
PM Emissions = Amount of paint sprayed, gal per year x (% solids in paint/100) lb/gal x (1-TE) x (1-CE)
PM Emissions = {443 gal A/yr x (32% solids/100) + 534 gal B/yr x (43% solids/100)} x (1-0.7) x (1-0.85)
(141.76 A lb PM/yr + 229.62 B lb PM/yr) x 0.3 x 0.15 =
16.71 lb PM/yr
Extra Calcs:
**NOTE: You will need to find the HAP% by in the "Composition Information" section of your SDS for these initial calculations.
Density of Coating * (HAP content in % by weight / 100) = HAP Content (lb/gal)
Example:
Density = 12 lb/gal and HAP Content = 25% by wt; HAP Content = 12 lb/gal x 25%/100 = 3.0 lb HAP/gal
If MSDS doesnt have Density of Coating then: Specific Gravity * 8.34 lb/gal = Density of Coating (lb/gal)
Example:
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
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
Name or ID #
Example Mat'l
Material #1
Material #2
Material #3
Material #4
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
Transfer efficiency (TE):
70%
Collection efficiency (CE): 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)
= 96.5 gallons solids/yr x 0.3 x 0.15 = 4.34 pounds CB/yr from paints
Welding Emissions:
Emission Factor: Table 12.19-2, AP-42
Amount of electrode used:
12,100 pounds carbon steel electrode per year
GMAW - 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
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 year
Aluminum (Al): 4.9 lb Al/1000 lb electrode
Al = (4.9 lb Al / 1000 lb electrode) * 1200 lb electrode /yr
= 5.88 pounds Al/yr
Emissions (lb/hr) = Max Fuel Volume (CF6 or GAL3) / hour x EF lb pollutant/fuel volume
CF6 = million cubic feet of gas
GAL3 = 1000 gallons of oil
Pollutant
B01
Max.
lb/hr
0.180
0.090
B02
Max.
lb/hr
0.120
0.060
0.023
0.015
0.6
0.008
0.6
0.008
7.1
0.639
NOx
140
1.820
100
1.300
20
1.800
VOC
2.8
0.036
5.3
0.069
0.2
0.018
CO
35
0.455
20
0.260
5
0.450
* NG PM/PM10/PM2.5 emissions are based on updated EF from USEPA Roy Myers "NG_process_gas_LPG_PM_factors" spreadsheet.
0.426
1.200
0.012
0.300
PM/ *
PM10 *
PM2.5 *
NG EF
10-100 MMBTU
lb/CF6
0.52
0.52
0.43
0.006
0.43
0.006
SO2 **
** Fuel oil SO2 EF based on 0.05% sulfur = 142 * %S or 142 * (0.05) = 7.1 lb/1000 gal (lb/gal3)
0.25
0.021 cf6/hr
MTE
Emission Factor
(lb/cf6) ***
(lb/hr)
(tpy)
2.00E-04
2.10E-03
1.20E-05
1.10E-03
1.40E-03
8.40E-05
1.20E-03
7.50E-02
1.80
3.80E-04
2.60E-04
2.10E-03
6.98E-04
2.40E-05
3.40E-03
4.20E-06
4.41E-05
2.52E-07
2.31E-05
2.94E-05
1.76E-06
2.52E-05
1.58E-03
3.78E-02
7.98E-06
5.46E-06
4.41E-05
1.47E-05
5.04E-07
7.14E-05
1.84E-05
1.93E-04
1.10E-06
1.01E-04
1.29E-04
7.73E-06
1.10E-04
6.90E-03
1.66E-01
3.50E-05
2.39E-05
1.93E-04
6.42E-05
2.21E-06
3.13E-04
*** Natural gas HAP emission factors from AP-42, "Natural Gas Combustion", Tables 1.4-3 and 1.4-4, (7/98).
HAP
2-Methylnaphthalene
3-Methylchloranthrene
7,12-Dimethylbenz(a)anth
Acenaphthene
Acenaphthylene
Anthracene
Benz(a)anthracene
Benzo(a)pyrene
Benzo(b)fluoranthene
Benzo(g,h,i)perylene
Benzo(k)fluoranthene
Chrysene
Dibenzo(a,h)anthracene
Fluoranthene
Fluorene
Indeno(1,2,3-cd)pyrene
Naphthalene
Phenanthrene
Pyrene
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Mercury
Manganese
Nickel
Selenium
0.15 gal3/hr
21.2 mmbtu/hr
MTE
(lb/hr)
(tpy)
3.54E-05
1.55E-04
3.21E-05
1.41E-04
9.54E-06
4.18E-05
9.15E-03
4.01E-02
4.95E-04
2.17E-03
9.30E-04
4.07E-03
1.64E-05
7.16E-05
MTE
(lb/hr)
(tpy)
8.48E-05
3.71E-04
6.36E-05
2.79E-04
6.36E-05
2.79E-04
6.36E-05
2.79E-04
1.27E-04
5.57E-04
1.91E-04
8.36E-04
6.36E-05
2.79E-04
1.27E-04
5.57E-04
6.36E-05
2.79E-04
3.18E-04
1.39E-03
**** Fuel Oil HAP emission factors from AP-42, Tables 1.3-8, 1.3-9 and 1.3-10, 5/10.
Emission Factor
(lb/cf6)
2.40E-05
1.80E-06
1.60E-05
1.80E-06
1.80E-06
2.40E-06
1.80E-06
1.20E-06
1.80E-06
1.20E-06
1.80E-06
1.80E-06
1.20E-06
3.00E-06
2.80E-06
1.80E-06
6.10E-04
1.70E-05
5.00E-06
6.98E-04
Each engine will require its own set of emissions calculations based on the size of the engine, the fuel type used and the hours of
operation limit. Find the maximum capacity of the engine based on the emission factor units listed below. Either HP (horsepower) or
the MMBTU/HR (million BTU per hour) should be listed on the name plate of the engine, or in a operations manual.
Equations:
Emission (lb/hr) = Heat Input or Power Output (MMBtu/hr or HP) x Emission Factor (lb/MMBtu or lb/HP-hr)
Emission (ton/yr) = Emissions (lb/hr) x Operating Hours (hr/yr) x 1 lb/2,000 ton
Operating hours: Note that to be considered an "emergency" engine (restricted use RICE) In WI, emergency engines
cannot operate more than 200 hr/yr, based on the definition in s. NR 400.02(136m), Wis. Adm. Code.
Engine Type
Small Diesel (600 hp)
Small Diesel (600 hp)
Large Diesel (>600 hp)
Large Diesel (>600 hp)
NG-2 stroke Lean Burn
NG-4 stroke Lean Burn
NG-4 stroke Rich Burn
Gasoline
EF Units
lb/mmbtu
lb/hp-hr
lb/mmbtu
lb/hp-hr
lb/mmbtu
lb/mmbtu
lb/mmbtu
EF Source
AP-42, Table 3.3-1
AP-42, Table 3.3-1
AP-42, Table 3.4-1
AP-42, Table 3.4-1
AP-42, Table 3.2-1
AP-42, Table 3.2-2
AP-42, Table 3.2-3
PM a
0.31
2.20E-03
0.10
7.00E-04
4.83E-02
9.99E-03
0.02
lb/mmbtu d
0.10
Criteria Pollutants
PM10 a
SO2 b
NOX c
0.31
2.20E-03
0.10
7.00E-04
4.83E-02
9.99E-03
0.02
0.29
2.05E-03
0.05
4.05E-04
5.88E-04
5.88E-04
5.88E-04
4.41
0.03
3.20
0.02
3.17
4.08
2.21
VOC
0.35
2.51E-03
0.09
7.05E-04
0.12
0.12
2.96E-02
CO c
0.95
6.68E-03
0.85
5.50E-03
0.386
0.317
3.72
0.10
0.08
1.63
2.10
0.99
Notes:
(a) PM10 EF provided in AP-42; table assumes PM to be 100% of PM 10
(b) Large Diesel SO2 EF as equation multiplying by %sulfur in fuel. Assume 0.05% sulfur as highest available diesel.
(c) NOX and CO for Natural Gas assumes 95-105% load.
(d) Gasoline = 0.125 mmbtu/gal
EF Units
lb/mmbtu
EF Source
Acetaldehyde
Benzene
Toluene
Xylene
Propylene
Formaldehyde
7.67E-04
9.33E-04
4.09E-04
2.85E-04
2.58E-03
1.18E-03
lb/mmbtu
2.52E-05
7.76E-04
2.81E-04
1.93E-04
2.79E-03
7.89E-05
lb/mmbtu
lb/mmbtu
lb/mmbtu
7.76E-03
8.36E-03
2.79E-03
1.94E-03
4.40E-04
1.58E-03
9.63E-04
4.08E-04
5.58E-04
2.68E-04
1.84E-04
1.95E-04
na
na
na
5.52E-02
5.28E-02
2.05E-02
Acrolein
7.78E-03
5.14E-04
2.63E-03