Plasma- and Laser-Cutting Tool

Purpose and use

Please read the following information for more effective use of this tool for compliance
demonstration. If you have questions or concerns, please contact us at sbeap@ksu.edu
or call 800-578-8898.

Introduction and summary: Plasma cutting uses electrically ionized gas (plasma) to cut
through materials such as steel, aluminum, brass and copper. Fumes and gases generated
by plasma cutting are dependent on dry or wet cutting, cutting speed, thickness of the
metal being cut, alloy contents of the metal being cut, and ventilation conditions. (AP-42
Chapter 12, Related Emission Factors: Emission of Fume, Nitrogen Oxides and Noise in
Plasma Cutting of Stainless and Mild Steel). This tool does not take into consideration
potential metal HAPs that may emit from your specific plasma-cutting activity but solely
focuses on particulate matter emissions. If your source has HAP emission limitations or
has other metal HAP emitting activities such as welding, it may be important to calculate
potential HAP emissions from plasma cutting as part of an overall plant-wide HAP
evaluation. Otherwise, the metal HAP emissions from plasma cutting are largely
insignificant for determination of construction approval or construction permitting
requirements.

This workbook is designed to calculate both the potential to emit (PTE) and actual
emissions from the source. It is designed to calculate a 12-month rolling total based on
actual hours operated during each month for each plasma-/laser-cutting activity. It can
be used in two (2) ways, and it is recommended that a copy of two (2) spreadsheets be
used: one for PTE of new projects and a second for facility-wide calculation of actual
emissions from total operations.

If you are using this workbook to

calculate PTE to determine if you will need a construction approval or permit for new
equipment you plan to install, you will only enter in the "new" equipment in the
“process info tab (yellow tab).” If you need to use the form for facility-wide PTE or 12-
month totals for plasma-/laser-cutting emissions, then you would enter all plasma-cutting
and/or laser-cutting units into the “process info" tab (yellow tab).

Process info Tab Sheet (yellow tab)

In the portion of the table titled "input data (put your information below),” the blue font
in the cream-colored cells indicates where you should enter information. The “cutting
technique” and “metal type” columns contain drop boxes. By clicking in the box, an
arrow will appear and allow you to pick from the choices.

The “unit identification” column is where specific identification of a unit can be entered.
The “cutting technique” drop box has three choices: semi-dry (defined as water about 50
mm under plate), wet (defined as burner 70 mm below water surface) and dry. If you
operate dry and have a control device, you will enter information about the control
device in the “control device type” and “% control efficiency” cells.

The “metal type” drop box offers five choices: aluminum, brass, stainless steel with a
width of 35 mm, stainless steel with a width of 8 mm and steel. If your specific metal is
not in the drop list, choose the one that best describes your operations, or choose the
worst-emitting metal (worst-case-emission rate is stainless steel with a width of 8 mm,
second-worst rate is brass and third is steel). Choosing the worst-case metal for your
operations will give a safety factor element to the emission calculations.

“Metal thickness” should correlate with actual thickness of the metal plate or material
cut. Enter the thickness in inches.

“Kerf” is the width of the cut made on the metal. Enter the kerf in inches.

“Metal cutting speed/feed rate” should correlate to the rated speed at which the metal
is cut. The manufacturer provides this information, if it is a plasma-cutting table or
computer-controlled unit. Otherwise it must be estimated if manually performed. Cutting
speed is measured in inches per minute (in/min).

Enter information about any add-on control device, such as a filter or baghouse, in the
“control device type” column. The control device manufacturer can supply the “%
control efficiency” to enter in that column.

The remainder of the table under the title “calculated data (do not alter),” contains
formulas to calculate emissions from the data entered specific to the plasma-/laser-
cutting operation at your facility. These calculations are based on emissions information
provided in EPA’s AP-42.

Please be advised, if you have other activities that emit particulate matter, you should use
this information to determine your facility-wide PTE as well as actual emissions. If you
need assistance with calculating your facility-wide emissions, please contact us at
sbeap@ksu.edu.
New construction calculations (orange tab)

This tab is strictly a "new construction PTE calculation sheet" based on what equipment
and information was entered on the “process info (yellow tab)” sheet. Do not enter any
information into any other areas of the form. This form will determine if the new pieces
of equipment you plan to install will require a construction approval or permit.

Hours operated (blue tab)

The table in this sheet allows you to enter the hours operated for each unit in the chosen
months and chosen year. All hourly information must be entered manually each month
to reflect the month for that given 12-month period being tracked. The ending month is
chosen from a drop down box. Enter the year manually in the cream-colored box. Then
you must enter the appropriate hours for the month and year in the table.

12-month summary (red tab)

This tab is for those sources needing to track PM10/PM2.5 emissions to meet a facility-
wide limit on PM10/PM2.5 in a construction approval or permit, or in an operating
permit. Be sure, if you are using this tool to track 12-month consecutive totals, all
plasma-/laser-cutting units are listed in the yellow “process info” tab.

Specific gravity- fume generation (moss tab)

Please do not edit the information in this tab. It is used in the spreadsheets for
calculating and tracking emissions.

Last revised: June 2017

Process Descriptions
If your metal type/thickness isn't listed in the drop down box, choose the most accurate type. If the plasma cutter or laser
different metal types, worst case emission rate is Stainless Steel 8 mm, second worst rate is brass and third is steel. Use t
operations.

Edit Only the Areas with Blue Font and cream colored background(examples are provided)

Facility Name: ABC Company Source ID Number: 1730000

INPUT DATA (PUT YOUR INFORMATION BELOW)
Unit Identification Cutting Technique Metal Type Metal Kerf Metal Cutting
(semidry = water (choose from drop down box) Thickness (width of Speed -Feed
about 50 mm under (Inches) cut in Rate
plate; wet=burner 70 Inches) (inches/minute)
mm below water (Manufacturer's
surface) rating or best
(Choose from drop engineering
down box) knowledge if
manual feed)

Laser Unit 1 Semidry Brass 0.3 0.01 12

Plasma Cutter 1 Wet Stainless Steel, 35mm 1.38 0.01 20
Plasma Cutter 2 Dry Stainless Steel, 8mm 0.321 0.01 15
Plasma Cutter 3 Dry Brass 0.05 0.01 15
Plasma Cutter 4 Dry Aluminum 0.01 0.01 15
Laser Unit 2 Dry Stainless Steel, 35mm 1.25 0.5 6
Sources
AP-42 Chapter 12 Related Emission Factor Documents
https://www3.epa.gov/ttn/chief/efdocs/welding.pdf
pe. If the plasma cutter or laser cutter is used to cut several
brass and third is steel. Use the worst case metal for your

Calculated Data (DO NOT ALTER)

Control % Control Specific Density Fume PM2.5/PM10 Metal Feed PM/PM2.5/PM10
Device Type Efficiency Gravity Conversion Generated Emission Rate Emissions -
(lb/in3) (% of Factor (inches/hr) Uncontrolled
Particulate (lb/inch) (lb/hr)
Generated)

water 0 8.7 0.3143049 0.5 4.71457E-06 720 0.00339449292

water 0 7.7 0.2781779 0.01 3.83886E-07 1200 0.0004606626
baghouse 95 7.7 0.2781779 7 6.25066E-05 900 0.05625591672
baghouse 95 8.7 0.3143049 5 7.85762E-06 900 0.00707186025
baghouse 95 2.8 0.1011556 5 5.05778E-07 900 0.0004552002
none 0 7.7 0.2781779 1 0.001738612 360 0.625900275
#N/A #N/A #N/A #N/A 0 #N/A
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NOT ALTER)
PM/PM2.5/PM10 PM2.5/PM10 PM2.5/PM10
Emissions - Emissions - Emissions -
Controlled (lb/hr) Uncontrolled Controlled
(tons per year) (tons/year)

0.00339449292 0.014867879 0.014867879

0.000460662602 0.0020177022 0.002017702
0.002812795836 0.2464009152 0.012320046
0.000353593013 0.0309747479 0.001548737
2.276001E-05 0.0019937769 9.968884E-05
0.625900275 2.7414432045 2.741443205
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 Contruction Permit Thresholds - Uncontrolled
PERMIT LIMITS Emissions APPROVAL LIMITS
PM (TPY) PM10 (TPY) PM2.5 (TPY)

K.A.R. 28-19-300(a) 25 15 10

Construction Permit
No No No
Required?

PM2.5/PM10 Emissions PM2.5/PM10 PM2.5/PM10 PM2.5/PM10

- Uncontrolled (lb/hr) Emissions - Emissions - Emissions -
Controlled (lb/hr) Uncontrolled Controlled
(tons per year) (tons/year)

0.00339449292 0.00339449292 0.014867879 0.01486787899

0.0004606626024 0.000460662602
0.056255916717 0.002812795836
0.00707186025 0.000353593013
0.0004552002 2.276001E-05
0.625900275 0.625900275
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0.0020177022 0.0020177022
0.2464009152 0.01232004576
0.0309747479 0.00154873739
0.0019937769 9.96888438E-05
2.7414432045 2.7414432045
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
 0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0

SUM 0.69 0.63 3.04 2.77

 Contruction Approval
Thresholds - Uncontrolled
APPROVAL LIMITS Emissions
PM (lb/hr) PM10 (lb/hr)

K.A.R. 28-19-300(b) 5 2

Construction
No No
Approval Required?
Operating Hours for 12-month rolling total ending
with: September 2017 9

Hours Operated (Monthly)

(hours) (hours) (hours) (hours) (hours) (hours) (hours) (hours) (hours) (hours) (hours) (hours) (hours)
Process Information 2017 2017 2017 2017 2017 2017 2017 2017 2017 2016 2016 2016 12-mo

Unit Identification Jan. Feb. Mar. Apr. May Jun. Jul. Aug. Sept. Oct. Nov. Dec. Total
Laser Unit 1 2.66 2.66 2.66 2.66 2.66 2.66 2.66 2.66 2.66 2.66 2.66 2.66 32
Plasma Cutter 1 23.33 23.33 23.33 23.33 23.33 23.33 23.33 23.33 23.33 23.33 23.33 23.33 280
Plasma Cutter 2 80 80 80 80 80 80 80 80 80 80 80 80 960
Plasma Cutter 3 91.66 91.66 91.66 91.66 91.66 91.66 91.66 91.66 91.66 91.66 91.66 91.66 1100
Plasma Cutter 4 52.5 52.5 52.5 52.5 52.5 52.5 52.5 52.5 52.5 52.5 52.5 52.5 630
Laser Unit 2 45.83 45.83 45.83 45.83 45.83 45.83 45.83 45.83 45.83 45.83 45.83 45.83 550
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
 Plasma Arc/Laser Cutting emissions for 12-month rolling total ending with: September 2017
Sum of all units: 12-month Rolling totals
Emission Factors - Uncontrolled Emission Factors - Controlled Actual Emissions - Uncontrolled Actual Emissions - Controlled Actual Emissions - Uncontrolled Actual Emissions - Controlled
(lb/hr) (lb/hr) (tpy) (tpy) (tpy) (tpy)
Process Information PM10 PM2.5 PM10 PM2.5 PM10 PM2.5 PM10 PM2.5 PM10 PM2.5 PM10 PM2.5
PM PM PM PM PM PM
Not A Title Not A Title Not A Title Not A Not A Title Not A Title
V Pollutant V V Pollutant Title V V V Pollutant
Pollutant Pollutant Pollutant
Unit Identification
Laser Unit 1 0.003 0.003 0.003 0.003 0.003 0.003 0.000 0.000 0.000 0.000 0.000 0.000
Plasma Cutter 1 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.20 0.20 0.20 0.17 0.17 0.17
Plasma Cutter 2 0.056 0.056 0.056 0.003 0.003 0.003 0.027 0.027 0.027 0.001 0.001 0.001
Plasma Cutter 3 0.007 0.007 0.007 0.000 0.000 0.000 0.004 0.004 0.004 0.000 0.000 0.000
Plasma Cutter 4 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
Laser Unit 2 0.626 0.626 0.626 0.626 0.626 0.626 0.172 0.172 0.172 0.172 0.172 0.172
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
Specific Gravity/Fume Generation Table
Note: When a range was listed for the density the highest number in the range was used.

Metal Dry Semidry Wet Specific Gravity

Aluminum 5 0.5 0.05 2.8
Brass 5 0.5 0.05 8.7
Stainless Steel, 35mm 1 0.1 0.01 7.7
Stainless Steel, 8mm 7 0.7 0.07 7.7
Steel 5 0.5 0.05 7.83
Monthly drop-down list
January 1
February 2
March 3
April 4
May 5
June 6
July 7
August 8
September 9
October 10
November 11
December 12