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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.
compounds (VOCs),
uel combustion. The
by a source to create
new refuse derived fuels or
d the emission factors are
VOC EMISSIONS CALCULATIONS
(Coatings)
Key Amount Coatings Used (gal/mo) x VOC Content (lb/gal) = VOC Emissions
Calculations: Add together VOC Emissions from each coating and solvent = Total VOCs per month
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 Density VOC Content VOC Content Amount Used VOC Emissions
Coatings Name or ID # (ratio) (lb/gal) (% by wt.) (lb/gal) (gal/month) (lb/mo)
Example #1 Material #1 12.00 65.00 7.80 50.00 390.00
Coating #1 0.00
Coating #2 0.00
Coating #3 0.00
Coating #4 0.00
Coating #5 0.00
Coating #6 0.00
Coating #7 0.00
(Just insert more lines here for more coatings) 0.00
0.00
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 Again thinned in 4:1 ratio, but only 1 gallon of previous 5 left
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.
Purchase = 1 drum every 3 months, return 1 drum used solvent every 4 months.
Mineral spirits: 6.7 pounds per gallon, 100% VOC content
Storage = Drums labeled with waste mineral spirits from degreasing units.
VOCs = 220.0 gal/yr - 165.0 gal/yr = 55.0 gal/yr x 6.7 lb VOC/gal 2000 lb/ton 0.18425 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.html
Mass Balance Allowed if NO Emission Factors - Must Be Well Documented
Hourly Emissions = 250 TPH x (0.032 + 0.22 + 0.075 + 0.027) lb PM / ton = 88.5 lb PM/hr
Welding Emissions:
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%.
Uncontrolled emissions = material collected / (CE) = 12.5 lb/hr / (0.85) = 14.7 lb/hr
Controlled emissions = uncontrolled emissions (1-CE) = 14.7 lb/hr (1-0.85) = 2.2 lb/hr
That 8 hours operation for one month was fairly average. Assume 120 hours per year:
Paint application: HVLP gun Coating A: 443 gallons/yr; 32% solids by weight
Transfer efficiency (TE): 70% Coating B: 534 gallons/yr; 43% solids by weight
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)
Coatings
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)
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 Specific Gravity Density HAP Content HAP Content Amount Used HAP Emissions HAP TOTALs
HAPs 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 50.00 150.00
HAP #1 Material #1 0.00
Material #2 0.00
Material #3 0.00
Material #4 0.00 0
HAP #2 0.00
(Just insert more lines here for more materials that contain this HAP) 0.00
HAP #3 0.00
HAP #4 0.00
HAP #5 0.00
HAP #6 0.00
HAP #7 0.00
(Just add more HAPs here.) 0.00
0.00
0.00
0.00
PM-based HAPs From Painting Operations
One 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 weight
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
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
HAPs = 220.0 gal/yr - 165.0 gal/yr = 55.0 gal/yr x 6.7 lb HAP/gal = 368.5 pounds HAP/yr
Welding Emissions:
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
BOILER FUEL EMISSIONS
Example Calculations: 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
Criteria Pollutant Emissions
EF for Natural Gas (NG): Tables 1.4-1 and -2, AP-42, for <10 mmbtu/hr and 10-<100 mmbtu/hr maximum capacity.
EF for Fuel Oil (FO): Tables 1.3-1, -2, and -3, AP-42, for #2 fuel oil/distillate fuel oil
B01 13 mmbtu/hr, maximum heat input capacity. Fuel use: Natural Gas = 0.013 cf6/hr; Fuel Oil = 0.09 gal3/hr
B02 8.2 mmbtu/hr, maximum heat input capacity. Fuel use: NG = 0.008 cf6/hr; FO = 0.06 gal3/hr
CF6/hr = mmbtu/hr 1,020 mmbtu/CF6
GAL3/hr = mmbtu/hr 140 mmbtu/GAL3
NOTE: 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.
Criteria Pollutants
Engine Type EF Units EF Source PM a PM10 a SO2 b NOX c VOC CO c
Small Diesel (600 hp) lb/mmbtu AP-42, Table 3.3-1 0.31 0.31 0.29 4.41 0.35 0.95
Small Diesel (600 hp) lb/hp-hr AP-42, Table 3.3-1 2.20E-03 2.20E-03 2.05E-03 0.03 2.51E-03 6.68E-03
Large Diesel (>600 hp) lb/mmbtu AP-42, Table 3.4-1 0.10 0.10 0.05 3.20 0.09 0.85
Large Diesel (>600 hp) lb/hp-hr AP-42, Table 3.4-1 7.00E-04 7.00E-04 4.05E-04 0.02 7.05E-04 5.50E-03
NG-2 stroke Lean Burn lb/mmbtu AP-42, Table 3.2-1 4.83E-02 4.83E-02 5.88E-04 3.17 0.12 0.386
NG-4 stroke Lean Burn lb/mmbtu AP-42, Table 3.2-2 9.99E-03 9.99E-03 5.88E-04 4.08 0.12 0.317
NG-4 stroke Rich Burn lb/mmbtu AP-42, Table 3.2-3 0.02 0.02 5.88E-04 2.21 2.96E-02 3.72
Gasoline lb/mmbtu d AP-42, Table 3.3-1 0.10 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