Instructions for Using this Worksheet

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.
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.
VOCs - generally the key methods used to determine VOCs are either using MSDS (Material
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
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
appropriate factors. Follow the PM instructions on using an emission factor if you happen to
have a VOC process with an EPA emission factor.
PM - in general 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 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.
HAPs - usually you will have either MSDS 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.
Fuel 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 source to test to develop
emission factors, but once developed the emission factors are used the same way AP-42 values are.

Key
Calculations:
Extra Calcs:

VOC EMISSIONS CALCULATIONS

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

Thinners and Clean up Solvents

Solvent #1
Solvent #2
Solvent #3
(Just insert more lines here for more solvents)

0.00
0.00
0.00
0.00
0.00
=

Total VOCs for

(write in month/year)

390.00

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
Thinner VOC

3.8 lb/gal
6.8 lb/gal

Coating is thinned in 4:1 ratio

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

Again thinned in 4:1 ratio, but only 1 gallon of previous 5 left

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.

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/yr
Disposed: 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.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

Drying, column: 0.22 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-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

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

PM From Painting Operations

One 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
Transfer efficiency:
70%
Collection efficiency: 85%

Coating A: 443 gallons/yr; 32% solids by weight

Coating B: 534 gallons/yr; 43% solids by weight

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

Key
Calculations:
Extra Calcs:

HAP EMISSIONS CALCULATIONS

(Coatings)
Amount Used (gal/mo) x HAP Content (lb/gal) = HAP Emissions
Add together HAP Emissions from each material = Total of each HAP per month
**NOTE: You will need to find the HAP% by in the Hazardous Ingredient section of your MSDS 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:

SG = 0.84; Density = 0.84 * 8.34 = 7.00 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.

Specific Gravity Density

HAP Content HAP Content Amount Used
HAP Emissions HAP TOTALs
(ratio)
(lb/gal)
(% by wt.)
(lb/gal)
(gal/month)
(lb/mo)
(lb/mo)
12.00
25.00
3.00
50.00
150.00
0.00
0.00
0.00
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
HAPs
Example HAP
HAP #1

Material
Name or ID #
Example Mat'l
Material #1
Material #2
Material #3
Material #4

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
Transfer efficiency:
70%
Collection efficiency: 85% from waterwash wall

Coating A: 443 gallons/yr; 3% carbon black by weight

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

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/yr
Disposed: 55 gal/4 mo x 12 mo/yr = 165 gal/yr
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: 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

= 3.87 pounds Mn/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

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-42
EF 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/hr

B02: 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
10-100 MMBTU

PM
SO2
NOx
VOC
CO

3
0.6
140
2.8
35

B01
NG EF
Max.
<10 MMBTU
lb/hr
0.039
3
0.0078
0.6
1.82
100
0.0364
5.3
0.455
20

B02
FO EF
Max.
lb/hr
0.024
2
0.0048
71.8
0.8
20
0.0424
0.2
0.16
5

B01
Max.
lb/hr
0.18
6.462
1.8
0.018
0.45

B02
Max.
lb/hr
0.12
4.308
1.2
0.012
0.3

Worst Case Emissions are from Fuel Oil for each boiler, so MTE is based on those calculations:
TABLE 2:
Pollutant
PM
SO2
NOx
VOC
CO

MTE BOILER CRITERIA POLLUTANT EMISSIONS

B01
lb/hr

B02
lb/hr
0.18
6.46
1.82
0.036
0.455

0.12
4.308
1.2
0.042
0.3

Totals
lb/hr
0.3
10.768
3.02
0.078
0.755

B01
TPY
0.788
28.295
7.972
0.158
1.993

B02
TPY
0.526
18.869
5.256
0.184
1.314

Totals
TPY
1.314
47.164
13.228
0.342
3.307

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